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V-8 Models covered in this manual also MerCruiser versus Sea Ray cross reference.
Cubic Inch
MerCruiser
Sea Ray
Displacement Drives
1987 1988 1988 Engine Type Available
MCM 200 5.0 Litre
305 production Alpha One
MCM 230 5.0 Litre LX
305 production Alpha One
MCM230 TR 305 production TR
MCM 260 5.7 Litre 5.7L 350 production Alpha One, TR
MCM 260 TR
350 production TR
MCM 350 Magnum 350 Magnum SRX 5.7L 350 production Alpha One
MCM 454 Magnum SRX 7.4L 454 production Alpha One
7.4 Litre 454 production · Bravo One, TR
454 Magnum SRX 7.4L-H 454
production
performance
Bravo One
MCM 330 B/W
454 production TR, TRS II SSM
MIE 230 5.0 Litre 305 production Borg-Warner
MIE 260 5.7 Litre 5.7L 350 production Borg-Warner
MIE 340
7.4 Litre 7.4L 454 production Borg-Warner
5.7 Ski 5.7 Litre Camp. Ski
350 production
production
MCM 300 Tempest (1986)
350 TRS, IISSM
.
performance
production Alpha One SS,
...:'-' MCM 320 EFI HP 320 EFI
350
performance Bravo One
production
MCM 370 TRS
454 TRS, IISSM
performance
production
MCM 400 (1986)
454 TRS, IISSM, IIISSM
performance
production
MCM 420 (1986) HP 420
454 TRS, IISSM, IIISSM
performance
production
MCM 440 (1986)
454 IIISSM, IVSSM
performance
production
MCM 460 (1986)
482 IIISSM, IV SSM
performance
production
MCM 575 HP 575
540 IIISSM, IVSSM
performance
IMPORTANT: Refer to "Engine Identification", page
NOTICE
Refer to appropriate MerCruiser Stern Drive
Service Manual for transom assembly and
stern drive unit repair.
Service Manual Outline
Section 1 Important Information
-
A-Important Information
B-Maintenance
C-Troubleshooting
Section 2 Removal and Installation
-
A-MCM Models with I Drive
B -MCM Models with I Drive with Drive-
shaft Extension
C-330 (B-W) TR-TRS
D -MCM Models with TR/TRS Drives
E-MIE Models/5.7 Ski
F-MCM Models with Bravo Drive
Section 3 -Engine
A-V-8 GM (305/350 CID)
B-V-8 GM (454/482/540 CID)
Section 4 -Electrical System
A-Starting System
B -Ignition System
C-Charging System
D-Instrumentation
E -Electrical Kits
F-Wiring Diagrams
Section 5 Fuel System
-
A-Fuel Delivery System and Fuel Pumps
B -MerCarb 2 Barrel
C -Rochester 4 Barrel
D -Holley 4 Barrel (Model 4150)
E -Holley 4 Barrel (Model 4500)
F-Fuel Injectors/Fuel Rails
Section 6 -Cooling System
A -Seawater Cooled Models
B -Closed Cooled Models
Section 7 Exhaust System
-
A-General Information
B-Exhaust Manifolds/Elbows
C-Exhaust Risers
D-Exhaust Collectors
Section 8 -Drive Systems
A -Velvet Drive
(Borg-Warner) Transmission
B -Drive Shaft Models/Propeller Shaft
C-Hurth Transmission
Section 9 -Power Steering
A-Power Steering
0IMPORTANT
"--' INFORMATION
Index
Page
How to Use This Manual 1A-1
......................
Page Numbering 1A-1
..........................
Introduction 1A-1
.................................
Notice to Users of This Manual ................ 1A-1
Notice 1 A-2
.......................................
Replacement Parts 1 A-2
...........................
Engine Mechanical Components 1A-2
..............
Directional References ........................ 1 A-3
Engine Rotation 1A-3
..............................
V-8 Engine Serial Number Locations ........... 1A-3
Engine Identification 1A-4
.........................
Propeller Information 1A-7
.........................
Hi-Performance Boating 1 A-7
......................
Engine 20-Hour Break-In Period ............... 1A-7
Water Testing New Engines 1A-8
...................
Boat and Engine Performance .................1A-8
Boat Bottom 1 A-8
..............................
Marine Fouling 1A-9
............................
Weight Distribution ........................1A-9
Water in Boat 1A-9
.............................
Elevation and Climate 1 A-1 0
....................
IMPORTANT INFORMATION -1A 90-1 4499--1 887
NOTICE
Refer to Appropriate Stern Drive service manual
for transom assembly and Stern Drive unit
repair.
Introduction
This comprehensive overhaul and repair manual is
designed as a service guide for the models previously
listed. If provides specific information, including procedures
for disassembly, inspection, assembly and
ajustment. To enable dealers and service mechanics to
repair and tune these engines.
How to Use This Manual
This manual is divided into sections which represent
major components and systems.
Some sections are further divided into parts which
more fully describe the component.
Page Numbering
Two number groups appear at the bottom of each
page. Following is an example and description.
90-14499--1 887
Manual No.
Revision No. 1
Month
Year
Section Description
Section
Section Part
Before attempting repairs or tune up, it is suggested
that the procedure first be read through to gain knowledge
of the methods and tools used and the cautions
and warning required for safety.
Notice To Users Of This
Manual
This service manual has been written and published by
the service department of Mercury Marine to aid our
dealers mechancis and company service personnel
when servicing the products described herein.
It is assumed that these personnel are familiar with the
servicing procedures of these products, of like or similar
products manufactured and marketed by Mercury
Marine. That they have been trained in the recommended
servicing procedures of these products which
includes the use of mechanics common hand tools and
the special Mercury Marine or recommended tools
from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a service
might be performed and of the possible hazards and/or
results of each method. We have not undertaken any
such wide evaluation. Therefore, anyone who uses a
service procedure and/or tool, which is not recommended
by the manufacturer, first must completely
satisfy himself that neither his nor the product's safety
will be endangered by the service procedure selected.
All information, illustrations and specifications contained
in this manual are based on the latest product
information available at time of publication.
It should be kept in mind, while working on the product,
that the electrical system and ignition system is
capable of violent and damaging short circuits or
severe electrical shocks. When performing any work
where electrical terminals could possibly be grounded
or touched by the mechanic, the battery cables should
be disconnected at the battery.
90-14499--1 887 IMPORTANT INFORMATION -1A-1
Any time the intake or exhaust openings are exposed
during service they should be covered to protect
against accidental entrance of foreign material which
could enter the cylinders and cause extensive internal
damage when the engine is started.
It is important to note that, during any maintenance
procedure, replacement fasteners must have the same
measurements and strength as those removed,
whether metric or customary. Numbers on the heads of
the metric bolts and on surfaces of metric nuts indicate
their strength. Customary bolts use radial lines for this
purpose, while most customary nuts do not have
strength markings. Mismatched or incorrect fasteners
can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be
saved for re-use in the same locations whenever possible.
Where the fasteners are not satisfactory for re-use,
care should be taken to select a replacement that
matches the original.
Notice
Throughout this publication, "Dangers", "Warnings"
and "Cautions" are used to alert the mechanic to special
instructions concerning a particular service or
operation that may be hazardous if performed incorrectly
or carelessly. --Observe them carefully!
These "Safety Alerts" alone cannot eliminate the
hazards that they signal. $trict compliance to these
special instructions when performing the service, plus
"common sense" operation, are major accident prevention
measures.
A DANGER
DANGER -Immediate hazards which WILL result in
severe personal injury or death.
A WARNING
WARNING -Hazards or unsafe practices which
COULD result in severe personal injury or death.
A CAUTION
CAUTION -Hazards or unsafe practices which could
result in minor personal injury of product or property
damage.
Replacement Parts
A WARNING
Electrical, ignition and fuel system components on
MerCrusier Engines and Stern drives are designed and
manufactured to comply with U.S. Coast Guard Rules
and Regulations to minimize risks of fire or explosion.
Use of replacement electrical, ignition or fuel system
components, which do not comply to these rules and
regulations, could result in a fire or explosion hazard
and should be avoided.
When servicing the electrical, ignition and fuel systems,
it is extremely important that all components are
properly installed and tightened. If not, any electrical
or ignition component opening would permit sparks to
ignite fuel vapors from fuel system leaks, if they
existed.
Engine Mechanical
Components
Many of the engine mechanical components are
designed for marine applications. Unlike automotive
engines, marine engines are subjected to extended
periods of heavy load and wide-open-throttle operation,
therefore, require heavy-duty components. Special
marine engine parts have design and manufacturing
specifications which are required to provide long
life and dependable performance. Marine engine parts
also must be able to resist the corrosive action of salt or
brackish water that will rust or corrode standard automotive
parts within a short period of time.
Failure to use recommended Quicksilver service
replacement parts can result in poor engine performance
and/or durability, rapid corrosion of parts subjected
to salt water and possibly complete failure of the
engine.
Use of parts other than recommended service replacement
will void the warranty on those parts which
are damaged as a result of the use of other than
recommended parts.
,;:.' .
1A-2 -IMPORTANT INFORMATION 90-14499--1 887
Directional References
Front of boat is bow: rear is stern. Starboard side is
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.
Engine Rotation
Engine rotation is determined by observing flywheel
rotation from the rear (stern end) of the engine looking
forward (water pump end). Propeller rotation 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 engine rotation.
a -Standard Left Hand Rotation -All MCM Stern Drive Engines;
MIE Inboard L H Rotation Engines
b-Opposite R1ght Hand Rotation -MIE Inboard R.H. Rotation
Engmes
90-14499--1 887
V-8 Engine Serial Number
Locations
a -Serial Number Plate
b -Starter Motor
MCM 200/230/260/350 Magnum/454 Magnum/
320 EFI/5.0 Litre/5.0 Litre LX/5.7 Litre/7.4 Litre
a-Stamped in Serial Number
MCM 300 Tempest Alpha One/TRS
a -Serial Number Plate
b-Starboard Side fo Flywheel Bell Housing and Cylmder Block
MCM 330 B/W/370 TRS (S.N. 6721528 and Above)
MCM 420/MCM 575
IMPORTANT INFORMATION -1A-3
a -Serial Number Plate
b -Flywheel Bell Housing
MCM 370 TRS (S.N. 6721527 and Below)/400 TRS/
400 Cyclone/440 Cyclone/460 Cyclone/230 TR/260 TR
a -Serial Number Plate
b-Starter Motor
MIE 230/260/340/5.7 Ski/5.0 litre/5.7 Litre/7.4 Litre
Engine Identification
a-Exhaust Elbow Mounted In Center of Manifold
b -Shift Plate On Side of Exhaust Elbow
c-Thunderbolt IV (HEI) Ignition System
MCM 200, 230, 260, 300 Tempest Alpha One,
350 Magnum, 454 Magnum, 5.0 Litre, 5.0 Litre LX,
5.7 Litre, 7.4 Litre
a-Center Mounted Exhaust Elbow
b-Thunderbolt IV (HEI) Ignition System
c -Borg-Warner Transmission
MCM 300 Tempest TRS
1A-4-IMPORTANT INFORMATION 90-14499--1 887
a -EFI System
b -Center Mounted Exhaust
MCM 320 EFI
a-Center Mounted Exhaust Elbow
b-Thunderbolt IV (HEI) Ignition System
c -Borg-Warner Transmission
15512
MCM 330 (B/W)/370 TRS (S.N. 6721528 and Above)
a -Rocker Arm Cover Decal -"370" or "Series 400"
b -Serial Number Plate on Flywheel Housing -"370" Stamped in
Plate
MCM 370 TRS (S.N. 6721527 and Below)
90-14499--1 887
a -Rocker Arm Cover Decal -"400"
b-Serial Number Plate on Flywheel Housing "400" Stamped in
Plate
c -Rochester 4 Barrel Carburetor
d -370 Type Exhaust Manifold and Elbow
MCM 400 Cyclone
18733
a-Rocker Arm Cover Decal -"440"
b-Serial Number Plate on Flywheel Housing -''440" Stamped in
Plate
c-Early Models Had Rochester 4 Barrel Carburetor, Later Models
Had Holley 4 Barrel Carburetor
d -Center Outlet Type Exhaust Manifold
MCM 440 Cyclone
IMPORTANT INFORMATION -1A-5
a-Rocker Arm Cover Decal -"460" or "420"
b -Serial Number Plate on Flywheel Housing -"460" Only Serial
Number Plate on Starboard Side, Rear of Engine Block "420"
Only
c-Holley 4 Barrel Carburetor
d -Center Outlet Type Exhaust Manifold
MCM 460 Cyclone/MCM 420
a -Exhaust Elbow Mounted in Center of Manifold
b-Thunderbolt IV (HEI) Ignition System
MIE 230/260/340, 5.0 Litre, 5.7 Litre, 7.4 Litre
a-Exhaust Elbow Mounted in Center of Manifold
b -Coventional Ignition System
MIE 5.7 Ski
MCM 230TR/260TR
17314
17314
Mercury Marine Hi-Performance Products has built 2
TR Production Performance Power Packages. "Removal,
Installation and Alignment" are similar to the MCM
330 (B-W) in "Section 2". For transmission and tailBorg-
Warner transmission (for TR package) added to
engine. Repair and specifications for engine is the
same as M IE 260.
a -Rocker Arm Decal "575"
b-Holley 4 Barrel Carburetor
c -"Stelling" Exhaust "Headers"
MCM 575
stock repair, refer to "Section 8".
MCM 230TR: MIE 230 (L.H.) inboard engine with a
Borg-Warner transmission (for TR package) added to
engine. Repair and specifications for engine is the
same as MIE 230.
MCM 260TR: MIE 260 (L.H.) inboard engine with a
Propeller Information
Refer to the "Propeller" Section in appropriate MerCruiser
Stern Drive Service Manual, or order publication
P/N 90-86144 "What You Should Know About
Quicksilver Propellers".
Changing diameter, pitch or coupling of a propeller
will affect engine RPM and boat performance. The
blade configuration also will affect performance. Two
like propellers, same pitch and diameter, from two different
manufacturers also will perform differently.
It is the responsibility of the boat manufacturer and/or
selling dealer to equip the boat with the correct propeller
to allow the engine to operate within its specified
RPM range at wide open throttle (W.O.T).
Because of the many variables of boat design and
operation, only testing will determine the best propeller
for the particular application.
To test for correct propeller, operate boat (with an
average 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,
engine speed will not fall below specifications.
If engine exceeds the specified RPM, an increase in
pitch and/or diameter is required.
If engine is below rated RPM, a decrease in pitch
and/or diameter required.
Normally, a change of approximately 300 to 500 RPM
will be achieved for each single pitch change of propeller.
A CAUTION
If a propeller is installed that does not allow engine
RPM to reach the specified full-throttle RPM range, the
engine will "labor" and will not produce full power.
Operation under this condition will cause excessive
fuel consumption, engine overheating and possible
piston damage (due to detonation). On the other hand,
installation of a propeller, that allows engine to run
above the specified RPM limit, will cause excessive
wear on internal engine parts which will lead to premature
engine failure.
Hi-Performance Boating
Written by Marine Engineers, order publication P/N
90-86168, entitled "Hi-Performance Boat Operation.
Engine 20-Hour Break-In
Period
IMPORTANT: Proper break-in is essential to obtaining
minimum oil consumption, maximum engine performance
and service.
The first 20 hours of operation is the engine (new or
rebuilt) break-in period. During this period, it is extremely
important that the engine is operated, as outlined
following.
1.
Do not operate engine below 1500 RPM for extended
periods of time during the first 10 hours.
During this period, shift into gear as soon as possible
after starting engine and advance throttle so
that RPM is above 1500 (provided that conditions
permit safe operation at this speed).
2.
Do not operate at any one constant speed for
extended periods of time.
3.
Do not exceed 3/4 of full throttle during the first 10
hours of operation. During the next 10 hours, occasional
operation at full throttle (5 minutes at-a-time
maximum) is permissible.
4.
Avoid full throttle acceleration from stopped
position.
5.
Do not operate at full throttle until engine reaches
normal operating temperature.
6.
Observe instrumentation carefully. If an abnormal
reading occurs, stop engine immediately and determine
cause.
7.
Frequently check crankcase oil level and add oil if
necessary. It is normal for oil consumption to be
somewhat high during the break-in period.
8.
At end of 20-hour break-in period, drain break-in oil
from crankcase and replace oil filter. Fill crankcase
with correct grade and viscosity oil.
90-14499--1 887
IMPORTANT INFORMATION -1A-7
Water Testing New Engines
Use care during the first 20 hours of operation on new
MerCruiser engines or possible engine failure may
occur. If a new engine has to be water-tested at full
throttle before the break-in period is complete, follow
this procedure.
1.
Start engine and run at idle RPM until normal operating
temperature is reached.
2.
Run boat up on plane.
3.
Advance engine RPM (in 200 RPM increments)
until engine reaches its maximum rated RPM.
IMPORTANT: Do not run at maximum RPM for more
than 2 minutes.
Boat and Engine Performance
Boat Bottom
For maximum speed, a boat bottom should be as flat as
possible in a fore-aft direction (longitudinally) for
approximately the last 5 ft. (1.5m).
a -Critical Bottom Area
For best speed and minimum spray, the corner between
the bottom and the transom should be sharp.
a-Flat
b -Sharp Corner
The bottom is referred to as having a "hook" if it is
concave in the fore-and-aft direction. A hook causes
more lift on the bottom near the transom and forces the
bow to drop. This increases wetted surface and reduces
boat speed. A hook, however, aids in planing and
reduces any porpoising (rhythmical bouncing) tendency.
A slight hook is often built in by the manufacturer.
A hook also can be caused by incorrect trailering
or storing the boat with support directly under the
transom.
a-Hook
A "rocker" is the reverse of a hook. The bottom is
convex or bulged in the fore-and-aft direction. It can
cause the boat to porpoise.
Any hook, rocker or surface roughness on the bottom,
particularly in the all-important center-aft portion will
have a negative effect on speed, often several milesper-
hour on a fast boat.
a-Rocker
1A-8 -IMPORTANT INFORMATION
90-14499--1 887
Marine Fouling
Fouling is an unwanted build-up (usually animalvegetable-
derived) occuring 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, minerals
and other pollutants. In salt water, barnacles, moss and
other marine growth often produce dramatic buildup
of material quickly. So it is important to keep the hull
as clean as possible in all water conditions to maximize
boat performance.
Special hull treatments, such as anti-fouling paint, will
reduce the rate of bottom fouling. However, due to the
fact that drive units (outboard or stern drive) are made
primarily of aluminum, be sure to select an anti-fouling
paint having a copper-free, organa-tin base. The BIS
(Tri Butyl Tin) Adipate (TBTA) base paint will not set
up a galvanic corrosion "cell" as it is completely compatible
with aluminum and avoids any electrolysis
problems connected with many other paints. Applied
according to instructions, it also is very effective.
Weight Distribution
Weight distribution is extremely important; it affects a
boat's running angle or attitude. For best top speed, all
movable weight-cargo and passengers-should be
as far aft as possible to allow the bow to come up to a
more effecient angle (3° to 5°). On the negative side of
this approach is the problem that, as weight is moved
aft, some boats will begin an unacceptable porpoise.
Secondly, as weight is moved aft, getting on plane
becomes more difficult.
Finally, the ride in choppy water becomes more uncomfortable
as the weight goes aft. With these factors in
mind, each boater should seek out what weight locations
best suits 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 performance
and handling characteristics of the boat. Operation 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 distribution.
Uneven weight concentration to port or starboard
of the longitudinal centerline can produce a severe
listing attitude that can adversely affect the boat's performance,
handling ability and riding comfort. In
extreme rough water conditions, the safety of the boat
and passengers may be in jeopardy.
Water in Boat
When a boat loses performance, check bilge for water.
Water can add considerable weight to the boat, thereby
decreasing the performance and handling.
Make certain that all drain passages are open for complete
draining.
90-14499--1 887 IMPORTANT INFORMATION -1A-9
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 increases, the engine
begins to starve for air. Humidity, barometric pressure
and temperature do have a noticeable effect on the
density of air. Heat and humidity thin the air. This
phenomenon can become particularly annoying when
an engine is propped out on a cool, dry day in spring
and later, on a hot, sultry day in August, does not 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 lower-pitch
propeller for specific high-elevation locations. 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 profound 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.
Rated HP
Horsepower Loss
Due to Atmosphere
Conditions
Summer HP
Secondary Loss Due
to Propeller Becoming
Too Large for
-----Summer --Horsepower
I
RPM Drop ----+1I
Due to
I Weather I
I
ENGINE RPM Rated RPM
1A-10 -IMPORTANT INFORMATION 90-14499--1 887
MAINTENANCE
Index
Page
Maintenance Schedule ........................ 1B-1
Tune-Up Specifications (MCM 200,
MCM 230, MCM 260/350 Magnum) ......... 1 B-3
Tune-Up Specifications (MCM 330 B/W/454
Magnum/MCM 370 TRS-S.N. 6721528
and Above, MCM 370 TRS-S.N. 6721527
and Below/400 TRS) ....................... 1 B-4
Tune-Up Specifications (MCM 300 Tempest
All Drives 320 EFI All Drives) ............... 1 B-5
Tune-Up Specifications (MCM 230 TR,
MCM 260 TR) ............................. 1 B-6
Tune-Up Specifications MCM 420 (MCM 400
Cyclone, MCM 440 Cyclone, MCM 460
Cyclone, MCM 575) ....................... 1 B-7
Tune-Up Specifications (MIE 230, MIE 260,
MIE 340) .................................. 1 B-8
Tune-Up Specifications (MIE 5.7 Ski) .......... 1 B-9
Fluid Capacities ............................. 1B-10
Fuel, Oil Fluid and Coolant Specifications ..... 1 B-1 1
No Lead Gasoline/Alcohol Blends ......... 1B-12
Lead ..................................... 1 B-12
Gasoline/Alcohol Blends .................. 1B-12
Effects of Gasoline/Alcohol Blends on
Marine Engines ....................... 1 B-12
Boat/Motor Storage ................... 1 B-12
Winter Storage ........................ 1 B-12
Warranty .............................. 1 B-12
Continuing Evaluations ................ 1 B-12
Test for Alcohol Content in Gasoline
Procedure ......................... 1B-13
Crankcase Oil ............................ 1 B-13
Power Steering Fluid ..................... 1 B-13
Transmission Fluid ....................... 1 B-13
Coolant .................................. 1 B-13
Page
Maintaining Crankcase Oil Level ............. 1 B-14
Overfilled Engine Crankcase .............. 1 B-14
Checking Engine Oil Level/Filling ......... 1B-14
Changing Oil and Filter ...................... 1B-14
Maintaining Power Steering Pump Fluid
Level ................................. ... 1 B-15
With Engine Warm from Operation ........ 1B-15
With Engine Cold ......................... 1B-15
Filling and Bleeding Power Steering System ... 1 B-16
Maintaining Closed Cooling Coolant Level .... 1 B-16
Flushing Cooling System .................... 1 B-17
Belt Driven Seawater Pickup Pump ........ 1 B-17
MCM-1/Aipha One Stern Drive Unit
SeawaterPickupPump ................ 1B-18
Boat Out-of-Water ..................... 1 B-18
Boat In-the-Water ..................... 1 B-18
Maintaining Transmission Fluid Level ......... 1 B-19
Lubrication ................................. 1 B-19
Throttle Cable ............................ 1B-19
Shift Cable ............................... 1 B-20
Engine Coupler/U-Joint Shaft Splines ..... 1 B-21
U-Joint Shaft Splines (Stern Drive Models
with Borg-Warner Transmissions) ...... 1 B-21
Drive Shaft Extension Models
(MCM 200, 230, 260) ................... 1 B-22
Staggered Engine ........................ 1 B-23
Starter Motor Lubrication ................. 1 B-23
Out-of-Season Storage ...................... 1 B-24
Precautions .............................. 1 B-24
Layup ................................... 1 B-24
Recommissioning ........................ 1 B-25
MAINTENANCE -18 90-1 4499--1 887
Location and Service
When
Starting
Engine
Each Day
After
First 20
Hours of
Operation
Every 50
Hours of
Operation
Every 100
Hours of
Operation
At Least
Once
Each
Year
Closed Cooling Models Only -Check coolant
leveL •
Engine Crankcase Oil -Check level •
Power Package (Entire) -Observe for obvious
leaks (water, fuel, oil, exhaust, etc.) •
Remote Control and Steering System Check
for proper operation •
Transmission oil level (if equipped) (A) •
Cooling System Hose Clamps -Check
tightness. • •
Note 1 •
Drive Belts (All) -Inspect condition and check
tension. • • •
Exhaust System -Inspect condition. Check
hose clamps for adequate tightness. • •
Note 1 •
Ignition System -Clean and inspect condition • • Note 1 •
Power Package (Entire) -Check for loose,
missing or damaged parts, (especially engine
mount fasteners and starter, and alternator
mounting fasteners).
• • •
Crankcase Oil and Oil Filter -Change • Refer to Page •
Engine Alignment -Check • •
Ignition System -Check timing and adjust,
if necessary. • •
Battery -Check electrolyte level and specific
gravity. Inspect case for damage. • •
Electrical System (Entire) -Check loose or
di rty connections or damaged wiring
(especially battery cables).
•
Note 2 •
-
dence of fueL • •
Flame Arrestor and Crankcase Ventilation
System -Clean and inspect • •
Hoses (All) -Inspect for cracks, swelling, weather
checking or other signs of deterioration. Check
connections for adequate tightness.
• •
Maintenance Schedule
NOTE: Refer to the end of this chart for explanation of
lettered references (A, B, C) and "NOTES".
A WARNING
Always disconnect battery cables from battery BEFORE
working around electrical system componenets
to prevent injury to yourself or damage to electrical
system should a wire be accidentally shorted.
-r...,, ..-. . .
..._. t'if..\ti?l •• !:>J+I.....
.·h! t
Fuel Pump Sight Tube (or Glass) -Check for evi
90-14499--1 887 MAINTENANCE -1B-1
When
After At Least
Starting
Fir st 20
Every 50 Every 100 OnceLocation and Service
Engine
Hours of Hours of Each
Each Day
Hours of
OperationOperation Operation Year
•
Shift and Throttle Cable and Linkage
•
Lubricate and inspect. (B) Note 1
• Note 1 •
Fu el Filters -Replace
Lubricate starter motor (C)
•
Carburetor/EFI adjust As Requi red
Closed Cooling Models Only -Clean closed
As Required NOTE 3
cooling section
Closed Cooling Models Only -Check coolant
At Least Once A Year
for alkalinity
Power Package Exterior Surfaces -Spray Fresh Water Areas -Every 6 Weeks
with rust preventive. (D)
Salt Water Areas -Every 2-3 Weeks
Seawater Cooling System -Flush
After Use Each Day
(CORROSIVE AREAS ONLY)
(A) Use Automatic Transmission Fluid (ATF), Type NOTES: (1) In fresh water areas, every 100 hours of operation or 120
F, Dexron or Dexron II. days (whichever comes first). ln saltwater areas, every 50
(B) Use SAE 30 engine oi l. hours of operation or 60 days (whichever comes first).
(C) Use Lubriplate Extra-Heavy Gear Shield or its (2) In fresh water areas, every 50 hours of operation or 60
equivalent. days (whichever comes first). In saltwater areas, every 25
(D) Use Quicksilver Corrosion and Rust Preventive hours of operation or 30 days (whichever comes first).
Type II. (3) Requires more frequent attention, if used in extremely
salty, polluted or mineral-laden waters.
1B-2 -MAINTENANCE
..n; ..( iA) to· -:t...) ,di''l '; ..n',rl:... ...:rc,_,J:)•;;nn,:: ,_,
·..i
..---............ ,.... .. .. ..
90-1 4499--1 887
Tune-Up Specifications
MCM 200, MCM 230, MCM 260/350
5.0 Litre 5.0 Litre LX Magnum/5.7 Litre MODEL
Horsepower 200 230 260
(Kilowatts)
(149) (172) (194)
Number of Cylinders
V-8
305 CID
350 CID
Displacement
(5.7L)
(5L)
4.00 ln./3.48 ln.
3.74 ln./3.48 ln.
Bore/Stroke
(101 .6/88.4mm)
Compression Ratio
(98/88.4mm)
8.5:1
Compression
155 PSI
(1069 kPa)
150 PSI 150 PSI
(1035 kPa) (1 035 kPa)
Idle RPM
Pressure
650-700
(In Forward Gear)
Max. RPM (At W.O.T.)
3800-4200 4200-4600
Oil PSI
30-55 PSI
(207-379 kPa)
Min. Oil PSI
(At 2000 RPM)
4 PSI
(28 kPa)
Fuel Pump PSI
(At Idle)
5-1/2 -7 PSI
(38 -48 kPa)
Electrical System
(At 1800 RPM)
12 Volt Negative (-) Ground
Min. Battery Cold
305 350Cranking Amps
Firing Order
1-8-4-3-6-5-7-2
AC-MR43T Champion -RV8C
Spark Plug Type
Autolite-144 NGK-BR6FS
Spark Plug Gap
.035 ln. (.9mm)
Timing (At Idle RPM)
8° BTDC
Preliminary
2-3 Turns 1-1/4 Turns
Idle Mixture
Thermostat 143° F (62° C)
90-1 4499--1 887 MAINTENANCE -1 8-3
Tune-Up Specifications
7.4 Litre, MCM 370TRS MCM 370TRS
MODEL MCM 330 B/W (S.N. 6721 528 (S.N. 6721 527 454 Magnum
454 Magnum and Above) and Below)/400TRS (1 988)
Horsepower 330 370 365
(Kilowatts) (246) (276) (272)
Number of Cylinders V-8
Displacement
454 Cubic Inches
(7.4L)
Bore/Stroke
4.25 ln./4.00 ln.
(108mm/102mm)
Compression Ratio 8.5:1 8.6:1
Compression 150 P.S.I.
Pressure (1035 kPa)
Idle RPM
650-700 800-850 650-700(In Forward Gear)
Max. RPM (At W.O.T.) 4200-4600 4800-5200 4600-5000
Oil PSI 35-70 P.S.I.
(At 2000 RPM) (241 -483 kPa)
Min. Oil PSI 4 P.S.I. 5 P.S.I.
(At Idle) (28 kPa) (34 kPa)
Fuel Pump PSI 5.5-7 P.S.I. 3-5 P.S.I. 5.25-6.5 P.S.I. 3-7 P.S.I.
(At 1800 RPM) (38-48 kPa) (21-34 kPa) (36-45 kPa) (21-48 kPa)
Electrical System 12-Volt Negative (-) Ground
Min. Battery Cold
450Cranking Amps
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type AC-M43T, Champion RV8C, Autolite-1 44, NGK-BR6FS
Spark Plug Gap .035 ln. (0.9mm)
Breaker Point Gap
.016 -.01 9 ln.
(0.40 -0.48mm)
Dwell 26° -31°
Breaker Point 25 -30 Oz.
Spring Tension (709 -850g)
Timing (At Idle RPM) 8° BTDC 10° BTDC 8° BTDC
Preliminary
2-3 Turns
Idle Mixture
Thermostat 143° F (62° C)
90-1 4499--1 887
18-4 -MAINTENANCE
Tune-Up Specifications
MODEL
MCM 300 Tempest MCM 320 EFI
All Drives All Drives
Horsepower 300 320
(Kilowatts) (224) (239)
Number of Cylinders V-8
Displacement
350 Cu. ln.
(5.7 L)
Bore/Stroke
4.00 ln./3.48 ln.
(1 02/88mm)
Compression Ratio 9:1
Compression 150 P.S. I.
Pressure (1035 kPa)
Idle RPM
750-800(In Forward Gear)
Max. RPM (At W.O.T.) 4800 -5200
Oil PSI 30 -60 P.S.I.
(At 2000 RPM) (207 -41 4 kPa)
Min. Oil Pressure 5 P.S.I.
(At Idle) (34 kPa)
3-7 P.S. I.
29 P.S.I. (269 kPa)
Fuel Pump Pressure
(21-48 kPa)
Above Intake
Manifold Pressure
Electrical System 12-Volt Negative (-) Ground
Min. Battery Cold
350Cranking Amps
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type
AC-MR43T, Champion RV8C, Autolite
144, NGK-BR6FS
Spark Plug Gap .032 ln. (0.8mm)
Timing (At Idle RPM) 8° BTDC 12° BTDC
Preliminary
2-3 Turns
Idle Mixture
Thermostat 143° (62° F)
90-14499--1 887 MAINTENANCE -18-5
Tune-Up Specifications
MCM 260 TR
MODEL MCM 230TR 5.7 Litre
Horsepower 230 260
(Kilowatts) (1 72) (194)
Number of Cylinders V-8
Displacement
305 Cu. ln.
(5L)
350 Cu. ln.
(5.7L)
Bore/Stroke
3.74/3.48 ln.
(95/88mm)
4.00/3.48 ln.
(102/88mm)
Compression Ratio 8.5:1
Compression 155 P.S. I. 150 P.S.I.
Pressure (1 069 kPa) (1 035 kPa)
Idle RPM
(In Forward Gear)
650-700
Max. RPM (At W.O.T.) 4000-4400
Oil Pressure 30-55 P.S. I.
(At 2000 RPM) (207-379 kPa)
Min. Oil Pressure 4 P.S.I.
(At Idle) (28 kPa)
Fuel Pump Pressure
5.5-7 P.S.I.
(38-48 kPa)
Electrical System 12-Volt Negative (-) Ground
Min. Battery Cold
Cranking Amps
305 350
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type
AC-MR43T
Autolite-1 44
Champion RV8C,
NGK-BR6FS
Spark Plug Gap .035 ln. (0.9mm)
Timing (At Idle RPM) 8° BTDC
Preliminary
Idle Mixture
2-3 Turns
Thermostat 143° F (62° C)
1 B-6 -MAINTENANCE 90-1 4499--1 887 "<, · .. , • .
Tune-Up Specifications
MODEL
MCM 420 MCM 400 MCM 440 MCM 460 MCM 575
HP 420 CYCLONE CYCLONE CYCLONE HP 575
Horsepower
(kilowatts)
Number of Cylinders
420 400 440 460 575
(313) (298) (328) (343) (429)
V-8
Displacement
Bore/Stroke
454 CID 482 CID 540 CID
(7.4L) (7.9L) (8.9L)
4.25 ln./4.00 ln. 4.25 ln./4.25 ln.
4.440 ln./
(108mm/102mm) (1 08/1 08mm)
4.375 ln.
(1 13/1 11mm)
Compression Ratio 8.6:1 9.2:1 8.75:1
Compression
Pressure
150 PSI 160 PSI 150 PSI
(1035 kPa) (1 103 kPa) (1035 kPa)
Idle RPM
(In Forward Gear)
800-850 950
Max. RPM (At W.O.T.) 4800-5200 4800-5400 4800-5200
Oil PSI
(At 2000 RPM)
35-70 PSI
(241 -483 kPa)
Min. Oil PSI
(At Idle)
5 PSI
(35 kPa)
Fuel Pump PSI
(At 1800 RPM)
5-7 PSI
(35-48 kPa)
Electrical System 12-Volt Negative (-) Ground
Min. Battery Cold
Cranking Amps
450
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type
AC-MR 43T Champion RV8C
Autolite-1 44 NGK-BR6FS
AC-MR41T
Spark Plug Gap .035 ln. (.9mm)
Breaker Point Gap
.01 6-.01 9 ln.
(0.40-0.45mm)
Dwell 28°-31°
Breaker Point
Spring Tension
25-30 Oz.
(709-850g)
Timing (At Idle RPM) 10° BTDC 15° BTDC 10° BTDC
Preliminary
Idle Mixture
2-3 Turns 1-1/4 Turns
Thermostat 143° F (62° C)
Valve Lash 0 .025 ln. (.65mm)
90-14499--1 887 MAINTENANCE -18-7
18-8 -MAINTENANCE 90-14499--1 887
Tune-Up Specifications
..I...MODEL
MIE 230/ MIE 260/ MIE 340/
5.0 LITRE 5.7 LITRE 7.4 LITRE
.;
Horsepower 230 260 340
(Kilowatts) (1 72) (194) (254)
Number of Cylinders V-8
Displacement 305 CID 350 CID 454 CID
(5L) (5.7L) (7.5L)
Bore/Stroke
3.74 ln./3.48 ln. 4.00 ln./3.48 ln. 4.25 ln./4.00 ln.)
(95/88mm) (102/88mm) (1 08/1 02mm)
Compression Ratio 8.5:1
Compression 155 PSI 150 PSI
Pressure (1 069 kPa) (1035 kPa)
Idle RPM
650-700(In Forward Gear)
Max. RPM (At W.O.T.) 4000-4400
Oil PSI 30-50 PSI 30-70 PSI
(At 2000 RPM) (207-379 kPa) (207-483 kPa)
Min. Oil PSI 4 PSI
(At Idle) (28 kPa)
Fuel Pump PSI 5-1/2-7 PSI
(At 1800 RPM) (38-48 kPa)
Electrical System 12-Volt Negative (-) Ground
Min. Battery Cold
305 350 450Cranking Amps
Firing Order L. H. Rot. 1-8-4-3-6-5-7-2 R. H. 1-2-7-5-6-3-4-8
Spark Plug Type
AC-MR43T Champion RV8C
Autolite-1 44 NGK-BR6FS
Spark Plug Gap .035 ln. (0.9mm)
Timing (At Idle RPM) 8° BTDC
Preliminary
2-3 Turns
Idle Mixture
Thermostat 143° F (62° C)
Tune-Up Specifications
MODEL MIE 5.7 Ski/5.7 Litre Comp Ski
Horsepower 260
(Kilowatts) (194)
Number of Cylinders V-8
Displacement
350 Cu. ln.
(5.7L)
Bore/Stroke
4.00/3.48 ln.
(1 02/88mm)
Compression Ratio 9:1
Compression 150 P.S.I.
Pressure (1 035 kPa)
Idle RPM
650-700(In Forward Gear)
Max. RPM (At W.O.T.) 4000-4400
Oil Pressure 30-55 P.S.I.
(At 2000 RPM) (207-379 kPa)
Min. Oil Pressure 4 P.S.I.
(At Idle) (28 kPa)
Fuel Pump Pressure
3-7 P.S.I.
(21-48 kPa)
Electrical System 12-Volt Negative (-) Ground
Min. Battery Cold
350Cranking Amps
Firing Order
L. H. Rot. 1-8-4-3-6-5-7-2
R.H. Rot. 1-2-7-5-6-3-4-8
Spark Plug Type
AC-MR43T Champion RV8C,
AutoIite-1 44 NGK-BR6FS
Spark Plug Gap .035 ln. (0.9mm)
Breaker Point Gap
.01 6-.01 9 ln.
(0.40-0.48mm)
Dwell 28° -31°
Breaker Point 25-30 Oz.
Spring Tension (709-850g)
Timing (At Idle RPM) 10° BTDC
Preliminary 2-3 Turns
Idle Mixture
Thermostat 143° F (62° C)
90-1 4499--1 887 MAINTENANCE -1 8-9
Fluid Capacities NOTICE
All capacities are approximate fluid measures.
MODEL
MCM 200/
5.0 Litre
5.7 Litre
MCM 230/ MCM 260/ MCM 300 Tempest/ MCM 300 Tempest/
5.0 Litre LX 350 Magnum 320 EFI Alpha One 320 EFI TRS
Crankcase
(with Fi Iter)
5 Ots.
(4.7L)
5-1/2 Qts. 6-1/2 Qts.
(5.2L) (6L)
Standard
Cooling System
Closed
Cooling System
Transmission
15 Ots.
(14.1 L)
20 Qts.
(19L)
2.1 Qts. (2L)
MODEL
MCM 454 Magnum
7.4 Litre
MCM 330 B/W MCM 370TRS/400 TRS
Crankcase
(with Filter)
7 Qts.
(6.6L)
6 Qts.
(5.6L)
Standard
Cooling System
20 Qts.
(19L)
Closed
Cooling System
28 Qts.
(26.5L)
Transmission
2 Qts.
(1.8L)
MODEL
MCM 400/440
CYCLONE
MCM 460
CYCLONE
MCM 420
HP 420
MCM 575
HP 575
Crankcase
(with Filter)
7 Ots.
(6.6L)
10 Qts.
(9.4L)
6 Qts.
(5.7L)
7 Ots.
(6.6L)
Standard
Cooling System
20 Qts.
(19L)
Transmission
(Approx.)
2 Qts.
(1.8L)
MODEL MCM 230TR MCM 260TR/
5.7 Litre
Crankcase
(with Filter)
6 Qts.
(5.6L)
Standard
Cooling System
15 Qts.
(14.1L)
Closed
Cooling System
20 Qts.
(19L)
Transmission
2 Qts.
(1.8L)
90-14499--1 887
18-10-MAINTENANCE
MODEL
MIE 230/
5.0 Litre
Crankcase
(with Fi Iter)
Standard
Cooling System
Closed
Cooling System
Transmission
1:1
Transmission
1.5:1-3.0:1
Transmission
V-Drive
MIE 260/ MIE 340/
5.7 Litre 7.4 Litre
6 Qts. 7 Qts.
(5.6L) (6.6L)
15 Qts. 20 Qts.
(14.1 L) (1 9L)
20 Qts. 28 Qts.
(1 9L) (26.5L)
2 Qts.
(1 .8L)
3 Qts.
(2.8L)
4-1/2 Qts.
(4.2L)
MODEL
MIE 5.7 Ski
5.7 Litre Comp Ski
Crankcase 4 Qts.
(with Filter) (3.8L)
Standard 15 Qts.
Cooling System (14.1 L)
Transmission
In-Line
Direct Drive
2 Qts.
(1 .9L)
Transmission
In-Line with
Reduction
3 Qts.
(2.9L)
Fuel, Oil, Fluid and Coolant
Specifications
FUEL
A CAUTION
Use of improper gasoline can damage the engine
seriously. Engine damage, that results from use of
improper gasoline, is considered misuse of the engine
and is not covered under MerCruiser Warranty.
The use of any good grade regular leaded, premium,
low-lead or lead-free automotive gasolines with a
minimum posted octane rating of 86 (research
octane number 90), are satisfactory for use in MerCruiser
marine engines. [Hi-Performance models:
However, gasolines containing alcohol, either methyl
alcohol (methanol) or ethyl alcohol (ethanol) may
cause increased:
• Corrosion of metal parts.
• 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 tendency
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.
The adverse effects of alcohol are more severe with
methyl alcohol (methanol) and are worse with
increasing alcohol content.
A WARNING
FIRE AND EXPLOSION HAZARD: Fuel leakage from
any part of the fuel system can be a fire and explosion
hazard which can cause serious bodily injury or
death. Careful periodic inspection of the entire fuel
system is mandatory, particularly after storage. All
fuel components including fuel tanks, whether plastic,
metal or fiberglass, fuel lines, fittings, fuel filters,
fuel pumps and carburetors should be inspected for
leakage, softening, hardening, swelling or corrosion.
Any sign of leakage or deterioration necessitates
replacement before further engine operation.
Because of the possible adverse effects of alcohol in
gasoline, it is recommended that only alcohol free
gasoline be used where possible. If only alcohol containing
fuel is available, or if the presence of alcohol
is unknown, then increased inspection frequency for
leaks and abnormalities is required.
Minimum posted octane rating of 88 (research
octane number 93). If 88 octane is not available, a
gasoline with an average octane rating as low as 86
(research octane number 90) may be used; however,
ignition timing must be retarded 4° to prevent harmful
detonation.]
90-1 4499--1 887
MAINTENANCE -18-11
No Lead Gasoline/ Alcohol Blends
LEAD
Recent regulations by the U.S. Enviromental Protection
Agency (EPA) and the Canadian government
have required the removal of lead (anti-knock compound)
from all gasoline by 1988 due to the lead
emission in exhaust being a health hazard.
In order to maintain octane ratings, many gasoline
manufactures are adding ethyl alcohol (ethanol) or
methyl alcohol (methanol) to the gasoline to replace
the lead.
Since 1975, Mercury Marine has recommended operation
of MerCruiser marine engines with any good
grade regular leaded, premium, low-lead or no-lead
gasolines with a minimum average octane rating of
88. Prior to that time, recommendations were to use
one tank of leaded gasoline for every four tanks of
no-lead gasoline. Mercury Marine has recently
amended its fuel recommendations for MerCruiser
engines.
NO LEAD GASOLINE WITH A MINIMUM POSTED
AVERAGE OCTANE RATING OF 86, MAY BE USED
IN MERCRUISER MARINE ENGINES AS STATED
ABOVE. (HI-PERFORMANCE MODELS ARE EXCEPTIONS.)
GASOLINE/ ALCOHOL BLENDS
Many new motor vehicle owner manuals are warning
about the potential damage from using gasoline containing
alcohol, especially METHANOL. They cite possible
fuel system damage and performance problems.
These are just two of the hazards that may be caused
by alcohol. These same problems as well as the additional
safety risk of fire and explosion from fuel system
leaks apply to marine inboard engines. METHANOL is
more severe in its bad effect than is ETHANOL. Alcohol
is also more severe in older engines since newer
engines have materials which are more resistant to
alcohol.
Effects of Gasoline/ Alcohol Blends on
Marine Engines
Corrosion of metals may result from use of alcoholgasoline
blends. Portable or permanently installed fuel
tanks of metal or fiberglass, fuel filters, fuel lines and
float bowls may be affected by alcohol blended fuels.
Many fiberglass fuel tanks are slowly dissolved by
alcohol, leading immediately to filter and carburetor
plugging and eventually to tank failure.
Alcohol containing fuels will absorb moisture from the
air. At first, this moisture will remain in solution, but
once the water content of the fuel has built up to about
one-half of one percent, it will separate out, (phase
separation) bringing the alcohol with it. This alcoholwater
mixture settles to the bottom of the fuel tank and
if this mixture gets into the engine, engines can be
seriously damaged internally, as it may wash the protective
film of oil off the bore of any cylinder that it
enters. Before the engine can be restarted, it is neces
sary to remove the separated alcohol and water layer,
flush out the fuel system with clean fuel and remove
and dry the spark plugs.
BOAVMOTOR STORAGE
When operating a MerCruiser engine on gasoline containing
alcohol, storage of gasoline in the fuel tank for
long periods of time should be avoided.
Long periods of storage, common to boats, create unique
problems. In cars, gasoline/alcohol blend fuels
normally are consumed before they can absorb enough
moisture to cause trouble, but boats often sit idle long
enough for phase separation to take place. In addition,
internal corrosion may take place during storage if
alcohol has washed protective oil films from internal
components.
WINTER STORAGE
If boat is to be placed in winter storage, carburetors
must be run dry at idle RPM. Permanent fuel tanks
should be drained completely and Quicksilver Gasoline
Stabilizer and Conditioner added to any fuel
remaining in the tank. Portable fuel tanks should be
emptied completely.
WARRANTY
Performance problems, fuel system or other damage
resulting from the use of gasoline-alcohol blended
fuels is not the responsibility of Mercury Marine and
will not be covered under our warranty.
CONTINUING EVALUATIONS
The effects of gasoline blended with ETHANOL and
METHANOL are still being evaluated by the United
States Coast Guard, the National Marine Manufacturers
Association (NMMA), Mercury Marine and other
engine and boat manufacturers.
We have recommended pump posting of alcohol content
of gasoline. Further we recommend using gasoline
known not to contain any METHANOL or ETHANOL
when possible.
18-12 -MAINTENANCE 90-14499--1 887
TEST FOR ALCOHOL CONTENT IN GASOLINE
The following is an acceptable and widely used field
procedure for the detection of alcohol in gasoline.
(Outboard motors only; Test should be conducted
before the addition of oil as the oil may obscure any
change in separation level.) Use any small transparent
bottle or tube that can be capped and is or can be
provided with graduations or a mark at about 1/3full. A
pencil mark on a piece of adhesive tape may be used.
PROCEDURE
1.
Fill the container with water to the mark.
2.
Add fuel almost to fill the container, leaving some
air space; then, cap the container. The proportions
of fuel to water are not critical, but there
should be 2-3 times as much fuel as water.
3.
Shake container vigorously and allow it to sit
upright for up to about 3-5 minutes. If the volume of
water appears to have increased, alcohol is present.
If you are not sure, there is no need for concern. If
the dividing line between water and fuel becomes
cloudy, use the middle of the cloudy band.
Crankcase Oil
After the 20-hour break-in oil has been drained, select
a crankcase oil based on the prevailing daytime temperature
in the area in which the boat is operated.
The chart following is the guide to crankcase oil selection
and recommended change intervals. Oil filter
should always be changed with oil.
To help obtain optimum engine performance and to
provide maximum protection, we strongly recommend
the use of Quicksilver 4-Cycle Marine Engine Oil. If not
available, however, a good grade detergent automotive
oil of correct viscosity, that has an API classification of
"SE'' or "SF", may be used.
IMPORT ANT: The use of multi-viscosity oils specifically
is not recommended for use in MerCruiser Engines.
In those areas, however, where the recommended
straight weight oil is not available, a multiviscosity
oils (other than 20W-40 or 20W-50), oils
which contain "solid" additives, non-detergent oils, or
low quality oils specifically are not recommended.
Oll 1nd 011
Prevailing 01ytlme VIscosity 1nd
Temperature API Clalllflc.tlon
Filler Change
Intervals
SAE 40. "SE"or
a-QUICKSILVER4-CYCLEMARINEENGINEOIL
''SF''
SAE 30,
CHANGE Every 100 Hours of
Operation or 80 Days Wh•chever
Occurs First
"SE"or
"SF" 32"Fii"C SAE 20, "SE"or CHANGE Every 50 Hours of
Operation or 30
O"F "SF" Days Whichever
Occurs F1rst
Power Steering Fluid
IMPORTANT: Use only automatic transmission fluid
(ATF), Dexron® or Dexron II in Power Steering System.
Transmission Fluid
VELVET DRIVE® (BORG-WARNER)
Dexron® II, Type F, or other hydraulic transmission
Fluids which meet the Detroit Diesel Allison Type C3
specifications are recommended for use in all Velvet
Drive® marine transmissions.
Coolant
A CAUTION
Alcohol or Methanol base anti-freeze or plain water,
are not recommended for use in fresh water section of
cooling system at any time.
We recommend that the coolant section of Closed
Cooling System be filled with a 50/50 mixture of ethylene
glycol anti-freeze and water. In areas where the
possibility of freezing DOES NOT exist, it is permissible
to use a solution of rust inhibitor and water (mixed
to manufacturer's recommendations).
MerCruiser V-8 engines can use any type of permanent
anti-freeze or any brand anti-freeze solution that meets
G.M. specification 1825M.
90-14499--1 887
MAINTENANCE -18-13
Maintaining Crankcase Oil
Level
Overfilled Engine Crankcase
Overfilled crankcases (oil level being too high) can
cause a fluctuation or drop in oil pressure and rocker
arm "clatter", on MerCruiser engines. The over-full
condition results in the engine crankshaft splashing
and agitating the oil, causing it to foam (become aerated).
The aerated oil causes the hydraulic valve lifters
to "bleed down". This, in turn, results in rocker arm
"clatter" and loss of engine performance, due to the
valves not opening properly.
Care must be taken when checking engine oil level. Oil
level must be maintained between the "ADD" mark and
the "FULL" mark on the dipstick. To ensure that you
are not getting "false reading", make sure the following
steps are done before checking the oil level.
•
Boat "at rest" in the water, OR
•
If boat is on a trailer, raise or lower bow until the
boat is setting at the approximate angle that it
would be if setting "at rest" in the water.
•
Allow sufficient time for oil to drain into the crankcase
if engine has just been run or oil has just been
added.
Checking Engine Oil Level/Filling
1.
Stop engine and allow boat to come to a rest.
2.
Allow oil to drain back into oil pan-approximately 5
minutes.
3.
Remove dipstick. Wipe clean and reinstall. Push
dipstick all-the-way into dipstick tube.
4.
Remove dipstick and note the oil level.
5.
Oil level must be between the "FULL" and "ADD"
marks.
6.
If oil level is below "ADD" mark, proceed to 7 and 8.
7.
Remove oil filler cap from valve rocker arm cover.
8.
Add required amount of oil to bring level up to, but
not over, the "FULL" mark on dipstick.
Changing Oil and Filter
1.
Start engine and run until it reaches normal operating
temperatures.
IMPORTANT: Change oil when engine is warm from -............_, operation, as it flows more freely, carrying away more
impuritites.
2.
Stop engine.
3.
Remove drain plug from oil pan.
NOTE: If drain plug is not accessible because of boat
construction, oil may be removed thru dipstick tube,
using a Quicksilver Crankcase Oil Pump. (See Quicksilver
Accessory Guide)
4.
After oil has drained completley, reinstall drain
plug and tighten securely.
1 5870
a -Drain Plug
b-Oil Pan
c-Quicksilver Crankcase Oil Pump
Draining Oil (Typical Engine)
18-14 -MAINTENANCE
90-1 4499--1 887
5.
Remove and discard oil filter and its sealing ring.
6.
Coat sealing ring on new filter with engine oil, and
install new filter. Tighten filter securely (following
filter manufacturer's instructions). Do not overtighten.
7.
Fill crankcase with oil.
a -Oil Filter
b-Sealing Ring
Changing Oil Filter (Typical Engine)
r
Maintaining Power Steering
Pump Fluid Level
With Engine Warm From Operation
1.
Stop engine and position drive unit so that it is
straight back.
2.
Remove fill cap/dipstick from Power Steering pump
and note fluid level.
a -Fill Cap/Dipstick
b-Pump
3. Level should be between the "FULL HOT" mark and
"ADD" mark on dipstick.
4.
If level is low (below "ADD" mark), but fluid is still
visible in pump reservoir, add required amount of
automatic transmission fluid (ATF), type "F", Dexron,
or Dexron II, thru fill cap opening, to bring level
up to "FULL HOT" mark on dipstick -do not overfill.
5.
If fluid is not visible in reservoir, a leak exists in the
Power Steering system. Find cause and correct.
With Engine Cold
1.
Stop engine and position drive unit so that it is
straight back.
2.
Remove fill cap/dipstick from Power Steering pump
and note fluid level.
3.
Level should be between "FULL COLD" mark and
bottom of dipstick.
4.
If fluid level is below bottom of dipstick, but fluid is
still visible in pump reservoir, add required amount
of automatic transmission fluid (ATF), type "F",
Dexron, or Dexron II, thru fill cap opening, to bring
level up to "FULL COLD" mark on dipstick -Do not
overfill.
5.
If fluid is not visible in reservoir, a leak exists in the
Power Steering system. Find cause and correct.
90-1 4499--1 887
MAINTENANCE -18-15
Filling and Bleeding Power
Steering System
IMPORTANT: Power Steering system must be filled
exactly as explained, following, to be sure that all air is
bled from the system. All air must be removed, or fluid
in pump may foam during operation and be discharged
from pump reservoir. Foamy fluid also may cause
Power Steering system to become spongy, which may
result in poor boat control.
1.
Position drive unit so that it is straight back.
Remove shipping cap from Power Steering pump
and check fluid level with dipstick attached to fill
cap (provided). Add automatic transmission fluid
(ATF), Dexron or Dexron II as required, to bring
level up to "FULL-COLD" mark on dipstick.
IMPORTANT: Use only automatic transmission fluid
(ATF), Dexron or Dexron II In Power Steering System.
2.
Turn steering wheel back-and-forth to end of travel
in each direction several times; then, recheck fluid
level and add fluid, if necessary.
3.
Install vented fill cap.
A CAUTION
DO NOT operate engine without water being supplied
to seawater pickup pump or pump Impeller may be
damaged and subsequent overheating 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 backand-
forth to end of travel in each direction 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, 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.
IMPORTANT: Drive unit must be positioned straight
back and Power Steering fluid must be hot to accurately
check fluid level.
6.
If fluid is still foamy (in Step 5), repeat Steps 4 and 5
until fluid does not foam and level remains constant.
Maintaining Closed Cooling
Coolant Level
A WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly; then, push down and turn cap all-the
way off.
1.
Coolant level in heat exchanger should be within 1
in. (25mm) from bottom of filler neck.
IMPORTANT: When reinstalling pressure cap, be sure
to tighten It until It contacts stop on filler neck.
2.
Coolant level should be between the "ADD-FULL"
marks on coolant recovery reservoir with the engine
at normal operating temperature.
a-Filler Cap
90-14499--1 887
1 B-16 -MAINTENANCE
Flushing Cooling System
If engine is operated in salty, polluted, or mineral-laden
water, flush cooling system (preferably after each use)
r to reduce corrosion and prevent the accumulation of
\'-deposits in the system. Thoroughly flush cooling system
prior to storage.
IMPORTANT: If cooling system is to be flushed with
boat in the water, water inlet valve {if so equipped)
must be closed or water inlet hose must be disconnected
and plugged, to prevent water from flowing into
boat and cooling system. If a valve is to be installed for
this purpose, valve used must have an internal crosssectional
area equal to or greater than water inlet hose
to prevent restricting water flow during normal operation.
A 1-1/4 in. {32mm) or larger brass ball valve or
gate valve is recommended.
Belt Driven Seawater Pickup Pump
All V-8 engine equipped with an engine mounted, belt
driven seawater pickup pump, follow these instructions.
ACAUTION
Belt Driven Pump Models Equipped with MerCruiser I
or Alpha One Stern Drives: In addition to pump on
engine, cooling water also must be supplied to seawater
pickup holes in gear housing or overheating and
subsequent damage to drive unit will result.
1.
Disconnect seawater inlet hose from appropriate
location.
a -Seawater Pickup Pump
b-Seawater Inlet Hose -Remove
V-8 Engine Except MCM 370TRS/400TRS and 454
C.I.D. Cyclone Engines
a-Disconnect Hose at Appropriate Location -Cooling Water Must
Flow thru Cooler(s), If Engine Is So Equipped
MCM 370TRS/400TRS/ and Hi-Performance 454 C.I.D.
Engines
2.
IMPORTANT: V-8 engines, equipped with MerCruiser
I or Alpha One Stern Drives, which will be
flushed with boat out-of-water, use Flush Test
Device 73971 A2 to supply cooling water to drive
unit.
a -Flush Device
b -Garden Hose
Flush Test Device 73971A2 Installed on MerCruiser 1/
Alpha One Stern Drive
Using appropriate connector, connect city water tap to
pump inlet connection and partially open water tap
(approximately 1/2 maximum capacity). Do not use full
city water pressure.
A WARNING
When flushing cooling system with boat out of the
water, be certain that area in vicinity of propeller is
clear and that no person is standing nearby. As a precautionary
measure, it is recommended that propeller
be removed.
A CAUTION
DO NOT run engine above 1500 RPM, as suction
created by seawater pickup pump may collapse water
supply hose and cause engine to overheat.
3.
Place the remote control lever in neutral position
and start engine. Operate engine at idle speed in
neutral gear for 10 minutes or until discharge water
is clear; then, stop engine.
90-1 4499--1 887
MAINTENANCE -18-17
A CAUTION Watch temperature gauge at dash to ensure that
engine does not overheat.
4. Shut off water tap. Remove flushing connector from
pump inlet and reconnect water inlet 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.
MCM-1/ One Stern
Seawater Pump A CAUTION
Drive Unit
DO NOT run engine above 1500 RPM when flushing, as
suction created by seawater pickup pump in drive unit
may collapse garden hose and cause engine and/or
drive unit to overheat.
BOAT OUT-OF-WATER
1. Install Flush-Test-Device 73971 A2 over water pickup
holes in gear housing. Attach a garden hose
between the device and water tap.
2. Partially open water tap (approximately 1/2 maximum
capacity). DO NOT use full city water pressure.
A WARNING When flushing cooling system, be certain that area in
vicinity of propeller is clean and that no person(s} is
nearby. As a precautionary measure, it is recommended
that propeller be removed.
3. Place remote control in neutral, idle speed position,
and start engine.
4. Operate engine at idle speed in neutral for 10 minutes,
or until discharge water is clear; then, stop
engine.
5. Shut off water tap. Remove Flush-Test-Device and
garden hose.
18-18-MAINTENANCE
BOAT IN-THE-WATER
1. Raise drive unit to full "Up" position.
2. Install Flush-Test-Device 73971 A2 over water pickup
holes in gear housing. Attach a garden hose
between the device and water tap.
3. Lower drive unit to full "In" position.
4. Follow Steps 2 thru 4 under "Boat Out-of-Water".
5. Shut-off water tap.
6. Raise drive unit to full "Up" position -Remove
Flush-Test-Device and garden hose.
a-Flush Test Device 73971 A2
b -Garden Hose
90-14499--1 887
Maintaining Transmission
Fluid Level
1. Remove dipstick. Check to ensure that fluid is indicated
on dipstick. Fluid level may be somewhat over
the full mark, as some of the fluid from transmission
fluid cooler and hoses may have drained back into
transmission. If level is low, add automatic transmission
fluid (ATF) until level comes up to full mark
on dipstick.
a-Dipstick b-Full Mark
c -Dipstick Tube
Checking Transmission Fluid Level
IMPORTANT: To accurately check fluid level, engine
MUST BE run 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.
IMPORTANT: 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.
5. If transmission fluid level was extremely low, carefully
check transmission, fluid cooler and hoses for
leaks.
Lubrication
Throttle Cable
a-SAE 30W Engine Oilb -2-4-C Marine Lubricant
Typical 2-Barrel Carburetor
a-SAE 30W Engine Oil
b-2-4-C Marine Lubricant
Typical 4-Barrel Carburetor
90-14499--1 887 MAINTENANCE -18-19
a-SAE 30W Engine Oil
b -2-4-C Marine Lubricant
EFI
Shift Cable
a-SAE 30W Engine Oil
b-2-4-C Marine Lubricant
MCM Models with MR, Alpha One Drives, Bravo I Drive
(Without Neutral Switch)
a-SAE 30W Engine Oil
b -2-4-C Marine Lubricant
MCM Models with Transmissions (TR/TRS)
a-SAE 30W Engine Oil
b-2-4-C Marine Lubricant
MCM Models with Transmissions (TR/TRS)
18-20 -MAINTENANCE 90-14499--1 887
a-SAE 30W Engine Oil
b-2-4-C Marine Lubricant
MIE Models (Typical) Shift Cable and Transmission
Linkage
Engine Coupler/U-Joint Shaft Splines
NOTE: Refer to MerCruiser Stern Service Manual, for
stern drive unit removal and installation.
a-2-4-C Marine Lubricant
MCM Models with Alpha One Drive
90-14499--1 887
a -2-4-C Marine Lubricant
Alpha One Drive
U-Joint Shaft Splines (Stern Drive
Models with Borg-Warner
Transmission)
NOTE: Refer to appropriate MerCruiser Stern Drive
Service Manual, for stern drive unit removal and installation.
a -2-4-C Marine Lubricant
TR/TRS Stern Drive Unit
MAl NTENANCE -1 8-21
a-2-4-C Marine Lubricant
Bravo One Drive
a-2-4-C Marine Lubricant
Engine End
Drive Shaft Extension Models (MCM
305, 350 CID)
a -2-4-C Marine Lubricant
MCM 1/ Alpha One Stern Drive U-Joint
a -2-4-C Lubricant
Transom End
lB-22 -MAINTENANCE 90-14499--1 887
Staggered Engine All Models
a-2-4-C Marine Lubricant
b-Bell Housing
Tailstock Assembly
a-2-4-C Marine Lubricant
Tailstock and Drlveshaft (Transom End)
a-2-4-C Marine Lubricant
Driveshaft (Engine End)
Starter Motor Lubrication A WARNING When performing the following procedure, be sure to
observe the following: • Be sure that engine compartment is well ventilated
and that no gasoline vapors are present, to avoid the
possibility of a fire. • Be sure to keep hands, feet and clothing clear of
engine moving parts. • Be sure to ground coil hi-tension wire to block.
Failure to ground coil wire may cause damage to
ignition coil, in addition to being a safety hazard.
MCM 330 8/W, and MIE 230, 260, 5.0
Litre, 5. 7 Litre, 340, 7.4 Litre and 5. 7 Ski
MCM 300 Tempest TRS, 370/400 TRS,
400/440/460 Cyclone, MCM 420/575
90-14499--1 887
a -Remove ignition coil hi-tension wire from distributor cap tower
and ground it to engine block with jumper wire. While cranking
engine with starter motor, lubricate starter motor front bushing
thru oil cover with Lubriplate Extra-Heavy Gear Shield or its
equivalent. Reinstall coil hi-tension wire.
b-Remove plastic plug from flywheel housing. Lubricate starter
motor shaft with Lubriplate Extra-Heavy Gear Shield thru hole
in flywheel housing. Reinstall plastic plug.
Starter Motor Lubrication
MAINTENANCE -18-23
Out-of-Season Storage
Precautions
A WARNING
Be careful while working on fuel system; gasoline is
extremely flammable and highly explosive under certain
conditions. Be sure that ignition key is "OFF" and
do not smoke or allow sources of spark and/or open
flames in the area.
A WARNING
To prevent a potential fire hazard, be sure that engine
compartment is well ventilated and that there are no
gasoline vapors present during starting or fogging of
engine.
A CAUTION
DO NOT operate engine without cooling water being
supplied to seawater pickup pump, or water pump
impeller will be damaged and subsequent overheating
damage to engine may result.
A CAUTION
Cooling System must be completely drained for storage,
or trapped water may cause freeze and/or corrosion
damage to engine. If engine has been exposed to
freezing temperatures, the boat should be placed in a
warm area before attempting to run engine or drain
cooling system.
A CAUTION
If engine is equipped with Closed Cooling System,
Closed Cooling section must be kept filled with a solution
of ethylene glycol anti-freeze and water (mixed
anti-freeze manufacturer's recommended proportions
to protect engine to lowest temperature to which it will
be exposed). Seawater section, however, must be
drained completely.
A CAUTION
A discharged battery can be damaged by freezing.
18-24 -MAINTENANCE
Layup
NOTICE
Refer to "Precautions", in this section, BEFORE proceeding.
1.
Fill fuel tank(s) with fresh gasoline that does not '-...../.· contain alcohol and a sufficient amount of Quicksilver
Gasoline Stabilizer and Conditioner to treat
the gasoline.
IMPORTANT: If boat is to be placed in storage (with
fuel containing alcohol in fuel tanks), carburetors must
be run dry at idle RPM. Fuel tanks should be drained
completely and Quicksilver Gasoline Stabilizer and
Conditioner added to any fuel remaining in the tank.
Also, refer to "Fuel Requirements"; see Table of Contents.
320 EFI Only: Drain tanks completely and add one
gallon of gasoline mixed with Quicksilver 2-Cycle outboard
Oil at 20:1 gasoline/oil ratio. Run engine to distribute
fuel mix throughout engine EFI system without
running dry.
2.
Replace all fuel filters.
3.
Start engine and check for fuel leaks.
4.
Run engine sufficiently to bring it up to normal
operating temperature; shut off engine and change
oil and filter.
5.
If boat has been operated in salty, polluted or
mineral-laden waters, flush cooling system.
6.
Remove flame arrestor assembly and restart engine.
While operating engine at fast idle (1000-1500
RPM), fog internal surfaces of induction system
and combustion chambers by squirting approximately
8 ounces (227 grams) of Quicksilver Storage
Seal or SAE 20 SE engine oil into carburetor bores.
Stall engine by squirting last 2 ounces (57 grams) of
Storage Seal or oil rapidly into carburetor. Turn
ignition to "OFF".
7.
Close fuel shut off valve, if so equipped.
8.
Clean flame arrestor and crankcase ventilation
hoses and reinstall.
9.
Lubricate all items outlined in "Lubrication".
10. Drain cooling system.
11. Closed
Cooling System Models, test coolant to
ensure that it will withstand lowest temperature
expected during storage.
12. Service batteries.
13. Clean
outside of engine and repaint any areas
required with Quicksilver Primer and Spray Paint.
After paint has dried, spray Quicksilver Corrosion
and Rust Preventive Type II or wipe down with
Quicksilver Storage Seal or SAE 20 SE engine oil.
14. For Stern Drive Unit Refer to "Stern Drive Manual.
90-1 4499--1 887
Recommissioning
NOTICE
Refer to "Precautions", in this section, BEFORE prof'
· ceeding.
1. Check that all cooling system hoses are connected
and tight and all petcocks and drain plugs are in and
tight.
2. Inspect all drive belts.
3. Check engine belts.
4.
Perform all lubrication and maintenance specified
for completion "At Least Once Each Year" in maintenance
chart, except items which were performed
at time of engine layup.
5.
Install Stern Drive unit. (Refer to Stern Drive
Manual).
A CAUTION
When installing battery (in next step), be sure to connect
negative (grounded) battery cable to negative (-)
battery terminal and positive battery cable to positive
(+) terminal. If battery cables are reversed, damage to
electrical system WILL result.
6.
Install fully-charged battery. Clean battery cable
clamps and terminals and reconnect cables. Be
sure to tighten clamps securely. Apply a thin coat of
petroleum base grease to clamps and terminals to
help retard corrosion.
7.
Start engine and closely observe instrumentation to
ensure that all systems are functioning properly.
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 control
for proper operation.
90-14499--1 887
MAINTENANCE-18-25
..
TROUBLESHOOTING
SPECIP
CAUSE 1. Distributor cap or sp;
1.
2.
. . . components
Moisture on Ignition
. damaged wiring
Battery. electrical connections.
3. Ignition switch
4. Shift interruptor switch 5. Disconnect tachorr
5. Shorted tachometer
7. Fouled, burned, cr
Ignition timing6. 8. Faulty insulation.
1. Spark plugs
8 Spark plug wires
10. Check componel·
d'rtY distributor cap
9 cracked or I . " .
. . onents . 11 Synchronizer10. Faulty igmtlon comP
. d) hooked up in senes on .
(parallel cirCUit)
izer (if equlppe
11. Engine (dual engines only)
Index
NOTICE
Refer to "Precautions", BEFORE proceeding with
troubleshooting.
Page
Precautions .................................. 1 C-1
Used Spark Plug Analysis ..................... 1 C-1
Spark Plug Analysis .......................... 1C-1
Poor Boat Performance and/or
Poor Maneuverability ...................... 1 C-4
Improper Full Throttle Engine RPM ............ 1 C-4
RPM Too High ............................ 1C-4
RPM Too Low ............................. 1C-4
Engine Cranks Over But Will Not Start
or Starts Hard ............................. 1 C-5
Important Information ..................... 1 C-5
Conventional Ignition (No Spark) ........... 1 C-5
Thunderbolt IV (HEI) Ignition (No
Spark) ................................. 1 C-5
Thunderbolt IV (HEI) Ignition Test .......... 1 C-6
Fuel System Rich .......................... 1C-7
Fuel System Lean ......................... 1C-7
Miscellaneous ............................. 1 C-8
Engine Will Not Crank Over ................... 1 C-8
Charging System Inoperative .................. 1 C-8
Noisy Alternator ........................... 1 C-8
Instrumentation Malfunction .................. 1 C-8
Radio Noise .................................. 1C-9
Poor Fuel Economy .......................... 1 C-9
Carburetor Malfunctions ..................... 1C-10
Engine Runs Poorly at Idle ...................1C-11
Engine Acceleration Is Poor .................. 1 C-11
Engine Runs Poorly at High RPM ............. 1C-12
Troubleshooting with Vacuum Gauge ......... 1C-12
Engine Noise ................................ 1C-13
Important Information .................... 1C-13
Valve Cove Area .......................... 1 C-13
Cylinder Area ............................ 1C-13
Camshaft Area ........................... 1 C-14
Crankshaft Area .......................... 1 C-14
Miscellaneous ............................ 1C-15
Oil Pressure ................................. 1C-16
Important Information .................... 1C-16
Low Oil Pressure ......................... 1C-17
High Oil Pressure ........................ 1C-17
Excessive Oil Consumption .................. 1C-18
Water in Engine ............................. 1C-19
Important Information .................... 1C-19
Water on Top of Pistons .................. 1C-19
Water in Crankcase Oil ................... 1C-19
Engine Overheats (Mechanical) .............. 1 C-20
EngineOverheats (Cooling System) .......... 1 C-21
Insufficient Water Flow from MC-1 Stern
Drive Seawater Pickup Pump ........... 1 C-22
Insufficient Water Flow from Belt Driven
Seawater Pickup Pump ................ 1 C-22
Power Steering .............................. 1 C-23
Poor, Erratic or No Assist ................. 1 C-23
;':_.4 ..-..·
Noisy Pump .............................. 1 C-23
Fluid Leaks .............................. 1 C-23
320 EFI Troubleshooting ..................... 1 C-24
Hurth Transmission ......................... 1 C-39
90-14499--1 887
TROUBLESHOOTING -1C
Precautions
A WARNING
Always disconnect battery cables from battery
BEFORE working on fuel system to prevent fire or
explosion.
A WARNING
Be careful when cleaning flame arrestor and crankcase
ventilation hose; gasoline is extremely flammable and
highly explosive under certain conditions. Be sure that
ignition key is "OFF". DO NOT smoke or allow sources
of spark or open flame in area when cleaning flame
arrestor and crankcase ventilation hose.
A WARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". DO NOT smoke or allow sources of spark or
flame in the area while changing fuel filter. Wipe up any
spilled fuel immediately.
A WARNING
Make sure no fuel leaks exist, before closing engine
hatch.
A CAUTION
DO NOT operate engine without cooling water being
supplied to water pickup holes in gear housing, or
water pump impeller will be damaged and subsequent
overheating damage to engine may result.
A CAUTION
DO NOT operate engine without water being supplied
to seawater pickup pump on engine, or pump impeller
may be damaged and subsequent overheating damage
to engine may result. Engine may be operated with
boat out-of water, if instructions, under "Running
Engine with Boat Out-of-the-Water", following are
completed.
A WARNING
When running engine with boat out of water, be certain
that area in vicinity of propeller is clear and that no
person is standing nearby. As a precautionary measure,
it is recommended that the propeller be removed.
A CAUTION
DO NOT run engine above 1500 RPM, as suction
created by seawater pickup pump may collapse water
supply hose and cause engine to overheat.
A WARNING
Be sure that engine compartment is well ventilated and
that no gasoline vapors are present to prevent the possibility
of a FIRE.
A WARNING
DO NOT leave helm unattended while performing idle
speed adjustment.
Used Spark Plug Analysis
Use the following illustrations for determining serviceability
of spark plug. Spark plug condition also can
suggest a variety of possible engine malfunctions and,
therefore, can indicate needed engine repairs. When
old plugs are replaced, replace entire set. Perform plug
service only on those plugs suitable for additional service,
using the following procedures:
A.
Remove any oil deposits with solvent and dry plugs
thoroughly.
B. Open electrode gap wide enough to permit cleaning
and filling.
C. Remove combustion deposits from firing end of
spark plug with a plug cleaner. Blow off with
compressed air to remove abrasives.
D. File
electrode surfaces to restore clean, sharp
edges. Again remove fillings with compressed air.
E.
Reset gap to specifications by bending only side
electrode with proper tool.
Spark Plug Analysis
NORMAL CONDITION
Few deposits are present and probably will be light tan
or gray in color. This plug shows that plug heat range is
compatible with engine, and engine is electrically and
mechanically in good running condition. With proper
plug servicing (clean, file and regap), this plug can be
reinstalled with good results.
90-14499--1 887
TROUBLESHOOTING -1 C-1
CHIPPED INSULATOR
Chipped insulator usually results from careless plug
regapping. Under certain conditions, severe detonation
also can split insulator firing ends. Plug must be
replaced.
WET FOULING (OIL DEPOSITS}
Plug becomes shorted by excessive oil entering combustion
chamber, usually in engines with many hours
of operation. Worn piston rings, cylinder walls, valve
guides or valve stem seals are causes of oil entering
combustion chamber. Only engine repairs will permanently
relieve oil wet fouling.
IMPORTANT: New engines or recently overhauled
engines may wet foul plugs before normal oil control is
achieved with proper break-in procedures. Such fouled
plugs may be serviced (clean, file and regap) and reinstalled.
COLD FOULING
Dry, black deposits indicate rich fuel mixture or weak
ignition. Clogged flame arrestor, flooding carburetor,
sticky choke or weak ignition components all are probable
causes. If, however, only one or two plugs in set
are fouled, check for sticking valves or bad ignition
leads. After correcting cause, service (clean, file and
regap) plugs and reinstall.
OVERHEATING
Insulator is dull white or gray and appears blistered.
Electrodes are eroded and there is an absence of deposits.
Check that correct plug heat range is being
used. Also check for over-advanced ignition timing,
cooling system malfunction, lean fuel/air mixtures,
leaking intake manifold or sticking valves. Replace
spark plugs.
.......' -:-:}; .. ....t ··r<.,).·t i,. ..
...r.. t-.. ..
1C-2 -TROUBLESHOOTING 90-14499--1 887
HIGH SPEED GLAZING
Insulator has yellowish, varnish-like color, indicating
that temperatures suddenly have risen, usually during
hard, fast acceleration under heavy load. Normal deposits
do not get a chance to blow off. Instead, they
melt and form a conductive coating. Replace plugs. If
condition re-occurs, use colder heat range plug and
service plugs more frequently.
SCAVENGER DEPOSITS
Powdery white or yellow deposits are built up on shell,
insulator and electrodes. This is a normal appearance
with certain branded fuels. Accumulation on ground
electrode and shell areas may be unusually heavy, but
may be easily chipped off. Plugs can be serviced
(clean, file and regap) and reinstalled.
PRE-IGNITION DAMAGE
Pre-ignition damage is caused by excessive high
temperatures. Center electrode melts first, followed by
ground electrode. Normally, insulators are white but
may be dirty if plug has been misfiring. Check for
correct plug heat range, advanced ignition timing, lean
fuel mixture, incorrect fuel used, malfunctioning cooling
system, leaking intake manifold or lack of lubrication.
REVERSED COIL POLARITY
Concave erosion of ground electrode is an indication
of reversed polarity. Center electrode will show only
normal wear. Engine will misfire and idle rough. To
correct, reverse primary coil leads. Replace spark
plugs.
SPLASHED DEPOSITS
Spotted deposits, which sometimes occur after long
delayed tune-up, accumulate after a long period of
misfiring. When normal combustion temperatures are
restored, upon installation of new plugs, deposits
loosen from top of piston and head and are thrown
against hot insulator. Clean and service plugs and
reinstall.
08958
MECHANICAL DAMAGE
Mechanical damage to spark plug firing end is caused
by foreign object in combustion chamber. Because of
valve overlap, small objects can travel from one cylinder
to another. Check all cylinders, intake manifold
and exhaust manifold to prevent further damage.
90-1 4499--1 887
IMPORTANT: When working on engine, spark plug
holes and carburetor throat should be kept covered to
prevent foreign objects from entering combustion
chamber.
TROUBLESHOOTING -1 C-3
Poor Boat Performance and/
or Poor Maneuverability
SYMPTOM CAUSE
1. Bow too low
2. Bow too high
3. Propeller ventilating
1.
2.
3.
A. Improper drive unit trim angle
B. Improper weight distribution
C. Boat is underpowered
D. Permanent or power hook in boat bottom
E. False bottom full of water
F. Improperly adjusted trim tabs (after planes)
A. Improper drive unit trim angle
B. Propeller pitch too great
C. Dirty boat bottom (marine growth)
D. Poor running engine
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 in the
water
E. Water pick-up or accessories located too close to propeller
F. Hook in boat bottom
G. Propeller plugged up with weeds
Improper Full Throttle Engine
RPM
RPM TOO HIGH
CAUSE
1.
Propeller
2.
Boat
SPECIAL INFORMATION
1.
Damaged; pitch too low; diameter too small; propeller
hub slipping
2.
Water pick-up or accessories mounted too close to propeller
(ventilation); keel located too close to propeller
and/or too deep in the water (ventilation). Drive installed
too high on transom; wrong gear ratio.
Operation
Unit trimmed out too far.
4. Engine coupler slipping
RPM TOO LOW
1. Propeller
CAUSE
1.
SPECIAL INFORMATION
Damaged; pitch too great; diameter too great.
2. Boat 2. Dirty or damaged bottom; permanent or power hook in
bottom; false bottom full of water. Drive installed too low
on transom; wrong gear ratio.
3. Operation Unit trimmed in too far
1C-4 -TROUBLESHOOTING
90-14499--1 887
Engine Cranks Over But Will
Not Start or Starts Hard
IMPORTANT INFORMATION
('.
1.
First, determine which engine system is causing the
problem. To make an engine run, basic components
-fuel, spark (ignition), and compression are
required. If all three components are present, the
engine should run. If any one of the three are missing,
weak, or arriving at the wrong time the engine
will not run.
CONVENTIONAL IGNITION (NO SPARK)
THUNDERBOLT IV (HEI) IGNITION (NO SPARK)
2.
Determine if there is fuel present by looking down
the carburetor venturi while actuating throttle.
There should be a stream of fuel coming out of the
accelerator pump nozzles if the carburetor has fuel.
3.
Check ignition system operation. Remove coil wire
from tower on distributor cap. Hold coil wire near
ground and check for spark while cranking engine
over. Repeat procedure with spark plug wires. If
there is spark at the spark plug wires, remove the
spark lugs and make sure the plugs are correct type
and heat range, and not fouled or burned.
4.
Run a compression check on engine to make sure
the engine is mechanically OK.
CAUSE SPECIAL INFORMATION
1. Moisture on ignition components 1. Distributor cap or spark plug leads arcing
2. Battery, electrical connections, damaged wiring
3. Ignition switch 3. May run in start position and lose spark in the run
position.
4. Shift interruptor switch (I/ Alpha One Models Only)
5. Shorted tachometer 5. Disconnect tachometer and try again. 6. Ignition timing 6. May crank over hard, backfire, or try to run backwards
7. Faulty ignition resistor wire or bypass wire
8. Ignition points improperly gapped, burned or dirty
9. Spark plugs 9. Fouled, burned, cracked porcelain·
10. Spark plug wires 10. Faulty insulation, broken wires
11. Cracked or dirty distributor cap or rotor
12. Coil
13. Condenser
CAUSE SPECIAL INFORMATION
1. Moisture on ignition components
2. Battery, electrical connections, damaged wiring
3. Ignition switch
4. Shift interruptor switch (I/ Alpha One Models Only)
5. Shorted tachometer 6. Ignition timing
7. Spark plugs
8. Spark plug wires
9. Cracked or dirty distributor cap
10. Faulty ignition components
11. Engine synchronizer (if equipped) hooked up in series on
purple ignition wire (dual engines only)
1. Distributor cap or spark plug wires arcing
5. Disconnect tachometer and try again
7. Fouled, burned, cracked porcelain
8. Faulty insulation, broken wires
10. Check components
11. Synchronizers must be hooked up directly at coil terminal
(parallel circuit)
90-14499--1 887
TROUBLESHOOTING -1C-5
THUNDERBOLT IV (HEI) IGNITION TEST
Check all Terminal Connections
at Distributor, Ignition Amplitier
& Ignition Coil
Battery OK?
Dist. Clamping Screw Tight?
Replace
Ignition
Amplifier
Volts
Disconnect WHT I
RED Lead From
Dist. Term.; Then,
Check for 12-Volts
on This Lead
Volts
Replace
Ignition
Sensor in
Distributor
0
Volts
No Spark
With Key in "RUN" Position, Check
for 12-Volts at Positive (+) Terminal
on Ignition Coil
Volts
Check for 12-Volts at WHT/RED
Terminal on Distributor
Volts
Remove Hi-Tension Lead
from Dist. to Coil.
Insert a Spark Gap from
Coil Tower to Ground. Re
move WHT/GRN Lead from Dist.
Terminal -Ignition Key in
"RUN" Position. Strike the
Terminal on the WHT/GRN Lead
Against Ground
No Spark Coil
Substitute a New Ignition
Coil. Repeat Above Test
No Spark Coil
Replace Ignition Amplifier
0
Volts
Spark
@
Coil
Spark
@
Coil
Check Engine
& Instrument
Wiring Harness,
Battery Cables,
Key Switch
Replace
Ignition
Sensor in
Distributor
Install New
Ignition
Coil
1 C-6 -TROUBLESHOOTING 90-14499--1 887
FUEL SYSTEM RICH
CAUSE SPECIAL INFORMATION 1. Warm engine carburetor percolation
2. Clogged flame arrestor
3. Automatic choke not opening
4. Float adjustment
5. Float leaks or is saturated with fuel 6. Needle and seat leaking
7. Carburetor gaskets leaking
8. Excessive fuel pump pressure
9. Cracked or porous carburetor body
1. Fuel boils out of float bowl when shut off and warm.
Floods intake manifold.
8. Unseats needle and seat
FUEL SYSTEM LEAN
4.
7.
8.
9.
MISCELLANEOUS
CAUSE
SPECIAL INFORMATION
1. Empty fuel tank
2. Fuel shut off valve closed (if equipped)
3. Anti-siphon valve stuck closed (if equipped)
Vapor lock
4.
Engine will not start after warm engine shut down
5.
Automatic choke
5.
Stuck open, wrong adjustment
6.
Fuel tank vent plugged
6.
Engine will start initially. After a short time of running,
engine will stall and will not restart for a period of time.
Can varify it is a vent problem by running engine with filler
cap loose. Fill cap will act as a vent.
Air leak on suction side of fuel system
7. Sucks air into fuel system reducing fuel volume
Plugged or pinched fuel line
Fuel pump
9.
Low pump pressure
CAUSE
SPECIAL INFORMATION
1.
Low grade or stale fuel
2.
Water in fuel
3.
Vacuum leak
4.
Low compression
4.
Worn valves, rings, cylinder, or head gasket
Valve timing incorrect
5.
Timing chain or gears jumped or improperly installed
90-14499--1 887
TROUBLESHOOTING -1C-7
ENGINE WILL NOT CRANK OVER
CAUSE SPECIAL INFORMATION 1. Control lever not in neutral position
2. Battery charge low; damaged wiring; loose electrical
connections
3. Blown fuse at starter motor 3. Early models with red wire going to fuse on starter
terminal
4. Circuit breaker tripped
5. Ignition switch 6. Slave solenoid
7. Faulty neutral start safety switch 7. Open circuit
8. Starter solenoid
9. Starter motor
CHARGING SYSTEM INOPERATIVE
CAUSE SPECIAL INFORMATION
1. Loose or broken drive belt
2. Engine RPM too low on initial start
3. Loose or corroded electrical connections
4. Faulty ammeter or battery gauge
5. Battery will not accept charge 6. Faulty alternator or regulator
7. Failed fuse (if so equipped)
8. Refer to "Section 4, Part C" for complete "Charging
System" troubleshooting procedures.
2. Rev engine to 1500 RPM
4. Best way to test is to replace gauge
5. Low electrolyte, failed battery
7. Fuse located on starter terminal stud. Orange output wire
from alternator connects to fuse.
NOISY ALTERNATOR
CAUSE SPECIAL INFORMATION
1.
Loose mounting bolts
2.
Drive belt
2.
Worn, frayed, loose
3.
Loose drive pulley
Worn or dirty bearings
5.
Faulty diode trio or stator
INSTRUMENTATION MALFUNCTION
CAUSE SPECIAL INFORMATION
1. Faulty wiring, loose or corroded terminals
2. Bad key switch
3. Faulty gauge
4. Faulty sender
2. Test, as outlined in "Section 4 Part D"
3. Test, as outlined in "Section 4 Part D"
4. Test, as outlined in "Section 4 Part D"
1C-8 -TROUBLESHOOTING
90-14499--1 887
RADIO NOISE
CAUSE SPECIAL INFORMATION
1. A "popping" noise that will increase with engine RPM.
Noise will stop as soon as engine is turned off.
2. "High pitched whine" in the radio
1.
2.
Ignition System -wrong spark plugs; cracked distributor
cap; cracked coil tower; leaking spark plug wires; moisture
on ignition components.
Alternator -poor brush contact on the slip rings
A "hissing or crackling" noise when instruments are jarred
3. Instrumentation -loose connections, or antennae wire
with ignition on
routed too close to instruments
4. Accessories -bilge pump, bilge blower; fish finder, depth
locator; cabin heater motor, etc. Disconnect one at a time
until noise disappears.
4. Varying unexplained noises
POOR FUEL ECONOMY
3.
7.
8.
SPECIAL INFORMATION
CAUSE
1. Fuel leaks
2. Operator habits
Prolonged idling; slow acceleration; failure to cut back on
throttle once boat is on plane; boat overloaded; uneven
weight distribution
Bent, damaged, or wrong propeller. Water test boat for Engine laboring
3.
proper operating RPM at WOT.
4. Clogged flame arrestor
5. Engine compartments sealed too tight
6. Dirty (marine growth), hook, rocker
6. Boat bottom
Carburetor 7. Idle mixture settings, accelerator pump adjustment, linkage
binding, choke adjustment, carburetor flooding over,
main fuel jets
Improper fuel
9. Crankcase ventilation system not working
10. Engine needs tune-up
11. Engine running too cold or too hot
12. Plugged or restricted exhaust
13. Low compression
13. Engine
90-14499--1 887 TROUBLESHOOTING -1C-9
CARBURETOR MALFUNCTIONS
SYMPTOM CAUSE 1. Flooding 1. A. Needle and seat
B. Float adjustment
C. Saturated float
D. Gaskets leaking
E. Cracked fuel bowl
F. Fuel percolation
G. Automatic choke
2. Rough idle 2. A. Idle RPM too low
B. Idle mixture screws
C. Idle passages dirty
D. Throttle valves not closing
E. Engine flooding
F. Vacuum leak
G. Throttle body heat passages plugged
3. Hesitation or acceleration flatness A. Accelerator pump
B. Leaking gaskets
C. Automatic choke
D. Power piston or power valve
E. Throttle valves
F. Throttle body heat passages plugged
G. Main metering jets
H. Float adjustment
I. Secondary air valve wind-up
A. Main metering jets
4. Engine surges
B. Leaking gaskets
C. Float adjustment
D. Saturated float
E. Power piston or valve
F. Throttle valves
A. Power piston or valve
5. Low top speed or lack of power
6. Poor cold engine operation
7. Engine stalls
8. Hard starting
B. Float adjustment
C. Main metering jets
D. Leaking gaskets
6. A. Idle RPM too low
B. Idle mixture screws
C. Throttle valves
D. Automatic choke
E. Engine flooding
7. A. Idle RPM too low
B. Idle mixture screws
c. Engine flooding
D. Automatic choke
E. Dirt in carburetor
F. Accelerator pump
G. Leaking gaskets
8. Refer to "Engine Starts Hard"
90-14499--1 887
1C-10 -TROUBLESHOOTING
ENGINE RUNS POORLY AT IDLE
CAUSE .. 10 Clogged flame arrestor
20 Improper idle fuel mixture adjustment
30 Moisture on ignition components
40 Water in fuel
50 Low grade or stale fuel
60 Incorrect ignition timing
70 Automatic choke
80 Spark plugs
90 Incorrect point gap, burned or pitted points
100 Spark plug wires
110 Defective coil or condenser
120 Cracked or dirty distributor cap
13o lncorrect float level
140 Dirty carburetor
150 Vacuum leak
16o lncorrect fuel pump pressure
170 Low compression
180 Loose or worn distributor
190 Water leaking into cylinders
200 Loose or broken engine mounts
SPECIAL INFORMATION
30
Cap or spark plug wires arcing
80
Fouled, burned, cracked porcelain
10olnsulation break down, wires broken
150 Leak at manifold or carburetor base
160 Too low -can't supply the carburetor
Too high -unseats the needle and seat
170 Also check for blown head gasket
180 Timing and/or dwell changes
190 Head gasket, exhaust manifold, cracked head or valve seat
ENGINE ACCELERATION IS POOR
CAUSE 10 Also refer to "Poor Boat Performance"
20 Idle mixture screws
40
SPECIAL INFORMATION
10 See "Index"
90-14499--1 887
TROUBLESHOOTING -1C-11
30
Air valve spring out of adjustment
Incorrect ignition timing
50
Incorrect distributor or amplifier advance curve
60
Accelerator pump
70 Cracked or dirty distributor cap or rotor
80 Vacuum leak
90 Spark plugs
10o lncorrect point gap, dirty or burned points
110 Float adjustment
120 Dirty carburetor
130 Low compression
30
Rochester 4 barrel carburetor only
50
Refer to Section 4, Part B
60
Check for stream of raw fuel from accelerator pump discharge
nozzle, when opening throttle with engine shut off
80 Intake manifold or carburetor base
90 Fouled, burned; wrong heat range; cracked porcelain
ENGINE RUNS POORLY AT HIGH RPM
SPECIAL INFORMATION
CAUSE
2.
1. See "Index"
Also refer to "Poor Boat Performance"
2. Check oil level with boat at rest in the water. Refer to
Crankcase over-filled with oil
Section 1, Part B
3. Anti-siphon valve (if equipped) Restricting fuel supply
4. Plugged fuel tank vent
5. Fuel supply
Refer to "Carburetor Malfunctions." (See "Index")
6. Ignition timing
7. Low grade of fuel or water in the fuel
8. Spark plugs 8. Fouled, burned, cracked porcelain, incorrect heat range
9. Spark plug wires 9. Poor insulation, broken wires
10. Distributor cap or rotor 10. Dirty or cracked
11.Coil
12. Distributor 12. Points, condenser, worn cam, excessive play in shaft
13. Engine overheating 13. Refer to "Engine Over Heats" (See "Index")
14. Low compression 14. Worn valves, rings, cylinders, etc.
15. Restricted exhaust
TROUBLESHOOTING WITH VACUUM GAUGE
READING CAUSE
1. Steady reading betweeen 15-21 inches at idle RPM 1. Normal
2. Extremely low reading, but steady at idle RPM 2. Vacuum leak; incorfaulty boat bottom
rect timing; under powered boat;
Fluctuates between high and low at idle RPM Blown head gasket between 2 adjacent cylinders
Fluctuates 4 or 5 inches very slowly at idle RPM Carburetor needs adjustment; spark plug gap too narrow;
valves are sticking
5. Fluctuates rapidly at idle, steadies as RPM is increased
Valve guides are worn
6. Continuously fluctuates between low and normal reading 6. Burned or leaking valve
at regular intervals at idle RPM
1C-12-TROUBLESHOOTING 90-14499--1 887
ENGINE NOISE
IMPORTANT INFORMATION
No definite rule or test will positively determine source
of engine noise; therefore, use the following information
only as a general guide to engine noise diagnosis.
1.
Use a timing light to determine if noise is timed with
engine speed or one-half engine speed. Noises
timed with engine speed, are related to crankshaft,
rods, pistons, piston pins, and flywheel. Noises
timed to one-half engine speed are valve train
related.
2.
The use of a stethoscope can aid in locating a noise
source; however, because noise will travel to other
metal parts not involved in the problem, caution
must be exercised.
3.
If you believe noise is confined to one particular
cylinder, ground spark plug leads, one at a time. If
noise lessens noticeably or disappears, it is isolated
to that particular cylinder.
VALVE COVER AREA
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.
5.
Sometimes noises can be caused by moving parts
coming in contact with other components. Examples
are: flywheel or coupler; exhaust flappers rattling
against exhaust pipe; crankshaft striking (pan,
pan baffle, or dipstick tube); rocker arm striking
valve cover; and loose flywheel cover. In many
cases if this is found to be the problem, a complete
engine tear down is not necessary.
6.
When noise is isolated to a certain area and component,
removal and inspection will be required. Refer
to proper sections of service manual for information
required for service.
7.
If noise cannot be distinguished between engine or
drive unit, remove drive from boat. Run a water
supply directly to engine. Run engine without the
drive to determine if noise is still there.
LOCATION
Valve cover area, timed to one-half engine speed, noise
could be confined to one cylinder or may be found in any
multitude of cylinders.
POSSIBLE CAUSES
1. A. Rocker arm, striking valve cover
B.
Rocker arm out of adjustment
C. Worn rocker arm
D. Bent push rod
E.
Collapsed lifter
CYLINDER AREA
POSSIBLE CAUSES
LOCATION
1.
Cylinder area, may be confined to one cylinder or found in A. Sticking valve
B. Carbon build-up
more than one cylinder, timed to engine speed
C. Connecting rod installed wrong
D. Bent connecting rod
E.
Piston
F.
Piston rings
G. Piston pin
H. Cylinder worn
90-14499--1 887
TROUBLESHOOTING 1C-13
CAMSHAFT AREA
LOCATION
1.
Camshaft area, front of engine, timed to one-half engine
speed
2.
Camshaft area, center of engine, timed to one-half engine
speed
POSSIBLE CAUSES
1.
A. Camshaft timing sprocket or gear
B. Timing chain
C. Fuel pump
D. Valve lifter
E.
Cam bearings
2.
A. Fuel pump
B.
Valve lifter
C. Cam bearings
3. Camshaft area, rear of engine, timed to one-half engine A. Distributor gear
speed
B.
Valve lifter
C. Cam bearings
4. Camshaft area, throughout engine, timed to one-half A. Loss of oil pressure
engine speed
B. Valve lifters
C. Cam bearings
CRANKSHAFT AREA
LOCATION
1.
Crankshaft area, front of engine, timed to engine speed
2.
Crankshaft area, center of engine, timed to engine speed
3.
Crankshaft area, rear of engine, timed to engine speed
4.
Crankshaft area, throughout engine, timed to engine
speed
POSSIBLE CAUSES
1.
A. Crankshaft timing sprocket or gear
B. Timing chain
C. Main bearing
D. Rod bearing
2.
A. Crankshaft striking pan or pan baffle
B.
Main bearing
C. Rod bearing
3.
A. Loose flywheel cover
B.
Loose coupler
C.
Loose flywheel
D.
Drive plate
E.
Main bearing
F.
Rod bearing
4.
A. Loss of oil pressure
B.
Main bearings
C. Rod bearings
90-14499--1 887
1C-14 TROUBLESHOOTING
MISCELLANEOUS
NOISE POSSIBLE CAUSE
1. Engine spark knock
2. Popping through carburetor
3. Hissing
4. Whistle
5. Sparks jumping
6. Squeaks or squeals
7. Rattling in exhaust pipe area
1. A. Advanced timing
B. Low octane fuel
C. Engine running hot
D. Carbon deposits in engine
2. A. Wrong ignition timing
B. Carburetor set too lean
C. Faulty accelerator pump
D. Vacuum leak
E. Valve adjustment
F. Valve timing
G. Burned or stuck valve
3. A. Vacuum leak
B. Fuel pump (hissing in sight tube)
C. Leaking exhaust (manifolds or pipes)
D. Loose cylinder heads
E. Blown head gasket
4. A. Vacuum leak
B. Dry or tight bearing in an accessory
5. A. Leaking high tension lead
B. Cracked coil tower
C. Cracked distributor cap
6. A. Drive belt slipping
B. Dry or tight bearing in an accessory
C. Parts rubbing together
7. A. Exhaust shutters
90-14499--1 887
TROUBLESHOOTING 1C-15
OIL PRESSURE
NOTICE
Refer to "Section 1, Part B" for minimum oil pressure
reading.
IMPORTANT INFORMATION
1.
Measuring oil pressure 1. Use a good automotive oil pressure test gauge. Do not rely
on the oil pressure gauge in the boat.
2. Check engine oil level with boat at rest in the water 2.
Oil level should be between the "ADD" and "FULL" marks
3.
Oil level in crankcase above "FULL" mark 3. May cause loss of engine RPM, oil pressure gauge flucuation,
drop in oil pressure, and hydraulic valve lifter noise at
high RPM
4.
Oil level in crankcase below "ADD" mark 4. Low oil pressure; oil pressure gauge flucuation; internal
engine noise and/or damage
5.
Change in oil pressure 5. 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. As the air temperature warms
up and engine is running at normal operating temperature,
it is normal for oil pressure to drop off slightly.
6.
Low engine oil pressure at idle 6. With modern engines and engine oils, low oil pressure
readings at idle does not necessarily mean there is a problem.
If valve lifters do not "clatter" (at idle), there is a
sufficient volume of 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 thin out somewhat
from heat.
7. Low engine oil pressure at idle after running at a high RPM
7. Refer to "No. 5 and 6", preceding
'-...._.,/
8.
Boats with dual engines 8. It is not uncommon to see different oil pressure readings
between the two engines, as long as both engines fall
within specifications. Differences in oil pressure can be
attributed to differences in engine tolerances, gauges, wiring,
senders, etc.
9. Boats with dual stations 9.
Refer to "No. 8", preceding
· ..
90-14499--1 887
1C-16 TROUBLESHOOTING
LOW OIL PRESSURE
NOTICE
Refer to "Section 1, Part B" for minimum oil pressure
readings.
CAUSE SPECIAL INFORMATION
1. Low oil level in crankcase
2. Defective oil pressure gauge and/or sender
3. Thin or diluted oil
4. Oil pump
5. Oil leak can be internal or external
6. Excessive bearing clearance
2. Verify reading with an automotive test gauge. Refer to
"Section 4, Part D" for instrument testing.
3. Oil broken down; contains water or gas; wrong viscosity;
engine running too hot or too cold; excessive idling in
cold water (condensation)
4. Relief valve stuck open; pick-up tube restricted; worn
parts in oil pump; air leak on suction side of oil pump or
pick-up tube
5. Oil passage plugs leaking, cracked or porous cylinder
block
6. Cam bearings, main bearings, rod bearings
HIGH OIL PRESSURE
CAUSE SPECIAL INFORMATION
1. Oil too thick
2. Defective oil pressure gauge and/or sender
3. Clogged or restricted oil passage
4. Oil pump relief valve stuck closed
1. Wrong viscosity, oil full of sludge or tar
2. Verify with an automotive test gauge
IMPORTANT: Oil pressure, slightly higher than normal,
does not always indicate a problem. Tolerance stack-up
in the engine, oil viscosity, and weather conditions could
cause high oil pressure.
90-14499--1 887 TROUBLESHOOTING 1C-17
EXCESSIVE OIL CONSUMPTION
SPECIAL INFORMATION CAUSE
1.
One quart of oil consumed in 5-15 hours of operation at
WOT {especially in a new or rebuilt engine) is normal
Normal consumption
2.
Clean bilge, run engine with clean white paper on bilge
floor, locate oil leak{s)
2.
Oil leaks
3.
Oil diluted or wrong viscosity
3.
Oil too thin
4.
Oil level too high
Drain holes in cylinder head plugged
5.
Oil will flood valve guides
6.
Defective valve seals
7.
Intake manifold gasket leaking
8. Worn valve stems or valve guides
9.
Defective oil cooler {if so equipped) Crack in cooler tubes
10. Defective piston rings 10. Glazed, scuffed, worn, stuck, improperly installed; ring
grooves worn; improper break-in; wrong end gap
11. Defective cylinders 11. Out of round, scored, tapered glazed; excessive piston to
cylinder clearance; cracked piston
12. Excessive bearing clearance
90-14499--1 887
1C-1 8 TROUBLESHOOTING
WATER IN ENGINE
IMPORTANT INFORMATION
CAUSE SPECIAL INFORMATION
1. Operator shut engine off at high RPM
2. Engine "diesels" or trys to run backwards 2. Engine out of tune, poor fuel, high idle RPM, timing set too
high
Rain water running into flame arrestor Hatch cover
4.
Spark plug misfiring
4.
Improper combustion causes moisture in the air to accumulate
in the cylinder
Backwash through the exhaust system
I
CAUSE
1. Water in boat bilge
2. Water seeping past piston rings or valves
3. Engine running cold
4. Intake manifold leaking near a water passage
5. Cracked or porous casting
SYMPTOM
1. Boat has been submerged or bilge water was high enough
to run in through dipstick tube.
2. Refer to "Water in Engine" ("On Top of Pistons")
3. Defective thermostat, missing thermostat; prolonged
idling in cold water
5. Check cylinder head, cylinder block, and intake manifold
90-14499--1 887 TROUBLESHOOTING 1C-19
IMPORTANT: First determine location of water in
engine. This information can be of great help when
trying to determine where the water came from and
how it got into the engine. The three most common
problems are "water on top of pistons, water in crankcase
oil, water in crankcase oil and on top of pistons".
The first step, after locating water, is to remove all the
water from the engine by removing all spark plugs and
pump 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 duplicated,
there more than likely is a mechanical problem. If the
WATER ON TOP OF PISTONS
problem cannot be duplicated, the problem is either an
operator error or a problem that exists only under certain
environmental conditions.
If water is contained to cylinder(s) only, it is usually
entering through the intake system, exhaust system, or
head gasket.
If the water is contained to crankcase only, it is usually
caused by a cracked or porous block, a flooded bilge,
or condensation.
If the water is located in both the cylinder(s) and the
crankcase, it is usually caused by water in the cylinders
getting past the rings and valves, or complete submersion.
Checking for rust in the intake manifold or exhaust
manifolds is a good idea. Rust in these areas will give
clues if the water entered through these areas.
6.
Improper engine or exhaust hose installation
7.
Cracked exhaust manifold
8.
Improper manifold to elbow gasket installation
9.
Loose cylinder head bolts
10. Blown cylinder head gasket
11. Cracked valve seat
I
I
12. Porous or cracked casting
WATER IN CRANKCASE OIL
6.
Refer to Section 6, Part C for exhaust specifications
10. Check for warped cylinder head or cylinder block
12. Check cylinder heads, cylinder block, and intake manifold
ENGINE OVERHEATS (MECHANICAL)
CAUSE SPECIAL INFORMATION
1. Engine RPM below specifications WOT (engine laboring) 1. Damage or wrong propeller; growth on boat bottom; false
bottom full of water
2. Wrong ignition timing 2. Timing too far advanced
3. Sticking distributor advance weights
4. Spark plug wires crossed (wrong firing order)
5. Lean fuel mixture 5. Refer to "Carburetor Malfunctions" in this section
6. Wrong heat range spark plugs
7. Exhaust restriction
8. Valve timing off 8. Jumped timing chain and/or gears, or improperly
installed
9. Blown head gasket(s) 9. 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.
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.
Refer to Section 6, Part A.
10. 1nsufficient lubrication to moving parts of engine 10. Defective oil pump, plugged oil passage, low oil level
1C-20 TROUBLESHOOTING 90-14499--1 887
ENGINE OVERHEATS (COOLING SYSTEM)
CAUSE SPECIAL INFORMATION
IMPORTANT: The first step Is to verify If the engine Is IMPORTANT: Best way to test gauge or sender Is to re-
actually overheating or the temperature gauge or sender place them.
is faulty.
1. Loose or broken drive belt
2. Seawater shut-off valve partially or fully closed (if
equipped)
3. Clogged or improperly installed sea strainer
4. Loose hose connections between seawater pick-up and 4. Pump will suck air. Pump may fail to prime or will force air
seawater pump inlet. (Models with belt driven seawater bubbles into cooling system.
pump only)
5. Seawater inlet hose kinked or collapsed
6. Seawater pick-up clogged
7. Obstruction on boat bottom causing water turbulence 7. Obstruction will be in front of seawater pick-up, causing
air bubbles to be forced into cooling system.
8. Defective thermostat
9. Exhaust elbow water outlet holes plugged
10. 1nsufficient seawater pump operation 10. Worn pump impeller
11. Obstruction in cooling system such as casting flash, sand, 11. Refer to waterflow diagram for engine type being serviced
rust, salt, etc.
12. Engine circulating pump defective
13. Also refer to "Engine Overheats (Mechanical)" 13. See "Index".
IMPORTANT: In addition to previous checks, make the
following checks if engine is equipped with closed cooling.
14. Low coolant level
15. Anti-freeze not mixed properly 15. Anti-freeze should be mixed 50/50 or maximum 60/40. 60%
anti-freeze, 40% water.
16. Heat exchanger cores plugged
17. Water hoses reversed at the water distribution block 17. Refer to water flow diagrams Section 6, Part C
18. For further testing of the closed cooling system 18. Refer to Section 6, Part B
90-14499--1 887
TROUBLESHOOTING 1C-21
INSUFFICIENT WATER FLOW FROM MC-1/ Alpha One
STERN DRIVE UNIT SEAWATER PICKUP PUMP
CAUSE
1. Seawater shut-off valve partially or fully closed (if
SPECIAL INFORMATION
equipped)
2.
Water pickups clogged with foreign material
3.
Kinked or broken bell housing-to-gimbal housing water
tube hose
4.
Corroded thru gimbal housing water tube
5.
Water pickup inserts warped. (Engine will overheat while
boat is underway only.)
6.
Damaged gear housing or accessories improperly installed
on boat bottom or transom (speedometer pickup,
depth sounder transducer, etc.). Substantial amount of
barnacles or other marine growth on gear housing or boat
bottom. (Engine will overheat while underway only.)
7.
Stern drive installed too high on transom or drive unit
trimmed too far out allowing air to be drawn into pump.
(Engine will overheat while underway only.)
8.
Bell housing-to-drive shaft housing "0" ring missing or
damaged
9.
Faulty seawater pickup pump
10. Seawater pickup pump water tube corroded thru
11. Drive shaft housing water pocket cover cracked
12. Broken-off impeller blade or other obstruction in water
passages (usually lodges in drive shaft housing water
pocket cover or cross-drilled water passage).
13. Water passage in drive shaft housing improperly drilled
INSUFFICIENT WATER FLOW FROM BELT DRIVEN
SEAWATER PICKUP PUMP
5.
Pickup inserts must not protrude above gear housing surface
or inserts will create an irregular or turbulent water
flow over the water pickup holes. Consequently, this may
cause loss of cooling water and subsequent engine overheating.
This condition also can be identified by cavitation
burn (pitting, erosion) on the gear housing in the area aft
of the water pickup inserts.
6.
An object or an irregularity on boat or gear housing in area
close to water pickups could create turbulence in water
flow going to water pickups. This could aerate the water
flow and cause engine to overheat.
7.
Contact boat company if stern drive is installed too high.
Instruct operator on proper trimming technique if unit is
trimmed out too far.
12. To check cross-drilled water passage in drive shaft housing,
remove welch plug and pipe plug located under decal
on starboard side of housing. Drive unit must be shifted
into reverse to remove pipe plug.
CAUSE SPECIAL INFORMATION
1. Drive belt
2. Seawater shut-off valve partially or fully closed 3. Clogged or improperly installed sea strainer
4. Loose hose connections between seawater pickup and
seawater pump inlet
5. Seawater inlet hose kinked or plugged
6. Seawater pickup clogged
7. Obstruction on boat bottom causing water turbulence
8. Faulty seawater pump
1. Loose or broken
4. Pump will suck air, pump may fail to prime or will force air
bubbles into cooling system.
7. Obstruction will be in front of seawater pickup, causing air
bubbles to be forced into cooling system
1C-22 TROUBLESHOOTING
90-14499--1 887
POWER STEERING
POOR, ERRATIC, OR NO ASSIST
CAUSE SPECIAL INFORMATION
1. Drive belt 1. Broken or out of adjustment
2. Low fluid level 3. Air in system 3. Air leak in lines, pump, or air from installation. Refer to
Section 7 for bleeding procedure.
4. Leaking hoses 4. Refer to Section 7 for bleeding procedure.
5. Steering cable and/or steering helm 5. Cable or helm partially froze from corrosion or rust; cable
over lubricated; improper cable installation
6. Binding in stern drive unit 6. Refer to appropriate "Stern Drive Service Manual"
7. Restriction in hydraulic hoses 7. Causes a loss of pressure
8. Control valve not positioned properly, not balanced properly,
or the mounting nut is loose
9. Mounting bracket adjusting screw loose or mounting tube
is loose
10. Faulty pump 10. Flow control valve may be sticking
11. Worn piston ring or scored housing bore in cylinder 11. Causes loss of pressure
12. Leaking valve body or loose fitting spool
NOISY PUMP
CAUSE SPECIAL INFORMATION
1. Drive belt 1. Check tension
2. Low fluid level 3. Air in fluid 3. Air leak in lines, pump, or air from installation. Refer to
Section 7 for bleeding procedure.
4. Faulty pump 4. Use stethoscope to listen for noise in the pump
5. Restricted fluid passages 5. Kinks or debris in hoses or debris in passages
6. Stop nut adjusted improperly 6. Refer to appropriate "Stern Drive Service Manual".
7. Steering cables installed that do not meet BIA standards 7. Refer to appropriate "Stern Drive Service Manual".
FLUID LEAKS
CAUSE SPECIAL INFORMATION
1. Loose hose connections 1. Refer to Section 7 for bleeding procedure.
2. Damaged hose 3. Oil leaking from top of pump 3. System overfilled; fluid contains water; fluid contain air
4. Cylinder piston rod seal
5. Faulty seals in valve
6. Faulty seals or "0" rings in pump
7. Cracked or porous metal parts
90-14499--1 887
TROUBLESHOOTING 1C-23
320 EFI Troubleshooting
TIMING PROCEDURE
It is essential to ground the red/yellow wire (Figure 1)
located in the wire harness, for adjusting the timing.
Failure to do so will obtain a retarded adjustment. The
initial timing mark on the harmonic balancer is marked
with a number 0 and should be adjusted to 12 degrees
BTDC. This mark may not be highlighted. The full
advance setting (Marked 34 degrees) can be checked
after initial timing is adjusted.
a-Red/Yellow Wire
Figure 1.
1 C-24 TROUBLESHOOTING
SETTING THE THROTTLE SENSOR
1. Connect the digital multi-meter (incorporated in
tester P/N 91-1 6850) to connector (a) by putting red
meter lead (b) in pin hole number 2 and black meter -.....,
lead (c) in pin hole number 3.
2. Put meter dial in 2K position. Rotate sensor (a)
counterclockwise until a reading of 50 to 100 ohms
is reached. Then tighten screws (b).
SAFETY WIRE INSTALLATION
IMPORTANT: Screws (b) securing throttle position
sensor must be safety wired.
Safety wire the screws as shown below.
90-14499--1 887
IMPORTANCE OF RETURN LINES
The fuel system for the 320 EFI incorporates an electric
fuel pump with a water separating filter. The pump is
pressure regulated to maintain a constant pressure of
39 PSI (268.90 kPa) between the fuel rails and intake
manifold.
The system also incorporates a fuel return line. The
return line must be installed and must not be any
smaller than 1/4 in. (6.4mm) I. D. Failure to install or use
the fuel return line could cause excessive pressure on
the rails or injectors. The fuel pump and water separating
filter must be mounted with in 12 in. (305mm) of the
engine to comply with USCG regulations/specifications.
ELECTRIC FUEL PUMP PRESSURE TESTER (P/N
91-16850)
An Instruction Book accompanies the Tester.
MerCruiser -Electric Fuel Pump Pressure Test
This test can tell if the electric fuel pump is capable of
producing the correct fuel pressure of 30-40 PSI. (205
to 274 kPa) needed for normal engine operation.
1. Connect pressure gauge to pressure port.
1149-H
90-14499--1 887
TROUBLESHOOTING 1C-25
2. Put ignition key switch in "ON" position with oil
pressure sensor bypassed.
3. Take fuel pressure reading.
4.
Reading must be 30 to 40 PSI. (205 to 274 kPa).
Refer to the Troubleshooting Chart following for
further testing.
Troubleshooting Fuel System
1.
COMPONENT CHECK
Testing Fuel Pump Circuit (Turn Key
to run position and oil pressure
sensor bypassed.)
RESULT
pump runs
pump doesn't run
REMEDY
Check fuel pressure STEP 4
Check for 12 volts at the pump
with key in run position and oil
pressure sensor bypassed
(No Voltage) Check harness, ECU
box. (See test procedure following.)
(Voltage) Check pump STEP 2.
2. Pump Test (Install jumper wire from 12V
source to "+" terminal on pump)
pump runs Check front mounted rectifier
STEP 5
pump doesn't run Check oil pressure sensor STEP 3
3. Oil Pressure Sensor (Remove both leads
from sensor and connect leads
together)
pump runs
pump doesn't run
Replace oil pressure sensor
Replace pump
pump doesn't run Check wire harness, ECU box.
(See test procedure following)
4. Testing Fuel Pressure (Install pressure
tester P/N 91-1 6850 per instructions.)
high or low pressure Replace fuel pressure regulator
5. Checking Rectifier (Unplug harness,
check with ohm meter. One meter lead
on termianl #3, other meter lead on
terminal #1 or #2. Noting the value of
the meter reading, reversing the connection
should obtain the opposite
value.)
shorted or open
reading
checked ok
Replace rectifier, refer to STEP 1
to retest pump
Check harness, ECU box. (See
test procedure following)
1C-26 TROUBLESHOOTING 90-1 4499--1 887
ENGINE ACCELERATION IS SLUGGISH
NO FAST IDLE WHEN COLD
COMPONENT CHECK
1.
Throttle Position Sensor (Ohms check
Rx1; throttle closed 50-100 ohms.
Throttle wide open over 180 ohms)
2.
Air Valve (Hold finger on valve opening
to check for air flow into valve)
3.
Water Temperature Sensor (Remove
leads and connect together)
RESULT
Low or High Ohm
Reading
Air Valve Ok
Air Valve Not Working
Air Valve Ok
Air Valve Not Working
REMEDY
Check ignition, Section 48 of
Service Manual 90-14499
Check fuel system. Refer to
troubleshooting chart preceding
Check ECU box
Check fuel supply, shut off valve,
fuel filter, tank pick-up, tank vent
Check front mounted rectifier
Check fuel pump
Replace pump
Check oil pressure sensor
Check elsewhere in wiring of
engine or boat
Oil sensor bad or no oil pressure.
CAUTION: Check oil in crankcase,
start engine to check oil pressure.
If oil pressure is ok, replace oil
sensor
REMEDY
Replace throttle position sensor
Check ECU box
Check water temperature sensor
Replace sensor
Replace air valve
TROUBLESHOOTING 1C-27
90-14499--1 887
ENGINE MISFIRES, RUNS ROUGH
COMPONENT CHECK
1.
Spark Check
2.
Battery Check (Use volt meter, check
for 12 volts)
Fuel Pressure (Install pressure gauge
per instructions, pressure MUST
range from 30 lbs. at idle to 40 lbs. at
wide open throttle)
4.
Injectors (With engine warm and idling,
remove electrical leads one at a time
from injectors) NOTE: If there are four
injectors misfiring at once such as 1, 4,
6, 7 or 2, 3, 5, 8 test ECU box
5.
Fuel Filter (Replace if clogged)
6.
Fuel Pump (Must have 12V to pump
and good ground connections)
RESULT REMEDY
No Spark Refer to Section 48 of Service
Manual 90-14499
Spark Check battery
Not 12V Change battery
12V Check fuel system
No or Low Pressure Check fuel filter. Check fuel pump
STEP 6.
High Fuel Pressure Change fuel regulator
Low Fuel Pressure Check fuel injectors. Change fuel
regulator
RPM Drop Injectors Ok
No RPM Drop Replace injectors or spark plugs
as needed
Injectors Ok Check ECU
Check fuel filter
No or Low Fuel
Pressure
Check fuel pump
No Fuel Pressure Replace pump
Low Fuel Pressure Replace fuel regulator, if pressure
is still low replace pump
·..
TROUBLESHOOTING -THE EFI ELECTRICAL SYSTEM
IMPORTANT: When checking the electronic components of the EFI system, only the EFI Tester (PIN 91-11001A2) can
be used. This tester tests the EFI components as a system.
By following the test procedure, a defective component can be found. Retest the complete system after the defective
component is replaced.
Following is the set-up and testing procedure for the EFI Tester.
1 C-28 TROUBLESHOOTING
90-14499--1 887
TESTING EFI ELECTRICAL SYSTEM
EFI TESTER SET-UP PROCEDURE-FOR CHECKING
EFI SYSTEM ON ENGINE A CAUTION Do not start or run engine with EFI system tester connected.
IMPORTANT: Check engine battery voltage before
using tester. If below 10 volts, recharge or replace
battery.
1. Disconnect EFI harness (a) from ECU (b).
2. Connect tester harness (a) to ECU and tester harness
(b) to EFI harness.
90-14499--1 887
3. Connect (red color) tester battery clip lead (a) to
+12V terminal.
Connect (black color) tester battery clip lead (b) to
engine ground.
19772
4. Connect red (a) and black (b) color test leads into
meter.
5. a. Turn meter selector (a) to 20VDC position.
b. Turn power switch to "ON".
c. Meter reading should be more than O.OOV.
d. If meter doesn't read over O.OOV, then check
tester battery clip leads for good con nections or
correct polarity.
6. The EFI tester is now set-up for checking the EFI
system.
TROUBLESHOOTING 1 C-29
EFI -TESTER SET-UP PROCEDURE -FOR TESTING
ECU IF REMOVE FROM ENGINE
IMPORTANT: Check battery voltage of the 12 volt battery
used in Step 2 before using tester. lf below 10 volts,
recharge or replace battery.
1. Connect tester harness (a) to ECU.
23307
2. Connect (red color) tester battery clip (a) to positive
(+) terminal on a 12 volt battery.
Connect (black color) tester battery clip (b) to negative
(-) terminal on the battery.
19772
1 C-30 TROUBLESHOOTING
3. Connect red (a) and black (b) color test leads into
meter.
4. a. turn meter selector to 20VOC position.
b. Turn switch to "ON".
c. Meter reading should be more than O.OOV.
d. If meter doesn't read over O.OOV, then check
tester battery clip leads for good connections for
correct polarity.
5. The EFI tester is now set-up for checking the EFI
system.
90-14499--1 887
For 320 EFI 4 Cycle Models
EFI Harness and EFI Wire Continuity Test
Fuel Injector Test
Refer to Page 2 to set-up tester
....Ill ... ...IllIll ...za:..:1: iL ...
EFI Harness if is on Boat
1. "Wires OK" test lamp should light which indicates harness is
good.
2 "Harness OK" test lamp not used in 320 EFI continuity test
EFI Harness if is Removed from Boat
1. Connect engine battery leads to a 12 volt battery.
.. ,.t,. *G-o• o•
Corrective Action if Test Lamp does not Light
Refer to EFI wi re·continuity check below to independently check each wire in
the harness to locate the defecttve wire(s).
....Ill ... ......5zi=z0u ...a:i iL ...
t Turn ognoloon key to "ON" posotoon2 Turn contonuoty check swotch to each of the lollowong wore check posotoon
EFI W1res if is Removed from Boat 1 Connect eng1ne battery leads to a 12 volt battery 2. Turn conlinu•ty check sw•tch to each of the followmg w1re check pos•t•on.
H1 CNEU
..,.t,. Locating Faulty Wire(s) • If test lamp lights. wire indicated in chart below is good
If test lamp does not light. the problem is in the indicated wire o•
circuit between No. 1, 4, 6. 7 injectors and ECU
H3 circuit between No. 2, 3. 5, 8 inject::>rs and ECU
H4 12V wire to ECU
HS 12V wire to ECU
H10 Ground to ECU Box wire(s)
I C 0 ( ...Illw .... a: · o ··"'" Position 1( c u 'AlA.( lEIS + 1 Sw'""
Positionsnn•'AIA.E lliS + Testing Injectors
Place your finger on the terminal part of the injectors being tested. If injector
is good. you will feel the injector pulsating. ...u ... ..,.. .... Test Steps
Set ECU PARAMETERS
Switch to each of the following
positions.
Set SYSTEM PARAMETERS
switch to each of
the following position . ...:::l ... 1 6 D Operates No. 1, 4, 6, 7 injectors.
2 6 F Operates No. 2, 3, 5, 8 injectors.
90-14499--1 887
TROUBLESHOOTING 1C-31
Refer to Page 2 to set-up tester
IM PORTANT: The original EFI tester is in an aluminum carrying case
and must not be used to test a 320 EFI. May result in damage to ECU.
Test Steps
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4 w.... a: 1:01-"' "' oz wa:w t-:Z:.J>.(!)
'f> .. coco __,
-IJ) 0 cOJrm(/)I00-I zG) ..()c:, (..)
..l(,.,
•
AIR
01l PAESSUAl
SENSOR
( )
VA\.VE
fUElP\J'\1P
FUEl .. SE('o.;SOR
..
WAf(R \ l(MP(RATURE
SENSOR i
Engine Electrical System Wiring Diagram
()I
STARTER
SLAVE
SOLENOiO
CIRCUIT BREAKER
WATER "..!\> TEMPERATURfSENOEA
913-HR
HOW EFI SYSTEM OPERATES
Fuel Delivery System -A electric fuel pump (Figure 2)
delivers fuel to the Fuel Injectors, via the fuel rails.
(Figure 1)
Figure 1. A Fuel Rails
A Water Separating Fuel Filter (Figure 2) is located on
the outlet side of the pump, to remove impurities before
they reach the fuel injection system.
a-To Fuel Rails
b-From Fuel Tank
c-12 Volt Supply
d-Water Separating Fuel Filter
e-Electric Fuel Pump I-Mounting Bracket
Figure 2.
The pressure of the fuel delivered to the Fuel Injectors
is controlled by a Fuel Pressure Regulator which
senses intake manifold pressure (vacuum) and maintains
the fuel pressure at 39 PSI (268.90 kPa) above the
manifold pressure, under all operating conditions.
1C-34 TROUBLESHOOTING
In this manner, the fuel pressure drop, across the Fuel
Injectors is maintained constant, at all times. The pump
delivers more fuel than the maximum requirement of
the engine, so that the pressure in the fuel delivery
system can be maintained, under all operating conditions.
Excess fuel diverted by the Pressure Regulator is
returned to the fuel tank (under no pressure) via the
Return Line.
Electronic Control Unit (ECU) -The solenoid operated
Fuel Injectors are controled by an Electronic Control
Unit (ECU) (Figure 3) which generates electrical
pulses. The electrical pulses produce a magnetic field
in the Injectors solenoid winding. This draws the armature
back and lifts the nozzle valve from its seat, allowing
fuel to flow from the nozzle.
The Fuel Injectors are divided into two separate
groups, with four injectors in each group connected
electronically together and opening simultaneously.
To provide uniform distribution of the fuel mixture,
each group of Fuel Injectors open twice per engine
cycle (once per engine revolution), delivering one-half
of the required fuel per opening of the injectors. The
group of Fuel Injectors are opened 180 degrees apart
from one another, to balance out the demands on the
fuel delivery system. Injection frequency is determined
by the ECU, by monitoring the electrical pulses on the
primary side of the ignition system.
The amount of fuel injected into the engine is controlled
by the duration of the electrical pulses generated
by the ECU. These requirements are calculated by
the ECU, based upon information received from the
following components: Pressure Sensor, Intake Air
Temperature Sensor and Throttle Position Sensor.
Pressure Sensor -The Pressure Sensor, a component
of the ECU is connected to the intake manifold via a
hose coming out of the back of the ECU (Figure 3) and
monitors intake manifold pressure (vacuum) to determine
the load on the engine. Under light to moderate
loads (Throttle Plate completely or partially closed),
the air pressure in the intake manifold is low (compared
to atmospheric pressure). The Pressure Sensor,
under this condition, signals the ECU to deliver less
fuel. As the load increases, the air pressure in the
intake manifold increases, and the Pressure Sensor
signals the ECU to deliver more fuel. Monitoring the
manifold pressure in this manner, allows the injection
system to react quickly to changes in load, so that the
proper air/fuel mixture can be maintained. This is one
of the key elements to the system's ability to provide
excellent throttle response and smoothness. In addition
to sensing the engine load, the Pressure Sensor
also compensates for changes in barometric pressure
and elevation. When the barometric pressure is low, or
when operating at high elevation, the Pressure Sensor
senses the lower atmospheric pressure and advises the
ECU to inject less fuel. The Pressure Sensor commands
the ECU to deliver more fuel when the barometric
pressure is high.
90-1 4499--1 887
20577
a-Pressure Sensor
Figure 3.
Intake Air Temperature Sensor The quantity of fuel
-
injected into the engine, once the engine is warm, is
controlled primarily by the ECU Pressure Sensor. Air
temperature affects air density which affects requirements.
This is performed by the Intake Air Temperature
sensor (Figure 4), located in the Air Intake System.
a-Intake Air Temperature Sensor
Figure 4.
As the air temperature decreases (air density increases),
the sensor operating through the ECU,
causes the amount of fuel injected to be increased, to
maintain the proper air fuel mixture. The sensor causes
the opposite to happen, when the intake air temperature
increases.
Throttle Position Sensor When the Throttle Plate
-
opens quickly (mild to hard acceleration), a slight
delay occurs before the Pressure Sensor reports this
condition to the ECU. This slight delay results from the
fact that the rise in pressure in the Pressure Sensor
takes slightly longer than the change in the position of
the Th rattle Plate. In order to bridge this slight delay in
response and prevent the engine from bogging, a
Throttle Position Sensor (Figure 5) is incorporated into
the system, which acts through the ECU to momentarily
enrichen the air/fuel mixture. The throttle position
sensor consists of a potentiometer (variable resistor),
which is attached directly to the throttle shaft. When
the throttle valve is opened, the ECU senses the speed
at which the throttle is being opened, by calculating the
change in resistance of the throttle position sensor. If
mild to hard accleration is sensed, the ECU momentarily
lengthens the electrical pulses to injection valves to
inject more fuel. The amount of fuel added is a function
of the throttle movement. Above 3000 RPM, the acceleration
circuit is disabled.
a-Throttle Position Sensor
Figure 5.
Cold Start/Warm Up Devices
NOTE: These items are not separate components.
They are incorporated, or components combined with,
the ECU circuitry.
In a cold engine, fuel condenses on the intake manifold
and cylinder heads. As a result, less fuel mixes with the
intake air, than in a warm engine. Additional fuel must
be added, under these circumstances, to obtain an
ignitable air fuel mixture. To overcome the increased
friction of a cold engine and maintain a steady idle
speed, additional air also must be added, to increase
the power output of the engine at idle. To handle the
cold engine requirements, special circuitry is incorporated
in the ECU, that works in conjunction with a
cooling system Water Temperature Switch, Fuel Pressure
Switch and an Auxiliary Air Valve.
When the engine is below 120° F (66° C) the cooling
system Water Temperature Switch signals the ECU
that additional fuel and air are required.
90-1 4499--1 887 TROUBLESHOOTING 1 C-35
All cylinders are simultaneously primed with fuel once,
during initial start up. This is accomplished by holding
the injection valves open for up to one-half second.
The duration of the prime is a function of engine
temperature, which is monitored by a thermistor in the
ECU. The prime is initiated, only after the fuel pressure
in the fuel rails reaches 25 PSI, (172 kPa) as established
by the Fuel Pressure Switch. The 25 PSI (172 kPa) is
necessary to prevent an insufficient prime, should
there be air in the fuel rails. The prime mode can be
repeated, if needed, by turning the ignition switch off
and then repeating the starting cycle.
After the initial prime, fuel enrichment is determined by
the thermistor in the ECU, which controls the length of
time that the Fuel Injectors are held open during each
engine revolution.
The thermistor gradually reduces the amount of enrichment,
as the engine warms up. Once the engine
reaches 120° F (66° C) the cooling system Water
Temperature Switch commands the ECU to cease fuel
enrichment. When the engine is below 120° F (66° C),
the Water Temperature Sensor actuates the Auxiliary
Air Valve (Figure 6), to provide additional air to the
engine. This air mixes with the enriched fuel supply,
causing the engine to produce more power for easier
starting and smooth warm up operation. This system
works in conjunction with the Idle Stabilizer Circuit,
incorporated in the ECU box, to produce a stable fast
idle speed of approximately 1000 RPM during the warm
up period. The engine automatically returns to normal
idle speed (600 RPM), when the cooling system Water
Temperature Switch senses the engine has reached
120° F (66° C).
a-Auxiliary Air Valve
Figure 6.
1C-36 TROUBLESHOOTING
Idle Stabilizer
ually attempting
in the ECU box.
On engines with fuel injection, the
fluctuations in intake manifold pressure can cause the
engine to hunt at idle, as the pressure sensor is continto
compensate for the pressure
changes. To prevent this condition, and to allow low,
stable idle speeds, an Idle Stabilizer was incorporated
The Idle Stabilizer consists of a special circuit that
works in conjunction with the Thunderbolt IV (H.E.I.)
System. The circuit controls the electronic advance in
the ignition amplifier, at the low RPM range, retarding
and advancing the timing as necesasry. Since retarding
the timing decreases the engine power, and advancing
the timing increases the power, the idle stabilizer
acts like a governor to stabilize the idle speed and
minimize the possibility of stalling. An in gear idle
speed of 600 RPM and out of gear idle speed of 620
RPM is obtained with this approach. Above 800 RPM,
the timing is progressively advanced until it reaches
the initial timing curve at approximately 2200 RPM. The
initial timing curve is maintained above 2200 RPM by
the Thunderbolt IV (H.E.I.) System with the Idle Stabilizer
circuit no longer working.
When the engine is below 120° F (66° C) or whenever
the engine is being cranked, the ignition timing is
•
advanced equal to or slightly retarded from the initial
timing curve, to allow easy starting and obtain a
smooth idle. A thermistor in the ECU gradually retards
the timing in accordance with the temperature of the
air surrounding the engine, to maintain a fast idle
speed of approximately 1000 RPM.
Once the engine reaches 120° (66° C), as established
by the cooling system Water Temperature Switch, the
Idle Stabilizer resumes its normal operation and the
idle speed returns to 600-620 RPM.
The Idle Stabilizer also works in conjunction with the
Throttle Position Sensor. Under a mild to hard acceleration
from idle, the ignition timing is instantly advanced
to the initial timing curve. This helps prevent a
backfire and improves the throttle response.
90-1 4499--1 887
Due to the Idle Stabilizer, a special procedure must be
used to set the ignition timing. The timing must be set
with the engine warmed up and idling, and with the
RED-YELLOW WIRE (Figure ?), located on the front of
the engine, grounded. This disables one bank of Fuel
Injectors and advances the timing to the initial timing
curve. The idle speed under this condition will be
approximately 600 RPM.
a-Red/Yellow Wire
Figure 7.
Overs peed Protection -In the event that the load on the
engine should be lost (propeller leaving the water). the
ECU incorporates special circuitry to limit the engine
speed to 5600 RPM to help prevent internal engine
damage. The special circuitry acts through the ignition
system and causes the engine to miss. when it reaches
the rev limit.
Fuel Pump Control/Loss of Oil -Pressure Protection
The fuel pump is controlled through the Ignition
Switch and Oil Pressure Switch (Figure 8). The Ignition
Switch activates the fuel pump only during cranking, to
ensure instantaneous pump response. Once the
engine starts and at least 4 PSI is generated in the
lubrication system. the Oil Pressure Switch closes and
energizes the pump. In the event of oil pressure failure
or a stalled engine, the fuel pump wil be automatically
turned off by the Oil Pressure Switch.
a-Oil Pressure Sw1tch
Figure 8.
90-14499--1 887 TROUBLESHOOTING 1C-37
Blocking Rectifiers -As mentioned earlier, the auxiliary
Air Valve and Fuel Pump are energized during the
cranking mode. This is accomplished by an interconnection
into the starter motor excitation circuit using
Blocking Rectifiers (Figure 9). If a direct connection
was made into this circuit, the possibility exists that the
engine could momentarily start if a remote start switch
was used to run the starter. It would also be possible to
actuate the starter if the fuel pump was hot wired during
servicing. Incorporating the Blocking Rectifiers
prevents this from occurring.
a -Front Rectifier
Figure 9.
b -Rear Rectifier
Figure 9.
1C-38 TROUBLESHOOTING
Limp-Home Feature -The MerCruiser EFI system has
been designed to allow the engine to run (with some
degradation in performance). if one or more· of the
following should fail:
1. Throttle Position Sensor "'-"'
2. Intake Air Temperature Sensor
3. Cooling System Water Temperature Switch
4. Pressure Sensor
5. Injector Valve Bank
6. Fuel Pressure Switch
7. Oil Pressure Switch
8. Some ECU Circuitry
90-14499--1 887
Troubleshooting
In case of trouble, check first whether all items of the present installation and operation instructions have been
.. complied with.
Trouble Possible Cause Remedy
1. Transmission gears cannot
be shifted
Shifting lever is loose
Remote control does not permit
lever travel required for testing
Remote control faulty
No shifting pressure available.
Tighten clamping screw on shifting
lever
Lift remote control off, if gears can be
shifted by hand, correct remote
control
Repair remote control
Refer to 7.
2. Gears are shifted sluggishly Lever travel of remote control is too
short; lever shift just short of minimum
traveling distance
Lift remote control off, if gears can be
shifted by hand, correct remote
control
3. Clutch is slipping, i.e. propeller
speed too low as compared
to engine speed
Inadmissible fluid used
Fluid contains water
Shifting pressure too low
Wear on clutch discs
Piston rings in clutch are damaged
Drain fluid, refill with prescribed
fluid, flush transmission while engine
runs in neutral position, drain fluid,
refill transmission
Refer to 9.
Refer to 6.
Disassemble transmission, replace
clutch discs
Disassemble transmission, replace
clutch
4. Transmission is blocked Medium piston ring in input shaft in
control block is faulty
Dished discs due to overheating of
slipping clutch
Needle bearings on input shaft are
worn out
Remove control block, replace piston
ring, if control block is worn, replace
likewise
Refer to 3.
Disassemble transmission, repair if
possible or use substitute transmission
5. Output shaft turns in neutral
position
Rotary slide valve in control block
is worn
Faulty needle bearing on input
shaft
Dished discs due to overheating of
slipping clutch
Replace control block
Disassemble transmission and input
shaft, replace bearing concerned and
other damaged parts
Refer to 3.
90-14499--1 1188 Troubleshooting -1 C-39
Trouble Possible Cause Remedy
6. Shifting pressure too low Fluid filter dirty
Fluid level in transmission is too
low
Fluid pump is worn out
Piston rings in input shaft in control
block are faulty
Piston rings in clutch are faulty
Replace fluid filter
Fill with fluid; in case of fluid loss
check transmission, cooler and pipelines
for leakage and remedy same;
also refer to 10 through 13
Replace control block together with
fluid pump
Remove control block and replace
piston rings. In case of wear in
control block due to faulty piston
rings replace block as well
Disassemble transmission, replace
clutch
7. No shifting pressure available Direction of engine rotation does not
agree with arrow on transmission
No fluid in the transmission
Fluid filter is dirty
Fluid level in transmission is too low
Fluid pump worn out
Fitting key in input shaft for fluid
pump drive is broken
Spring of shifting pressure relief
valve is broken
Replace with L.H. rotation engine
Refill with fluid
Replace fluid filter
Top-up with fluid. In case of loss of
fluid check transmission, cooler and
pipelines for leakage and remedy
same, also refer to 10-13
Replace control block together with
fluid pump.
Remove control block. Replace fitting
key, replace any other faulty parts
Replace control block
8. Excessive fluid temperature Excessive fluid in transmission
Fluid cooler is dirty on water side
Worn fluid pump in control block
Faulty piston rings in input shaft in
control block
Clutch is slipping
Clutch does not open completely
due to worn disc supports
Clutch does not open completely
due to broken cup springs
Low water flow from sea pump
Remove excessive fluid with
commercial suction pump
Detach coolant water lines and clean
fluid cooler on water side
Replace control block together with
fluid pump
Remove control block, replace piston
rings in input shaft. In case of wear in
the control block due to faulty piston
rings replace control block as well
Refer to 3.
Dismount transmission and coupling,
replace all faulty parts
Disassemble transmission, replace
inner disc support and/or clutch
Repair or replace sea pump
9. Water in the fluid, fluid looks
milky
Fluid cooler faul..y
High water level in engine compartment,
water entering at output shaft
seal
Repair leakage at cooler or replace
cooler. Change transmission fluid
Remedy cause for water level in
engine compartment, change transmission
fluid
1C-40 -Troubleshooting 90-1 4499--1 1188
90-1 4499--1 1188 Troubleshooting -1 C-41
Trouble Possible Cause Remedy
10. Fluid leakage at input shaft Breather clogged by paint or dirt Remove paint or dirt from breather
Shaft seal faulty Disassemble transmission, replace
seal. If seal location on input shaft is
worn, repair surface
11. Fluid leakage at output shaft Breather clogged with paint or dirt Remove paint or dirt from breather
Shaft seal faulty Disassemble transmission, replace
seal. If seal location on input shaft is
worn, repair surface
12. Fluid leakage at venting filter Excessive fluid in transmission Pump excessive fluid out with commercial
hand pump
13. Fluid leakage at joints or Bolts are not tight Tighten bolts to prescribed torque
screw connections
Seals on bolts have been used for Replace seals, tighten bolts to
several times prescribed torque
14. Fluid leakage at filter cap or Filler cap not flush or tight Reinstall filter cap flush with housing
breather and tighten
Filter cap 0-ring damaged Replace 0-ring
Fluid level too high Correct Fluid level
15. Transmission noise changes, Fluid level too low so that pump Top up with fluid to marking on
becomes louder sucks in air dipstick
Damage starting on flexible Replace flexible coupling. Check
coupling due to wear or fatigue, alignment between engine and
possibly due to misalignment be-transmission
tween engine and transmission
Beginning damage of bearings in Disassemble transmission, replace
transmission, e.g. due to torsional bearings concerned and other faulty
vibrations, running without fluid, parts. Find causes and remedy
overload, wrong alignment of transmission,
excessive motor output
Beginning damage of gearings, e.g. Disassemble transmission, remove
due to torsional vibrations, running faulty parts
without fluid, overload
Fluid baffle on transmission has Disassemble transmission, attach
come loose baffle plate
Fluid suction pipe in transmission Disassemble transmission, fix fluid
has come loose suction pipe
16. Chattering transmission noise The engine or propeller generate Mount a flexible coupling with
mainly at low engine speed torsional vibrations which another stiffness factor between
produce a "chattering" noise engine and transmission; a couin
the transmission piing with a higher stiffness factor
might be sufficient
Misaligned carden shafts on input Mount and align cardan shafts strictly
or output according to instructions issued by
cardan shaft manufacturer
REMOVAL and INSTALLATION
r
MCM Models with Alpha One Drives
Index
Page
Torque Specifications ........................ 2A-1
Tools/Lubricants ............................. 2A-1
Removal 2A-2
.....................................
Installation ................................... 2A-2
Alignment ................................... 2A-4
Attaching/Adjusting Throttle Cable ............ 2A-5
'.....__,/
REMOVAL and INSTALLATION -2A 90-1 4499--1 887
TORQUE SPECIFICATIONS
'..r:.r->;J 01 {..i... :r..a.lt
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Battery Cables Securely
Drive Unit Shift Cable
Brass Barrel Spread Cotter Pin
Cable End Guide (Note 1)
Front Engine Mount Securely
Hose Clamps Securely
Power Steering Fluid Hose Fittings
Large 20-25 (27-34)
Small 96-108 (1 1-12)
Rear Engine Mounts 35-40 (47-54)
Remote Control Shift Cable
Brass Barrel Securely
Cable End Guide (Note 1)
Remote Control Throttle Cable
Brass Barrel Securely
Cable End Guide (Note 1)
NOTE: Tighten, then back nut off 1/2 turn.
TOOLS/LUBRICANTS
TOOLS/LUBRICANTS
91 -57797A3 Engine Alignment Tool
92-861 54A 1 Quicksilver 2-4-C Marine-Lube
90-1 4499--1 887
I REMOVAL and INSTALLATION -2A-1
Removal
IMPORTANT: Stern drive unit must be removed prior
to engine removal. Refer to "Stern Drive Service
Manual".
1.
Disconnect battery cables from battery and remove
instrument harness connector plug from engine
harness receptacle.
2.
Disconnect fuel line and throttle cable.
3.
Disconnect trim position sender wires (coming
from gimbal housing) from terminal block on circuit
breaker/solenoid mounting bracket. After wires are
disconnected, remove wires from clamps that hold
the power steering hoses.
4.
Remove red and black Power Trim pump motor
wires from engine (some models).
5.
Disconnect water inlet hose and exhaust elbow
bellows.
6.
Remove both shift cables from shift plate.
7.
Disconnect any grounding wire or accessories that
are connected to the engine.
8.
Power Steering Models: Disconnect fluid hoses
from power steering control valve.
9.
Support engine with suitable sling thru lifting eyes
on engine and remove front and rear engine mounting
bolts.
10.Carefully remove engine.
Installation
1.
Lift engine with an overhead hoist, using suitable
sling and lifting eyes on engine.
2.
Lubricate engine coupling splines with 2-4-C
Marine-Lube.
3.
Place large fiber washer on top on transom plate
engine mounting bracket and double wound lockwasher
inside fiber washer.
4.
Place engine over transom plate mounting brackets.
hose clamps over rubber exhaust elbow bellows.
5.
Place steel washers and spacers on mounting bolts
and insert bolts down thru rear engine mounts,
washers and mounting brackets. Thread elastic
stop nuts on bolts. Torque to specification.
a-Rear Engine Mounting Bolts
b -Large Steel Washer
c -Metal Spacer
d -Rear Engine Mount
e -Fiber Washer With Double Wound Lockwasher in the Center
f-Mounting Brackets
g-Elastic Stop Nut (Hidden)
6.
Tighten all exhaust bellow clamps securely.
7.
Secure front engine mounts to boat.
8.
Check engine alignment. Refer to "Alignment".
After correct alignment is attained, tighten locknuts
securely.
a -Double Wound Lockwasher
b -Fiber Washer
c-Mounting Bracket
d-Elastic Stop Nuts (Engine Mounting Bolts)
a-Mounting Bolts
b-Locking Nuts
2A-2 -REMOVAL and INSTALLATION 90-1 4499--1 887
9. Place hose clamp over water inlet hose and place
hose over inlet tube. Tighten clamp securely.
a-Water Inlet Tube
b -Hose Clamp
c-Water Inlet Hose
10. Connect instrument harness to engine harness.
Secure with clamp and tighten securely.
11. Conect trim position sender wires as follows:
a -Power Steering Hydraulic Hose b -Hose Clips
c-Trim Position Sender Wires (Route Thru Hose Clips)
d -Sta-Strap Leads at This Location
90-14499--1 887
a-Terminal Block
b-Brown or Purple To Insulated
c-Brown/White
d-Without Sleeve-To Terminal Block Mounting Screw
12. Connect fuel line. Check for fuel leaks.
13. Connect drive unit and remote control shift cables
as follows:
IMPORTANT: Adjust shift cables as outlined in "Stern
Drive Service Manual".
a -Remote Control Shift Cable Anchor Points
b -Drive Unit Shift Cable Anchor Points
REMOVAL and INSTALLATION -2A-3
14. Connect throttle cable. Refer to "Attaching/ Adjusting
throttle Cable".
15. Connect red and black trim pump wires (some
models).
16. Connect any ground wires or accessories that may
have been disconnected.
17. Power Steering Models: Reconnect fluid hoses as
shown.
a-Control Valve
b-Small . . .
c _ Large Torque to Specefecateons
IMPORT ANT: Bleed power steering system as outlined
in "Stern Drive Service Manual".
18. Connect battery cables to battery.
Alignment
To ensure more engine coupler engagement during
the alignment of engines, modify the alignment tool
as shown. This modification will improve engine engagement
on the other model engines also.
IMPORTANT: DO NOT remove more than .560" from
gimbal bearing area of alignment tool. This dimension
ensures that the gimbal bearing will straddle the existing
"under cut" in alignment tool.
------To Engine Coupling
a-1.150" Dia.
b -.06" R. Permissible
c-.500"
d -.06 x45° Chamfer
e-1 .37 4" -1 .376" Dia.
f-.560
2A-4 -REMOVAL and INSTALLATION
1. Using Alignment Tool (91-57797A3), insert end of
shaft (which does not have threaded hole) thru
gimbal bearing. Move gimbal bearing, as required,
to insert shaft into engine coupling.
2. If shaft enters coupling freely with no pressure,
alignment is correct. If not, proceed as follows:
a. Loosen locknut on both front engine mounts.
b. Thread adjusting nut either way to raise or lower
front of engine.
IMPORTANT: Raise or lower each side of the engine
the same amount. Care must be taken not to "cock"
front of engine.
c. After correct alignment shaft fit is attained,
tighten locknuts securely. Recheck alignment
shaft fit.
a-Turn both Front Engine Mounts an Equal Amount in Direction
Required Until Alignment Shaft Enters Engine Coupling Freely
b-Locknut
c-Tab Washer
90-14499--1 887
Attaching/ Adjusting Throttle Cable
1.
Place remote control in neutral gear, idle position.
2.
Fasten cable end guide as shown.
.. 3.
Grasp throttle cable brass barrel and push cable
lightly toward throttle lever. Adjust barrel to align
with anchor stud. Fasten barrel as shown.
MODEL WITH 2 BARREL CARBURETOR
a -Cable End Guide
b-Washer, Nut, Screw and Bushing (DO NOT Over-Tighten)
c -Brass Barrel
d-Stud
e-Washer and Nut (DO NOT Over-Tighten)
f -Idle Stop Screw
MODELS WITH 4 BARREL CARBURETOR
a -Cable End Guide
b-Bushing
c-Washer, Nut and Screw (DO NOT Over-Tighten)
4.
Check that throttle valves are fully open when
remote control is at full throttle position. Level tang
should be against stop as shown in Figure 3 or 4.
5.
Return remote control to neutral gear, idle position.
Check that idle stop screw is against stop.
MODEL WITH 2 BARREL CARBURETOR
392-H
a -Throttle Lever Tang Against Stop
b -Idle Stop Screw
MODELS WITH 4 BARREL CARBURETOR
a-Tang
b -Carburetor Body
c-Idle RPM Adjustment Screw
d-Spacer
e -Brass Barrel
f-Washer and Nut (DO NOT Over-Tighten)
g -Anchor Stud
90-1 4499--1 887
REMOVAL and INSTALLATION -2A-5
320 EFI
a-Cable End Guide
b-Throttle Lever Stud
c -Elastic Stop Nut and Flat Washer
d -Throttle Lever
e -Idle Speed Adjustment Screw (Must Contact
Idle Speed Stop Screw}
f -Brass Barrel
g -Throttle Cable Anchor Stud
2A-6 -REMOVAL and INSTALLATION 90-14499--1 887
REMOVAL and INSTALLATION
('
.. .
MCM MODELS with I DRIVE
with DRIVESHAFT EXTENSION
Index
Page
Torque Specifications 28-1
........................
Tools/Lubricants 28-1
.............................
Removal 28-1
.....................................
Installation ...................................28-2
Alignment 28-5
...................................
Attaching/Adjusting Throttle Cable ............28-9
REMOVAL and INSTALLATION -28 90-14499--1 887
TORQUE SPECIFICATIONS
Fastener Location Lbs. Ft. (N.m)
Battery Cables Securely
Bearing Support to
Inner Transom Plate
35-40
(47-54)
Drive Shaft 50 (68)
Drive Shaft Shield 30 (41 )
Extension Housing to
Flywheel Housing
30 (41)
Flywheel Housing 30 (41 )
Front and Rear Engine Mounts Securely
Hose Clamps Securely
Rear Engine Mount Bracket 50 (68)
Remote Control Throttle Cable
Brass Barrel Securely
Cable End Guide (Note 1)
NOTE 1: Tighten, then back nut off 1/2 turn.
TOOLS/LUBRICANTS
Removal
IMPORTANT: Stern drive unit does not have to be
removed prior to engine removal. If stern drive is going
to be removed, refer to "Stern Drive Service Manual".
1.
Disconnect battery cables from battery and remove
instrument harness plug from engine harness receptacle.
2.
Disconnect fuel line and throttle cable.
3.
Slide sleeves back on black and white/green (or
gray) wires and disconnect engine harness wires
from shift cut-out switch harness.
4.
Disconnect trim position sender brown/white wire
from terminal block on engine. Terminal block
located on circuit breaker/solenoid mounting
bracket. After wires are disconnected, remove wires
from clamps that hold the power steering hoses.
5.
Disconnect water inlet hose (from engine seawater
pump).
6.
Disconnect exhaust pipes from exhaust hoses.
7.
Remove top shield and then bottom shield.
a-Top Shield
b -Bottom Shield
c-4 Screws/Nuts (2 Hidden)
d-3 Screws (Hidden)
TOOLS/LUBRICANTS
91-57797A3 Engine Alignment Tool
92-861 54A1 Quicksilver 2-4-C Marine-Lube
90-1 4499--1 887
REMOVAL and INSTALLATION -28-1
8. Disconnect drive shaft from output flange.
a -Output Flange
b -Drive Shaft
c-Screw/Nut (4)
9.
Disconnect fluid hoses from power steering control
valve (located on transom plate).
10. Disconnect any grounding wire or accessories that
are connected to the engine.
IMPORTANT: To avoid the need for a complete realignment
(after engine repair), do not move front or
rear mounts. Remove mounting bolts.
11. Support engine with suitable sling thru lifting eyes
on engine and remove front and rear mounting
bolts.
12. Carefully remove engine.
a-Mounting Bolts
28-2 -REMOVAL and INSTALLATION
Installation
IMPORTANT: If engine mounts or drive shaft have
been changed, refer to "Alignment" before starting
installation.
1.
Lift engine with an overhead hoist, using suitable
sling and lifting eyes on engine.
2.
Set engine on stringers.
3.
Connect drive shaft to output flange. Torque screws
and nuts to specifications.
4.
Relieve hoist tension from engine; then slide engine
fore or aft as needed to obtain a 1/4" (6mm)
between flange shoulder and extension shaft housing
bearing.
IMPORTANT: Failure to properly position output shaft
flange may result in bearing damage.
a -Flange Shoulder
b-Bearing
c-1/4" (6mm)
90-14499--1 887
5.
Position engine for correct engine and drive shaft
lateral alignment as follows:
a.
The distance between the center of the bearing
support attaching bolts on inner transom plate
and grease fitting on shaft extension housing
must be equal. If not, slide aft end of engine to
one side or the other until distances are equal.
b.
Measure distance between the center of the
bearing support attaching bolts and rear engine
mount adjusting bolt. These distances also must
be equal. If not, slide front of engine to one side
or the other until distances are equal.
a-Distance Between Bearing Support Attaching Bolts and Grease
Fitting
b-Distance Between Bearing Support Attachmg Bolts and Engine
Mount Bolts
6.
After engine has been aligiled correctly, fasten
front and rear engine mounts to stringers.
7.. Install top and bottom shield. Torque screws to r specifications .
a -Shaft Housing
b -Bottom Shield
c-Screws (Threads of Screws Are Coated with Loctite)
a-Top Shield
b -Bottom Shield
c-Screw (4 Used)
d-Nut (4 Used)
8.
Connect exhaust pipes to exhaust hoses.
a -Exhaust Pipe
b -Exhaust Hose
c -Clamps (Tighten Securely)
d -Exhaust Tube
90-14499--, 887
REMOVAL and INSTALLATION -2B-3
13.Reconnect power steering fluid hoses as shown.
9. Connect water inlet hose to seawater pump.
10. Reconnect shift cut-out switch harness to engine
IMPORTANT: Bleed power steering system as outlined
harness.
in "Stern Drive Service Manual".
a -Control Valve
. . .b -Small
c _ Large
a-Engine Harness
b-Switch Harness
c-Black
d -White-Green (or Gray)
11.Connect instrument harness to engine harness.
Tighten clamp.
12.Connect trim position sender brown/white wire as
shown.
14. Connect fuel line. Check for leaks.
15. Connect throttle cable. Refer to "Attaching/ Adjusting
Throttle Cable".
16. Connect any grounding wires or accessories that
may have been disconnected.
17. Connect battery cables to battery.
IMPORTANT: If stern drive unit was removed, refer to
"Alignment'.
a -Brown/White Wire -Route Thru Clamps That Hold the Power
Steering Hoses. Then Connect to Insulated Terminal
2B-4 -REMOVAL and INSTALLATION 90-14499--1 887
Alignment
1. Install bearing support, as shown. Do not tighten
bolts.
a-Bolt, Bearing Support (2)
b -Flat Washer (2)
c-Spherical Washer (4) (Install with Rounded Side Toward Bearing
Support)
d -Bearing Support
e-Nut (2)
2. Insert solid end of Alignment Tool (91 -57797 A3)
thru bearing in gimbal housing and into input shaft
splines.
a -Alignment Shaft
90-14499--1 887
3. Tighten bearing support bolts until snug [5-10 lbs.
ft. (7-13 N.m)]. Strike the head of both bolts with a
ball peen hammer, then torque bolts to specifications.
IMPORTANT: Bearing support attaching bolts must be
struck with a hammer to properly seat spherical
washers. If procedure is not followed, subsequent
damage to bearings may occur from misalignment.
ALIGNMENT
IMPORTANT: A Universal Protractor is required for
measuring the angles in the following steps. Protractor
readings will be taken off of vertical and horizontal
surfaces; therefore, both the oo and the 90° marks will
be used. It should be kept in mind that these are reference
marks only and the actual numbers should be
ignored. It is only necessary to note the number of
degrees and to which side (left or right) of the reference
marks the indicator needle rests. Protractor must
be viewed from the same side of power package
throughout alignment.
a -Protractor Reference Marks
1. Insert solid end of alignment tool thru bearing in
gimbal housing and into bearing support input shaft
splines.
2. Position base of protractor against input shaft
flange, as shown. Note and record the number of
degrees and to which side of the reference mark the
indicator needle has moved in the chart following.
READING from STEP 2
degrees to the
side of Reference mark.
REMOVAL and INSTALLATION -2B-5
IMPORTANT: Be sure that boat does not move once
reading has been taken from input shaft flange, as this
reading establishes reference point for aligning drive
shaft and engine following.
a-Input Shaft Flange b -Protractor
c-Indicator
16281
3. Lift engine into boat, using an overhead hoist and a
chain (attached to lifting eyes on engine). A CAUTION
When attaching drive 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 to
each other prior to tightening screws, or screws may
come loose during operation.
4. Attaching drive shaft to input shaft flange and output
shaft flange, as shown.
a-Input Shaft Flange
b -Drive Shaft
c-Screw (4 Used) (Torque to Specifications)
d-Nut (4 Used)
Drive Shaft Attached to Input Shaft Flange
28-6 -REMOVAL and INSTALLATION
a -Output Shaft flange
b -Drive Shaft
c-Screw (4 Used) (Torque to Specifications)
d -Nut (4 Used)
Drive Shaft Attached to Output Shaft Flange
5. Position base of protractor on drive shaft, then,
adjust engine mounts so that indicator needle is 1°
to 3° on either side of reading taken in Step 2.
Record this reading in the following chart for later
use.
a -Drive Shaft
b -Protractor
c -Output Shaft Flange
READING from STEP 5
degrees to the
side of Reference mark.
IMPORTANT: A minimum of 1/4" (6mm) up-and-down
engine mount adjustment must exist after engine has
been properly aligned. This is necessary to allow for ..
realignment of the engine in the future. If mount travel
is insufficient, boat stringer height must be adjusted.
90-14499--1 887
IMPORTANT: Failure to properly position engine (as
described following) may result in bearing damage.
6.
Relieve hoist tension from engine, then slide engine
fore or aft as needed to obtain a 1/4" (6mm)
between flange shoulder and extension shaft housing
bearing, as shown.
a-Flange Shoulder
b-Bearing
c-1/4" (6mm)
A CAUTION
Engine must be aligned correctly to achieve proper
engine operation and to prevent damage to drive shaft.
r-
If drive shaft is run at an incorrect angle, damage to
universal joint bearings may result.
7.
Position engine for correct engine and drive shaft
lateral alignment as follows:
a.
The distance between the center of the bearing
support attaching bolts (on inner transom plate)
and grease fitting on shaft extension housing
must be equal. If not, slide aft end of engine to
one side or the other until distances are equal.
b.
Measure distance between the center of the
bearing support attaching bolts and rear engine
mount adjusting bolt, as shown. These distances
also, must be equal. If not, slide front of
engine to one side or the other until distances
are equal.
a-Distance Between Bearing Support Attaching Bolts and Grease
Fitting
b -Distance Between Bearing Support Attaching Bolts and Engine
Mount Bolts
90-1 4499--1 887
8.
After engine has been aligned correctly, fasten
front and rear engine mounts to stringers.
9.
Position protractor on starter housing cover plate,
as shown. Raise or lower front engine reads exactly
the same number of degrees as that recorded in
Step 2.
a-Flywheel Housing
b -Starter Housing Cover Plate
c -Protractor
10. Position protractor on
drive shaft as shown and
recheck angle. Angle should be the same as that
recorded in Step 5. If not, raise or lower all engine
mount adjusting nuts an equal amount until correct
angle is reached.
a -Drive Shaft
b -Protractor
c -Output Shaft Flange
11. Tighten all engine mount locking nuts securely.
12. Remove alignment shaft from gimbal housing.
REMOVAL and INSTALLATION -2B-7
13.1nstall drive shaft shields.
Transom End
a-Top Shield
b-Bottom Shield
c-Screw (4 Used)
d-Nut (4 Used) (Torque to Specifications)
Engine End
a-Top Shield
b -Bottom Shield
c -Screw (4 Used)
d-Nut (4 Used) (Torque to Specifications)
14. 1nstall stern drive unit. Stern drive unit installation
procedure is the same as that for the standard
models, with the following exceptions: No alignment
is necessary, other than to align gimbal bearing
with bearing support input shaft. Steps 2 and 3.
IMPORTANT: Stern drive universal joints must be
aligned with drive shaft universal joints, as shown.
Place a reference mark (white paint) on shafts to correspond
with universal joint centerlines. After installing
stern drive, check to ensure that these marks are in
alignment.
a-Imaginary Centerline Running Thru This Universal Joint Bear
mg Must BeVertical b-Place a Reference Mark Here To Correspond with "a"
a-Imaginary Centerline Runnmg Thru Th1s Umversal Joint Bearing Must
Be Vertical (Once Drive Un1t1s Installed)
b-Place a Reference Mark Here To Correspond w1th "a"
2B-8 -REMOVAL and INSTALLATION 90-14499--1 887
Attaching/ Adjusting Throttle
Cable
1.
Place remote control in neutral gear, idle position.
2.
Fasten cable end guide as shown.
3.
Grasp throttle cable brass barrel and push cable
lightly toward throttle lever. Adjust barrel to align
with anchor stud. Fasten barrel as shown.
MODEL WITH 2 BARREL CARBURETOR
a -Cable End Guide
b-Washer, Nut, Screw and Bushing (DO NOT Over-Tighten)
c -Brass Barrel
d-Stud
e-Washer and Nut (DO NOT Over-Tighten)
f -Idle Stop Screw
MODELS WITH 4 BARREL CARBURETOR
a -Cable End Guide
b-Bushing
c -Washer, Nut and Screw (DO NOT Over-Tighten)
d-Spacer
e -Brass Barrel
f-Washer and Nut (DO NOT Over-Tighten)
g -Anchor Stud
90-1 4499--1 887
4.
Check that throttle valves are fully open when
remote control is at full throttle position. Level tang
should be against stop as shown in Figure 3 or 4.
5.
Return remote control to neutral gear, idle position.
Check that idle stop screw is against stop.
MODEL WITH 2 BARREL CARBURETOR
a-Throttle Lever Tang Against Stop
b -Idle Stop Screw
MODELS WITH 4 BARREL CARBURETOR
a-Tang
b-Carburetor Body
c-Idle RPM Adjustment Screw
REMOVAL and INSTALLATION -2B-9
320 EFI
a -Cable End Guide b-Throttle Lever Stud
c -Elastic Stop Nut and Flat Washer
d -Throttle Lever
e-Idle Speed AdJustment Screw (Must Contact
Idle Speed Stop Screw)
f -Brass Barrel
g-Throttle Cable Anchor Stud
2B-10 -REMOVAL and INSTALLATION 90-14499--1 887
REMOVAL and INSTALLATION
330 {B-W) TR-TRS
\.€;1:1 1 {,.
. . .
Index
Page
Torque Specifications ........................ 2C-1
Tools/Lubricants ............................. 2C-1
Removal 2C-2
.....................................
Installation/Alignment ........................ 2C-2
Attaching/Adjusting Shift Cable ............ ... 2C-5
Attaching/Adjusting Throttle Cable ............ 2C-6
REMOVAL and INSTALLATION -2C
TORQUE SPECIFICATIONS
r-'.
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Battery Cables Securely
Front Engine Mount Securely
Hose Clamps Securely
Power Steering Fluid Hose Fittings
Large 20-25 (27-34)
Small 96-108 (1 1-12)
Rear Engine Mount 100 (1 36)
Remote Control Shift Cable
Brass Barrel (Note 1)
Cable End Guide (Note 1)
Remote Control Throttle Cable
Brass Barrel (Note 1)
Cable End Guide (Note 1)
NOTE 1: Tighten, then back nut off 1/2 turn.
TOOLS/LUBRICANTS
TOOLS/LUBRICANTS
91-57797A3 Engine Alignment Tool
92-861 54A1 Quicksilver 2-4-C Marine-Lube
90-14499--1 887 REMOVAL and INSTALLATION -2C-1
Removal
IMPORTANT: Stern drive unit must be removed prior
to engine removal. Refer to "Stern Drive Service Manual".
1.
Disconnect battery cables from battery and remove
instrument harness connector plug from engine
harness receptacle.
2.
Disconnect fuel line and throttle cable.
3.
Disconnect trim position sender wires from terminal
block on flywheel housing.
4.
Disconnect water inlet hose and exhaust elbow
bellows.
5.
Remove shift cable.
6.
Remove buzzer tan/blue wire from water heat
switch in thermostat housing.
7.
Disconnect any grounding wire or accessories that
are connected to the engine.
8.
Power Steering Models: Disconnect fluid hoses
from power steering control valve.
9.
Support engine with suitable sling thru lifting eyes
on engine and remove front and rear engine mounting
bolts.
10. Pull engine forward to disengage transmission output
housing from gimbal housing and carefully
remove engine.
Installation/ Allignment
1.
Prepare transom assembly as shown.
a-Transom Gimbal Housing Assembly Opening (Lubricate with
2-4-C Marine Lube)
b -Double-Wound Lockwasher (2)
c -Fiber Washer (2)
d -Large Steel Washer (2)
e-Engine Supports
2C-2 -REMOVAL and INSTALLATION
2. Prepare transomission output housing as shown.
a -Transmission Output Housing
b-"0" Ring Seal (Lubricate with 2-4-C Marine Lube)
3.
Lift engine with an overhead hoist, using a suitable
sling and lifting eyes on engine.
4.
Position engine ahead of inner transom plate so
that transmission output housing is in line with
large opening in inner transom plate.
IMPORTANT: Take care when installing engine in next
step to prevent damage to "0" ring seal on transmission
output housing.
5.
Carefully guide transmission output housing into
transom gimbal housing assembly until holes in
rear engine mounts align with holes in inner transom
plate engine supports.
IMPORTANT: Do not relieve hoist tension entirely, as
inner transom plate engine supports and/or transmission
output housing may be damaged.
6.
Relieve hoist tension, as required, to allow rear
engine mounts to rest on inner transom plate
engine supports and washers.
7.
Secure rear engine mounts as shown. Torque bolts
to specifications.
a-Bolt e-Inner Transom Plate
b -Steel Washer f-Elastic Stop Nut
c -Fiber Washer
d -Rear Engine Mount
90-14499--1 887
8.
Insert solid end of Alignment Tool thru bell housing
bore and into transmission output housing until it
bottoms.
9. Slide plate toward bell housing and position bell
( housing, as required, to allow shoulder on plate to
enter bell housing bore.
10. With alignment tool plate positioned in bell housing
and engine supported with hoist, front engine
mounts should rest on top of stringers without disturbing
alignment tool plate position when hoist
tension is relieved.
NOTE: Boat stringers must position engine so that a
minimum of 1/4" (6mm) of up-and-down front mount
adjustment exists after mounts are lowered onto
stringers.
11. Relieve hoist tension entirely and fasten front engine
mounts (with slotted mounting hole toward
front of engine) to stringers.
a -Mounting Bolts
12. While pushing
in on alignment shaft and plate,
check for gap between plate and bell housing rear
surface at 12, 6, 3 and 9 o'clock positions. Engine
alignment is correct when no gap exists at any position.
If a gap exists, proceed as follows.
GAP AT 12 O'CLOCK POSITION
Loosen locking nuts on front engine mounts. Both
mounts must be adjusted equally to keep engine
level from side to side. Turn adjusting nut on both
mounts equally counterclockwise to raise front of
engine, until no gap exists. Tighten locking nuts
securely (until lockwasher is compressed).
GAP AT 6 O'CLOCK POSITION
Loosen locking nuts on front engine mounts. Both
mounts must be adjusted equally to keep engine
level from side to side. Turn adjusting nut on both
mounts equally clockwise to lower front of engine,
until no gap exists. Tighten locking nuts securely
(until lockwasher is compressed).
90-14499--1 887
REMOVAL and INSTALLATION -2C-3
GAP AT 3 O'CLOCK POSITION
Loosen lag bolts which fasten front engine mounts
to boat stringers and move engine to the right (starboard)
until no gap exists. Retighten lag bolts
securely.
GAP AT 9 O'CLOCK POSITION
Loosen lag bolts which fasten front engine mounts
to boat stringers and move engine to the left (port)
until no gap exists. Retighten lag bolts securely.
12. After correct alignment has been attained, re-check
all mount fasteners to be sure that they are tight.
13. Remove alignment shaft and plate.
14. Retighten
bellows clamps on exhaust manifold
elbows (both sides).
15. Connect water inlet hose to seawater pump. Tighten
clamp securely.
16.Connect
instrument harness to engine harness.
Secure with clamp and tighten securely.
17. Connect fuel line. Check for leaks.
18. Connect trim position sender wires as shown.
a-Flywheel Housing
b -Terminal Block Mounting Screw
c -Wire without Purple or Brown Sleeve
d-Insulated Terminal
e -Wire with Purple or Brown Sleeve
f-Brown/White Wire
19. Connect tan/blue buzzer wire as shown.
a -Cooling System Water Heat Switch
b-Tan/Blue Wire (From Oil Pressure Switch)
c-Tan/Blue Wire From Buzzer
20. Connect any ground wires or accessories that may
have been disconnected.
21 . Power Steering Models:
Reconnect fluid hoses as
shown.
IMPORT ANT: Bleed power steering system as outlined
in "Stern Drive Service Manual".
a -Control Valve
b-Large . . .
2C-4 -REMOVAL and INSTALLATION
22. For shift
and throttle connections,
following:
"Attaching/Adjusting Shift Cable"
"Attaching/Adjusting Throttle Cable"
23. Connect battery cable to battery.
refer to the
90-1 4499--1 887
Attaching/ Adjusting Shift
Cable ( 1. Place remote control shift lever in neutral position.
2. Place transmission shift lever in neutral position,
indicated when poppet ball (located behind shift
lever) is in center detent hole of shift lever.
a -Shift Lever
b -Poppet Ball In Center Hole of Shift Lever
3. Adjust brass barrel on shift cable, as required, to
align shift cable attaching holes with shift cable
lever and shift cable anchor studs. Center the cable
end play travel when making adjustment.
4. Install shift cable and secure with flat washers and
elastic stop nuts. Tighten nuts to specifications.
a -Lever Stud
b-Washer and Nut
c -Cable End Guide
90-14499--1 887
d -Anchor Stud
e-Washer and Nut
f -Brass Barrel
5. Place remote control shift lever in full forward gear
position. Check position of transomission shift
lever. Transmission shift lever must be positioned
so that the poppet ball is in rear detent hole of shift
lever.
a -Shift Lever
b -Poppet Ball In Rear Detent Hole
c -''F" On Transmission Case
6. Place remote control lever in full reverse gear position
and, again, check transmission shift lever position.
Poppet ball must be in front detent hole of shift
lever.
7. If transmission shift lever is positioned correctly in
one gear (forward or reverse). but not in the other,
recheck shift cable adjustment. If transmission
shift lever is not positioned properly in both gears,
move shift rod stud from top hole in transmission
lever to bottom hole and recheck for proper positioning
of shift lever. If proper positioning is still not
obtained, remote control does not provide sufficient
shift cable travel and must be replaced.
a -Shift Lever
b -Poppet Ball In Front Detent Hole
c -"R" On Transmission Case
d-Install Shift Rod Stud in This Hole, If Necessary, To Properly
Position Shift Lever With Poppet Ball
REMOVAL and INSTALLATION -2C-5
A CAUTION
Remote control and shift cable must position transmission
shift lever so that it is fully in the forward and
reverse gear detent position and over the letter "F" on
transmission case when propelling boat forward. Transmission
shift lever must be positioned properly (without
any modification to transmission) or transmission
failure may occur. Warner Gear Warranty 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 remote control and cable
do not position shift lever correctly.
Attaching/ Adjusting Throttle
Cable
1. Place remote control in neutral gear, idle position.
2. Fasten cable end guide as shown.
3. Grasp throttle cable brass barrel and push cable
lightly toward throttle lever. Adjust barrel to align
with anchor stud. Fasten barrel as shown.
a -Anchor Stud
b-Washer and Nut (DO NOT Over-Tighten)
c -Brass Barrel
d-Cable End Guide
e-Spacer
f-Screw
g-Washer and Nut (DO NOT Over-Tighten)
h-Bushing
2C-6 -REMOVAL and INSTALLATION
4. Check that throttle valve are fully open when
remote control is in full throttle position.
5. Return remote control to neutral gear, idle position.
Check that idle stop screw is against stop.
a-Tang
b -Carburetor Body
c -Idle RPM Adjustment Screw
90-14499--1 887
REMOVAL and INSTALLATION
m
MCM MODELS with TRS DRIVE
Index
Page
Torque Specifications 20-1
........................
Tools/Lubricants 20-1
.............................
Removal 20-2
.....................................
Power Steering Models 20-2
....................
Models with Transmission Oil Cooler
Mounted on Stringer ....................20-2
Models with Engine Oil Cooler Mounted
on Stringer .............................20-2
Transom Mounted Engine ..................20-2
Engine with Oriveshaft .....................20-2
Removal of Tailstock Housing .................20-3
Installation ...................................20-4
Oriveshaft Models 20-4
.........................
Installation ...................................20-5
Transom Mounted Model ..................20-5
Completing Installation .......................20-6
Attaching/Adjusting Shift Cables ..............20-7
Attaching/Adjusting Throttle Cables ...........20-9
REMOVAL and INSTALLATION -20 90-1 4499--1 887
TORQUE SPECIFICATIONS
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Battery Cables Securely
Driveshaft to
Tailstock Flange
50 (68)
(Note 2)
Driveshaft to Transmission
Output Flange 35 (48)
Drive Unit Shift Cable
Brass Barrel
Cable End Guide
Spread Cotter Pin
(Note 1)
Front Engine Mount Securely
Front Engine Plate Mount Securely
Hose Clamps Securely
Power Steering Fluid Hose Fittings
Large
Small
Rear Engine Mounts
(Transom Mounted Engine)
20-25 (27-34)
100 (1 36)
96-1 08 ( 11 -12)
Rear Engine Plate Mount Securely
Rear Engine Mounts 35-40 (47-54)
Remote Control Shift Cable
Brass Barrel
Cable End Guide
Securely
(Note 1)
Remote Control Throttle Cable
Brass Barrel
Cable End Guide
Securely
(Note 1)
Remote Control Shift Cable
Brass Barrel
Cable End Guide
(Note 1)
(Note 1)
Remote Control Throttle Cable
Brass Barrel
Cable End Guide
(Note 1)
(Note 1)
Tailstock Housing
Compression Nuts
70 (8)
Tailstock Mounts 100 (1 36)
NOTES: 1. Tight, then back nut off 1/2 turn.
2. Secure with safety wire.
TOOLS/LUBRICANTS
TOOLS/LUBRICANTS
91 -57797A3 Engine Alignment Tool
92-861 54A1 Quicksilver 2-4-C Marine Lube
90-14499--1 887 REMOVAL and INSTALLATION -20-1
Removal
IMPORTANT: Stern drive unit must be removed prior
to engine removal. Refer to "Stern Drive Service
Manual."
1.
Disconnect battery cables from battery and remove
instrument harness connector plug from engine
harness receptacle.
2.
Disconnect fuel line and throttle cable.
3.
Disconnect trim position sender wire (some
models).
4.
Remove red and black Power Trim pump motor
wires from engine (some models).
5.
Disconnect water inlet hose and exhaust system.
6.
Remove shift cable.
7.
Disconnect any grounding wire or accessories that
are connected to the engine.
8.
Power Steering Models:
a.
Fluid Cooler Mounted on Engine: Disconnect
fluid hoses from power steering control valve.
b.
Fluid Cooler mounted on Stringer: Disconnect
fluid hoses from cooler.
9.
Models with Transmission Oil Cooler Mounted on
Stringer: Disconnect oil hoses from cooler. Mark
location each hose was removed from.
10. Models with Engine Oil Cooler Mounted on Stringer:
Disconnect oil hoses from cooler. Mark location
each hose was removed from.
11. Disconnect hydraulic hoses from reverse lock valve
located on transmission (some models).
12. Support engine with suitable sling thru lifting eyes
on engine and remove front and rear engine mounting
bolts.
13.Transom Mounted Engine:
Pull engine forward to
disengage transmission output housing from gimbal
housing and carefully remove engine.
IMPORTANT: Driveshaft has been assembled and balanced
at the factory with the universal joint yoke on
both ends of shaft running in the same plane. If it is
necessary to remove splined end of shaft, end must be
reinstalled in splines in exactly the same position as
factory assembled, or damage to universal joints and
driveshaft may result.
14. Engine with Driveshaft:
Method A: Mark driveshaft in two locations as
shown, pull engine forward to disengage driveshaft
splines and carefully remove engine.
Method B: Disconnect driveshaft from transmission
output shaft. Carefully remove engine.
a -Transmission Output Shaft
b -Driveshaft
c -U-Bolts (2)
d-Elastic Stop Nuts (4) ...,__,·
e-Splines
f-Make Alignment Marks With Paint
20-2 -REMOVAL and INSTALLATION
90-14499--1 887
Removal of Tailstock Housing (Driveshaft
Models) A CAUTION Drlveshaft has been assembled and balanced at the
factory with the universal joint yokes on both end of
shaft running in the same plane. If It is necessary to
remove splined end of shaft, mark driveshaft in two
locations as shown. Driveshaft splines must be aligned
in exactly the same position as factory assembled, or
damage to universal joints and driveshaft may occur.
1. Disconnect both ends of driveshaft as shown.
a-Remove 4 Nutsb -Remove 2 U-Bolts
c -Make Alginment Marks With Paint
a -Cut Safety Wire
b -Remove 4 Bolts and Washers
90-14499--1 887
2. Remove driveshaft.
3. Loosen tailstock compression nuts.
a -Compression Nuts
b-Bell Housing
07449
4. Remove tailstock housing to inner transom plate
support fasteners.
a-Mounting Bolt (2) b-Large Steel Washers (4) c-Elastic Stop Nut (2)
d -Inner Transom Plate Support (2) 5. Remove tailstock housing from opening in gimbal
housing.
11953
REMOVAL and INSTALLATION -20-3
Installation
Driveshaft Models
1.
Lubricate rubber "0" ring seal on tailstock housing
assembly and opening in gimbal housing with 2-4-C
Marine Lube.
a-"0" Ring Seal (Lubricate with 2-4-C Marine Lube)
b -Compression Nuts (6)
a-Gimbal Housing Opening (Lubricate with 2-4-C Marine Lube)
2.
Loosen tailstock housing compression nuts.
20-4 -REMOVAL and INSTALLATION
3.
Insert tail stock housing assembly into gimbal housing
opening until holes in housing align with holes
in inner transom plate supports. Secure tailstock
housing to inner transom plate supports with bolts,
flat washers and elastic stop nuts, as shown. Torque
to specifications.
a -Mounting Bolt (2) c -Elastic Stop Nut (2)
b-Large Steel Washers (4) d-Inner Transom Plate Support (2)
4.
Torque tailstock housing "0" ring seal compression
nuts to specifications.
IMPORTANT: Driveshaft has been assembled (and
balanced) at the factory with the universal joint yokes
on both ends of shaft running in the same plane. If it is
necessary to remove spline end of shaft, end must be
reinstalled in splines in exactly the same position as
factory assembled, or damage to universal joints and
drive shaft may result.
5.
Attach driveshaft to tailstock housing flange with
bolts and washers. Torque to specifications.
6.
Secure bolts with stainless steel safety wire, in
such a manner that it does not loosen bolts.
a-Safety Wire
b-Bolts
90-14499--1 887
IMPORTANT: For bolt heads without holes, drill as 2. Prepare transmission output housing as shown.
shown for safety wire.
a-1/16" (2mm) Dia. Hole Thru
7.
Attach driveshaft to transmission output shaft with
U-bolts and elastic stop nuts. Torque to specifications.
8.
With dual engines mounted to boat stringers, port
engine must sit 1" to 1-5/16" (25 to 33mm) above or
below starboard engine and parallel to crankshaft
centerline of starboard engine (both vertically and
horizontally). Make sure that engine is directly in
line with tailstock housing. Move engine back-orforward,
so that driveshaft splines are positioned at
approximately mid travel. This will place driveshaft
at a 1 o -3° angle to crankshaft centerline necessary
for proper drive shaft operation.
9.
Fasten front and rear mounts using fasteners that
had been removed. Tighten bolts and nuts securely.
Installation
Transom Mounted Model
1.
Prepare transom assembly as shown.
a-Gimbal Housing Opening (Lubricate with 2-4-C Marine Lube)
b -Double-Wound Lockwasher (2)
c -Fiber Washer (2)
d -Large Steel Washer (2)
e -Engine Supports
a-Transmission Output Housing
b-"0" Ring Seal (Lubricate with 2-4-C Multi-Lube)
3.
Lift engine with an overhead hoist, using a suitable
sling and lifting eyes on engine.
4.
Position engine so that transmission output housing
is in line with large opening in inner transom
plate.
IMPORTANT: Take care when installing engine in next
step to prevent damage to "0" ring seal on transmission
output housing.
5.
Carefuly guide transmission output housing into
transom gimbal housing assembly until holes in
rear engine mounts align with holes in inner transom
plate engine supports.
IMPORTANT: Do not relieve hoist tension entirely, as
inner transom plate engine supports and/or transmission
output housing may be damaged.
6.
Relieve hoist tension, to allow rear engine mounts
to rest on inner transom plate engine supports and
washers.
7.
Insert mounting bolts up thru inner and rear
mounts as shown. Torque to specifications.
a -Elastic Stop Nut d-Bolt
b -Steel Washer e-Rear Engine Mount
c -Fiber Washer
90-14499--1 887 REMOVAL and INSTALLATION -20-5
8.
Insert solid end of Alignment Tool thru bell housing
bore and into transmission output housing until it
bottoms. Slid.e plate toward bell housing and position
bell housing to allow shoulder on plate to enter
bell housing bore.
9.
While pushing in on alignment shaft and plate,
check for gap between plate and bell housing rear
surface at 12, 3, 6 and 9 o'clock positions. Engine
alignment is correct when no gap exists at any position.
If a gap exists, proceed as follows:
Gap at 12 o'clock Position
Raise front of engine with hoist, as required, until
gap no longer exists.
Gap at 6 o'clock Position
Lower front of engine with hoist, as required, until
gap no longer exists.
Gap at 3 o'clock Position
Move engine to the right (starboard) until gap no
longer exists.
Gap at 9 o'clock Position
Move engine to the left (port) until gap no longer
exists.
10. After correct alignment has been attained, fasten
front mounts. Tighten fasteners securely.
11. After engine has been fastened securely to boat,
recheck engine alignement to ensure that engine
has not moved; then remove alignment tool.
12. Refer to "Completing Installation".
20-6 -REMOVAL and INSTALLATION
Completing Installation
1.
Connect hydraulic hoses to reverse lock valve as
shown. (Some models).
2.
Models with Engine Oil Cooler Mounted on Stringer:
Connect oil hoses to the same fittings that they
were removed from.
3.
Models with Transmission Oil Cooler Mounted on
Stringer: Connect oil hoses to the same fittings that
they were removed from.
Reverse Lock Valve (Some Models)
a -Reverse Lock Valve
b-Plastic Hose (From Power Trim Pump)
c-Gray Hose (From Transom Assembly)
IMPORTANT: Check all oil levels before and after first
5 minutes of running time.
90-1 4499--1 887
4. Power Steering Models:
Attaching/ Adjusting Shift
a. Fluid Cooler Mounted on Engine: Reconnect
Cable
fluid hoses to power steering control valve as
shown.
1. Place remote control shift lever in neutral position.
b. Fluid Cooler Mounted on Stringer: Reconnect 2. Place transmission shift lever in neutral position,
fluid hoses to cooler.
indicated when poppet ball (located behind shift
lever) is in center detent hole of shift lever.
IMPORTANT: Bleed power steering system as outlined
in "Stern Drive Service Mnaual".
a -Control Valve
5.
Reconnect any grounding wire or accessories that
were removed.
6.
Connect shift cable. Refer to "Attaching/Adjusting
Shift Cable".
7.
Reconnect trim position sender wire (some
models).
8.
Reconnect seawater inlet hose and exhaust system.
Tighten clamps securely.
9.
Reconnect red and black Power Trim pump motor
wires to engine (some models).
10. Reconnect fuel line. Check for fuel leaks.
11. Connect throttle cable. Refer to "Attaching/ Adjusting
Throttle Cable".
12.Connect instrument harness to engine harness.
Secure with clamp and tighten securely.
13. Connect battery cables to battery.
90-14499--1 887
a -Shift Lever
b-Poppet Ball In Center Hole of Shift Lever
3.
Adjust brass barrel on shift cable, as required, to
align shift cable attaching holes with shift cable
lever and shift cable anchor studs. Center the cable
end play travel when making adjustment.
4.
Install shift cable and secure with flat washers and
elastic stop nuts. Tighten nuts to specifications.
a -Lever Stud
b -Washer and Nut
c -Cable End Guide
d -Anchor Stud
e -Washer and Nut
f -Brass Barrel
g -Shift Cable Barrel Clamp Block
h-Washer
REMOVAL and INSTALLATION -20-7
5.
Place remote control shift lever in full forward gear
position. Transmission shift lever must be positioned
so that the poppet ball is in rear detent hole
a -Shift Lever
b-Poppet Ball In Rear Detent Hole
c-"F" On Transmission Case
6.
Place remote control lever in full reverse gear position
and, again, check transmission shift lever position.
Poppet ball must be in front detent hole of shift
7.
If transmission shift lever is positioned correctly in
one gear (forward or reverse), but not in the other,
recheck shift cable adjustment. If transmission shift
lever is not positioned properly in both gears, move
shift rod stud from top hole in transmission shift
lever to bottom hole and recheck for proper positioning
of shift lever. If proper positioning is still not
obtained, remote control does not provide sufficient
shift cable travel and must be replaced.
a -Shift Lever
b-Poppet Ball In Front Detent Hole
c-"R" On Transmtssion Case
d -Install Shift Rod Stud in This Hole, If Necessary, To Properly
Position Shift Lever With Poppet Ball
A CAUTION Remote control and shift cable must position transmission
shift lever so that It Is fully in the forward and
reverse gear detent position and over the letter "F" on
transmission case when propelling boat forward. Transmission
shift lever must be positioned properly (without
any modification to transmission) or transmission
failure may occur. Warner Gear Warranty 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 remote control and cable
do not position shift lever correctly.
2D-8-REMOVAL and INSTALLATION
90-14499--1 887
Attaching/ Adjusting
Throttle Cables
1. Place remote control in neutral gear, idle position.
2. Fasten cable end guide as shown.
3. Grasp throttle cable brass barrel and push cable
lightly toward throttle lever. Adjust barrel to align
with anchor stud. Fasten barrel as shown.
(Rochester Carburetor)
a -Anchor Stud
b-Bushing
c-Washer and Nut (Do Not Over-Tighten)
d -Brass Barrel (' e -Cable End Guide
f -Lever Stud
g-Washer and Nut (Do Not Over-Tighten)
(Holley Carburetor)
a -Anchor Stud
b-Washer and Nut (Do Not Over-Tighten)
c -Brass Barrel
d -Cable End Guide f' e -Lever Stud
f-Washer and Nut (Do Not Over-Tighten)
g-Idle RPM Adjustment Screw
90-14499--1 887
4. Check that throttle valves are fully open when
remote control is in full throttle position.
5. Return remote control to neutral gear, idle position.
Check that idle stop screw is against stop.
320 EFI
a-Cable End Guide
b-Throttle Lever Stud
c -Elastic Stop Nut and Flat Washer
d -Throttle Lever
e -Idle Speed Adjustment Screw (Must Contact Idle Speed
Stop Screw)
f-Brass Barrel
g -Throttle Cable Anchor Stud
REMOVAL and INSTALLATION -2D-9
REMOVAL and INSTALLATION
MIE MODELS 230/260/340/5.7L SKI/5.0 LITRE/
5.7 LITRE/7.4 LITRE
Index
Page
Torque Specifications 2E-1
........................
Lubricants 2E-1
...................................
Removal 2E-1
.....................................
Installation ...................................2E-2
Alignment 2E-4
...................................
Attaching/ Adjusting Standard Attachment
Shift Cable ................................2E-6
Single Station Mounting 2E-6
...................
Dual and Single Station Mounting 2E-7
..........
Attaching/Adjusting Reversed Attachment
Shift Cable ................................ 2E-9
Attaching/Adjusting Throttle Cable ...........2E-10
Single Station Mounting 2E-10
..................
Dual and Single Station Mounting 2E-11
.........
REMOVAL and INSTALLATION -2E
90-1 4499--1 887
TORQUE SPECIFICATIONS
Fastener Location Lbs. Ft. (N.m)
Battery Cables Securely
Engine Mount Pads Securely
Hose Clamps Securely
Mount Locking Nut
Securely
(Note 2)
Propeller Shaft Coupling 50 (68)
Remote Control Shift Cable
Brass Barrel Securely
Cable End Guide (Note 1)
Remote Control Throttle Cable
Brass Barrel Securely
Cable End Guide (Note 1)
Trunnion Clamping Screw/Nut 50 (68)
NOTES:
1.
Tighten, then back nut off 1/2 turn.
2.
Bend tab against adjusting nut.
LUBRICANTS
LUBRICANTS
92-86154A 1 Quicksilver 2-4-C Marine-Lube
Removal
1.
Disconnect battery cables from battery and remove
instrument panel harness connector plug from
engine harness receptacle.
2.
Disconnect fuel line and throttle cable.
3.
Disconnect shift cable.
4.
Disconnect water inlet hose and exhaust system.
5.
Disconnect any ground wires or accessories that
are connected to engine.
6.
Disconnect audio warning system tan/blue wire as
shown.
MIE 230/260/5.7L
a -Water Heat Switch
b-Tan/Blue Wire (Jumper Wire to Engine Oil Pressure Switch)
c-Disconnect Tan/Blue Wire (From Buzzer)
MIE 340
a -Water Heat Switch
b-Tan/Blue Wire (Jumper Wire to Engine Oil Pressure Switch)
c-Disconnect Tan/Blue Wire (From Buzzer)
90-14499--1 887
REMOVAL and INSTALLATION -2E-1
7.
Disconnect propeller shaft coupling from transmission
coupling.
8.
Support engine with suitable sling thru lifting eyes
on engine and remove front and rear engine mounting
bolts.
a-Bolts
b -Slot Forward
9.
Carefully remove engine.
2E-2 -REMOVAL and INSTALLATION
Installation
1.
Ensure that all mounts are:
a.
In the center of their up-and-down adjustment.
b.
Slot forward.
c.
Large diameter of mount trunnion extended as
shown.
d.
Each mount base is downward. Tighten clamping
screws and nuts slightly to prevent moving in
or out, but allowed to pivot when installing
engine.
a -Slot Forward b -Locking Nut
c -Adjusting Nut
d-Trunnion Clamping Screw and Nut
2.
Lift engine into boat and position on engine bed so
that transmission and propeller shaft couplings are
visibly aligned (no gap can be seen between coupling
faces when butted together). Adjust engine
bed height, if necessary, to obtain proper alignment.
Do not use mount adjustment to adjust
engine position at this time.
NOTE: Engine bed must position engine so that a min
imum of 1/4" (6mm) up-and-down adjustment still
exists on all 4 mounts after performing final alignment,
following. This is necessary to allow for realigning
engine in the future.
3.
Check all 4 mounts to ensure that they are still
positioned properly, then fasten mounts to engine
bed with lag bolts. Tighten securely.
4.
Disconnect and remove sling.
90-14499--1 887
10. Connect instrument harness
plug to engine harness
receptacle. Tighten clamp securely.
11. Connect the shift cable and throttle cable as outlined
in:
"Attaching/Adjusting Shift Cable".
"Attaching/Adjusting Throttle Cable".
a -Water Heat Switch
b-Tan/Blue Wire (Jumper Wire to Engine Oil Pressure Switch)
c -Tan/Blue Wire (From Buzzer)
14. Connect battery cables to battery. Tighten securely.
5.
Connect fuel line. Check for leaks.
6.
Connect seawater inlet hose. Tighten clamp securely.
7.
Reconnect exhaust system. Tighten clamps securely.
8.
Align engine as outlined in "Alignment" before
completing installation.
9.
After alignment is correct, connect propeller shaft
coupling to transmission coupling. Torque bolts
and nuts to specifications.
IMPORTANT: Exhaust hoses must be connected to
exhaust elbows so that they do not restrict the flow of
discharge water from the 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 thru.
12. Reconnect any ground wire and accessories that
may have been disconnected.
13. Connect audio warning system wires.
MIE 230/260/5.7L
a -Water Heat Switch
b-Tan/Blue Wire (Jumper Wire to Engine Oil Pressure Switch)
c-Tan/Blue Wire (From Buzzer)
MIE 340
90-1 4499--1 887
REMOVAL and INSTALLATION -2E-3
Alignment
IMPORTANT: Engine alignment must be checked with
boat in the water, fuel tanks filled and with a normal
load onboard.
Engine must be aligned so that transmission and propeller
shaft coupling centerlines are aligned and coupling
faces are parallel. This applies to installations
with solid couplings, as well as flexible couplings.
Engine must be properly aligned or vibration, noise and
damage to transmission output shaft oil seal and bearings
may result.
1.
Check mating faces on transmission and propeller
shaft couplings to make sure they are clean and flat.
2.
Center propeller shaft in shaft log as follows:
a.
Push down and then lift shaft as far as it will
move. Then place shaft in the middle of the
movement.
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, align engine to
shaft.
648-H
a-Up
b-Down
c-Port
d -Starboard
3.
Check that coupling centerlines align, by butting
propeller shaft coupling against transmission coupling.
Shoulder on propeller shaft coupling face
should engage recess on transmission coupling
face with no resistance.
NOTE: Some propeller shaft couplings may not have a
shoulder on mating face. On these installations, use a
straight edge to check centerline alignment.
0
i@QJt 0
G
a-Offset Misalignment "WRONG"
b -Angular Misalignment "WRONG"
c-Perfect Alignment "RIGHT" Coupling Faces are Parallel with
Distance Between Faces Exactly the Same at All Points
IMPORTANT: Remote V-Drive Models: Refer to
Remote V-Drive manufacturers instructions for drive
shaft (between transmission and remote V-Drive) Alignment.
4.
Check for angular misalignment, by hand holding
coupling faces tightly together and checking for a
gap between coupling faces with a .003" (.07mm)
feeler gauge at 90° intervals.
a -Feeler Gauge
b -Transmission Coupling
c-Propeller Shaft
2E-4 -REMOVAL and INSTALLATION
90-14499--1 887
5.
If coupling centerlines are not aligned or if coupling
faces are more than .003" out-of-parallel, adjust
engine mounts, as follows:
a.
TO ADJSUT ENIGNE UP OR DOWN. Loosen
.. locking nut on mounts requiring adjustment.
Raise or lower engine using adjusting nut.
·"'---'
IMPORTANT: Both front mounts must be adjusted
equally and both rear mounts must be adjusted equally
to keep engine level from side-to-side.
a-Locking Nut
b-Adjusting Nut
c -Clamping Screw and Nut
d-Lag Screws
e-Slot
b.
TO MOVE ENGINE TO THE LEFT OR RIGHT.
Loosen clamping screw and nut on all 4 mount
brackets and move engine to the left or right, as
necessary, to obtain proper alignment. If additional
right or left adjustment is needed, a small
amount of adjustment can be obtained with slot
on front end of mounts. Loosen lag bolts which
fasten mounts to engine bed and move engine to
the right or left as required. Retighten lag bolts
securely.
IMPORTANT: Large diameter of mount trunnion must
not extend over 3/4" (20mm) from mount brackets on
any of the mounts.
6.
After engine has been properly aligned, secure
engine mounts, as shown.
3/4"
{20mm) MAX.
a-Torque Clamping Screw and Nut on All 4 Mount Brackets to
Specifications
b-Tighten Locking Nut on All 4 Mounts Securely (Until Lockwasher
is Compressed)
c-Bend One of the Tabs on Tab Washer Down onto Flat of Adjusting
Nut, to Prevent Nut from Loosening During Operation
7.
Connect propeller shaft coupling to transmission
coupling. Torque coupling attaching screws and
nuts to specifications.
90-14499--1 887
REMOVAL and INSTALLATION-2E-5
Attaching/ Adjusting Standard
Attachment Shift Cable
Remote control must provide a total shift cable travel
(at transmission end) of at least 2-3/4" (70mm). This is
necessary to position transmission shift lever fully in
the forward and reverse gear positions. Insufficient
shift cable travel will cause transmission to slip and
eventually fail.
a-2-3/4" (70mm) Minimum
b-Forward Gear
c-Reverse Gear
a-Cable Brass Barrel (Does Not Move)
b -Cable End Gu1de (Does Move, Inner Core Wire Extends)
c •Cable End Guide MUST Move in This Direction When Remote
Control IS Shifted into Forward Gear Pos1tion
d-TransmiSSion Shift Lever
2E-6 -REMOVAL and INSTALLATION
IMPORTANT: 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 -N -R
a-Transmission Shift Lever
b-Shift Lever Must Be Over This Letter When Propelling Boat
FORWARD c-Shift Lever Must Be Over This Letter When Propelling Boat in
REVERSE
d -Poppet Ball Must Be Centered in Detent Hole for Each F-N-R
Position (Forward Gear Shown)
e-Install Shift Lever Stud in This Hole, If Necessary. To Center
Poppet Ball in Forward and Reverse Detent Holes
Single Station Mounting
1. Place remote control shift lever in neutral position.
2. Place transmission shift lever in neutral.
3. Adjust brass barrel on shift cable, as required, to
align shift cable attaching holes with shift lever stud
and shift cable bracket stud or screw hole. Center
cable end play travel when making adjustment.
4. Install shift cable and secure as shown. Tighten nut
that secures cable end guide until it bottoms out,
then back off 1/2-turn. Tighten nut that secures
brass barrel securely.
90-14499--1 887
Dual and Single Station Mounting
1.
Place remote control shift lever in neutral position.
2.
Place transmission shift lever in neutral position.
3.
Adjust brass barrel on shift cable to align holes in
brass barrel and cable end guide with attaching
points on transmission. Center cable end play travel
when making adjustment.
4.
Install shift cable, as shown. Tighten "g" until it
bottoms out, then back off 1/2-turn. Cable end
guide must be free to pivot. Tighten "d" securely.
a -Cable End Guide
b -Cable Brass Barrel
c -Anchor Stud
d -Elastic Stop Nut and Washer
e-Spacer
f-Shift Lever Stud
g -Elstic Stop Nut and Washer
a -Shift Lever
b -Shift Lever Stud
c-Elastic Stop Nut (Thick) and Flat Washer
d -Cable End Guide
e -Cable Brass Barrel
f-Shift Cable Bracket
g-Anchor Stud (In-Line Transmission)
h-Elastic Stop Nut (Thin)
i -Flat Washer
.j-Anchor Screw (V-Drive)
5.
Place remote control shift lever in full forward gear
position. Check position of transmission shift lever.
6.
Place remote control lever in full reverse gear position
and again check shift lever position.
7.
If transmission shift lever is positioned correctly in
one gear, but not in the other, recheck shift cable
adjustment. If transmission shift lever is not positioned
properly in both gears, move shift lever stud
from top hole in shift lever to bottom hole and
recheck for proper positioning. If proper positioning
is still not obtained, remote control does not
provide sufficient shift cable travel and must be
replaced.
90-14499--1 887
REMOVAL and INSTALLATION -2E-7
5.
Place remote control shift lever in forward gear
position and check position of transmission shift
lever. Shift lever must be positioned as shown.
6.
Place remote control lever in reverse gear position
and again check shift lever position. Lever must be
positioned as shown in (c).
F -N R
a -Cable End Guide
b -Cable Brass Barrel
c -Anchor Stud
d -Elastic Stop Nut and Washer
e-Spacer
f-Shift Lever Stud
g -Elstic Stop Nut and Washer
a-Transmission Shift Lever
b -Shift Lever Must Be Over This Letter When Propelling Boat
FORWARD
c-Shift Lever Must Be Over This Letter When Propelling Boat in
REVERSE
d -Poppet Ball Must Be Centered in Detent Hole for Each F-N-R
Position (Forward Gear Shown)
7.
If transmission shift lever is positioned properly in
one gear, but not in the other, recheck shift cable
adjustment. If transmission shift lever is not positioned
properly in both gears, move transmission
sh itt lever stud from top hole in sh itt lever to bottom
hole and recheck for proper positioning. If proper
positioning is still not obtained, remote control
does not provide sufficient shift cable travel and
must be replaced.
'.,·,
2E-8 -REMOVAL and INSTALLATION
90-14499--1 887
5.
Place remote control shift lever in forward gear
position and check position of transmission shift
lever. Shift lever must be positioned as shown.
6.
Place remote control lever in reverse gear position
and again check shift lever position. Lever must be
positioned as shown in (c).
F -N R
a -Cable End Guide
b -Cable Brass Barrel
c -Anchor Stud
d -Elastic Stop Nut and Washer
e-Spacer
f-Shift Lever Stud
g -Elstic Stop Nut and Washer
a-Transmission Shift Lever
b -Shift Lever Must Be Over This Letter When Propelling Boat
FORWARD
c-Shift Lever Must Be Over This Letter When Propelling Boat in
REVERSE
d -Poppet Ball Must Be Centered in Detent Hole for Each F-N-R
Position (Forward Gear Shown)
7.
If transmission shift lever is positioned properly in
one gear, but not in the other, recheck shift cable
adjustment. If transmission shift lever is not positioned
properly in both gears, move transmission
sh itt lever stud from top hole in sh itt lever to bottom
hole and recheck for proper positioning. If proper
positioning is still not obtained, remote control
does not provide sufficient shift cable travel and
must be replaced.
'.,·,
2E-8 -REMOVAL and INSTALLATION
90-14499--1 887
Attaching/ Adjusting
Throttle Cable
Single Station Mounting
1. Place remote control lever in neutral idle position.
2. Install throttle cable end guide on throttle lever
screw. Grasp cable behind brass barrel and push
lightly toward throttle lever, then adjust brass barrel
to align hole with throttle cable anchor stud (and
spacer) and slide barrel onto stud.
3. Secure brass barrel and cable end guide with flat
washers and elastic stop nuts. Tighten cable attaching
nuts securely, but do not over-tighten, because
anchor points must be free to pivot.
a -Cable End GUide
b-Bushmg
c-Washer, Nut and Screw (Do Not Over-Tighten)
d-Spacer
e -Brass Barrel
f-Washer and Nut (Do Not Over-Tighten)
g -Anchor Stud
2E-1 0-REMOVAL and INSTALLATION
4. Place remote control throttle lever in the full throttle
position and check that carburetor throttle plates
open fully and throttle lever contacts stop. If they do
not, check throttle cable and linkages for binding.
Return remote control to neutral, idle position and
check that carburetor throttle lever returns to idle
position and throttle plates are fully closed.
a-Tang
b-Carburetor Body
c-Idle RPM Adjustment Screw
90-14499--1 887
Dual and Single Station Mounting
1. Place remote control throttle lever in idle position
and attach cable end guide to carburetor throttle
lever as shown.
2. Grasp cable behind brass barrel and push lightly as
shown. Adjust brass barrel to align hole with anchor
stud, then slide barrel onto stud.
3. Tighten "c" and "h" securely, but do not overtighten.
DUAL STATION
.. SINGLE STATION
..
a-Cable End Guide
b-Throttle Lever Stud
c -Elastic Stop Nut and Washer
d-Spacer
e -Cable Brass Barrel
f-Anchor Stud
g-Washer
h-Elastic Stop Nut
4. Place remote control throttle lever in the full throttle
position and check that carburetor throttle plates
open fully and throttle lever contacts stop. If they do
not, check throttle cable and linkages for binding.
Return remote control to netural, idle position and
check that carburetor throttle lever returns to idle
position and throttle plates are fully closed.
a-Tang
b -Carburetor Body
c-Idle RPM Adjustment Screw
90-14499--1 887 REMOVAL and INSTALLATION -2E-11
REMOVAL and INSTALLATION
MODELS with BRAVO DRIVES
Index
Page
Torque Specifications 2F-1
........................
Tools/Lubricants 2F-1
.. ............ ....... ... .....
Removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-2
Installation ................................... 2F-2
Alignment 2F-4
..... ..... ........ .................
Attaching/Adjusting Throttle Cable ..... . . .....2F-5
REMOVAL and INSTALLATION -2F 90-14499--1 887
TORQUE SPECIFICATIONS
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Battery Cables Securely
Drive Unit Shift Cable
Brass Barrel Spread Cotter Pin
Cable End Guide (Note 1)
Front Engine Mount Securely
Hose Clamps Securely
Power Steering Fluid Hose Fittings
Large 20-25 (27-34)
Small 96-1 08 ( 11 -1 2)
Rear Engine Mounts 35-40 (47-54)
Remote Control Shift Cable
Brass Barrel Securely
Cable End Guide (Note 1)
Remote Control Throttle Cable
Brass Barrel Securely
Cable End Guide (Note 1)
NOTE: Tighten, then back nut off 1/2 turn.
TOOLS/LUBRICANTS
TOOLS/LUBRICANTS
91 -57797A3 Engine Alignment Tool
92-861 54A1 Quicksilver 2-4-C Marine-Lube
90-1 4499--1 887 REMOVAL and INSTALLATION -2F-1
Removal
IMPORTANT: Stern drive unit must be removed prior
to engine removal. Refer to "Stern Drive Service
Manual".
1.
Disconnect battery cables from battery and remove
instrument harness connector plug from engine
harness receptacle.
2.
Disconnect fuel line and throttle cable.
3.
Disconnect trim position sender wires (coming
from gimbal housing) from terminal block on circuit
breaker/solenoid mounting bracket. After wires are
disconnected, remove wires from clamps that hold
the power steering hoses.
4.
Remove red and black Power Trim pump motor
wires from engine (some models).
5.
Disconnect water inlet hose and exhaust elbow
bellows.
6.
Remove both shift cables from shift plate.
7.
Disconnect any grounding wire or accessories that
are connected to the engine.
8.
Power Steering Models: Disconnect fluid hoses
from power steering control valve.
9.
Support engine with suitable sling thru lifting eyes
on engine and remove front and rear engine mounting
bolts.
10.Carefully remove engine.
Installation
1.
Lift engine with an overhead hoist, using suitable
sling and lifting eyes on engine.
2.
Remove shipping plug and lubricate splines with
2-4-C Marine Lubricant.
a-Shipping Plug
22026
3.
Place large fiber washer on top on transom plate
engine mounting bracket and double wound lockwasher
inside fiber washer.
2F-2 -REMOVAL and INSTALLATION
4.
Place engine over transom plate mounting
brackets, hose clamps over rubber exhaust elbow
bellows.
5.
Place steel washers and spacers on mounting bolts
and insert bolts down thru rear engine mounts,
washers and mounting brackets. Thread elastic
stop nuts on bolts. Torque to specifications.
a-Rear Engine Mounting Bolts
b-Large Steel Washer
c -Metal Spacer
d -Rear Engine Mount
e -Fiber Washer With Double Wound Lockwasher in the Center
f-Mounting Brackets
g -Elastic Stop Nut (Hidden)
6. Tighten all exhaust bellow clamps securely.
7. Secure front engine mounts to boat.
8.
Check engine alignment. Refer to "Alignment".
After correct alignment is attained, tighten locknuts
securely.
a-Mounting Bolts
b-Locking Nuts
90-14499--1 887
9.
Place hose clamp over water inlet hose and place
hose over inlet tube. Tighten clamp securely.
a-Water Pickup Outlet
b -Hose Clamp (Tighen Securely)
c -Water Hose
10. Connect
instrument harness to engine harness.
Secure with clamp and tighten securely.
11. Connect trim position sender wires as follows:
a -Orange Lead -From Electrode on Transom Assembly
b -Red/Purple Lead -Connected (Other End) to Positive (+)
Battery Terminal
c -Black Lead -From Engine Harness
d -Trim Position Sender Lead Without Sleeve
e-Brown Lead -From Electrode on Transom Assembly
f-Trim Position Sender lead with Brown or Purple Sleeve
g-Brown/White Lead -From Engine Harness
A CAUTION
Use Loctite Pipe Sealant with Teflon on threads of
fitting going into fuel pump or water separating fuel
filter. Do not use Teflon tape.
12. Connect fuel I ine.
a-Remove Shipping Plug and Connect Flexible Fuel Line Here Torque
to 10-18 lb. ft. (14-24 N.m)
13. Connect drive unit and remove control shift cables
as follows:
IMPORTANT: Adjust shift cables as outlined in "Stern
Drive Service Manual".
a-Remote Control Shift Cable Anchor Points
b-Drive Unit Shift Cable Anchor Points
REMOVAL and INSTALLATION -2F-3
90-14499--1 887
14. Connect throttle cable. Refer to "Attaching/ Adjusting
throttle Cable".
15. Connect red and black trim pump wires (some
models).
16. Connect any ground wires or accessories that may
have been disconnected.
17. Power Steering Models: Reconnect fluid hoses as
shown.
a -Control Valve
b -Small .
c _ Large to Spec1flca11ons
IMPORT ANT: Bleed power steering system as outlined
in "Stern Drive Service Manual".
18. Connect battery cables to battery.
Alignment
1. Using Alignment Tool (91-57797 A3), insert end of
shaft (which does not have threaded hole) thru
gimbal bearing. Move gimbal bearing, as required,
to insert shaft into engine coupling.
a-Alignment Tool b-Insert this End of Alignment Tool thru Gimbal Housing
Assembly
2F-4 -REMOVAL and INSTALLATION
2. If shaft enters coupling freely with no pressure,
alignment is correct. If not, proceed as follows:
a. Loosen locknut on both front engine mounts.
b. Thread adjusting nut either way to raise or lower
front of engine.
IMPORT ANT: Raise or lower each side of of the engine
the same amount. Care must be taken not to "cock"
front of engine.
c. After correct alignment shaft fit is attained,
tighten locknuts securely. Recheck alignment
shaft fit.
19189
a -Turn Both Front Engine Mounts an Equal Amount in Direction
Required Until Alignment Shaft Enters Engine Coupling Freely
b-Locknut
c-Tab Washer
90-14499--1 887
Attaching/ Adjusting Throttle Cable
1.
Place remote control in neutral gear, idle position.
2.
Fasten cable end guide as shown.
3.
Grasp throttle cable brass barrel and push cable
lightly toward throttle lever. Adjust barrel to align
with anchor stud. Fasten barrel as shown.
a-Cable End Guide
b-Bushing
c-Washer, Nut and Screw (DO NOT Over-Tighten)
d-Spacer
e -Brass Barrel
f-Washer and Nut (DO NOT Over-Tighten)
g -Anchor Stud
4.
Check that throttle valves are fully open when
remote control is at full throttle position. Level tang
should be against stop.
5.
Return remote control to neutral gear, idle position.
Check that idle stop screw is against stop.
320 EFI
a -Cable End Guide
b -Throttle Lever Stud
c -Elastic Stop Nut and Flat Washer
d -Throttle Lever
e-Idle Speed Adjustment Screw (Must Contact Idle Speed Stop
Screw)
f -Brass Barrel
g -Throttle Cable Anchor Stud
a-Tang
b-Carburetor Body
c-Idle RPM Adjustment Screw
90-14499--1 887
REMOVAL and INSTALLATION -2F-5
V-8 GM 305/350 CID
Index
Page
Torque Specifications ......................... 3A-1
Tools/Lubricants/Sealants ..................... 3A-3
Engine Specifications .......................... 3A-4
General...................................... 3A-1 0
Engine Identification ...................... 3A-10
Cylinder Head Identification ................ 3A-10
Engine Rotation ........................... 3A-11
Crankshaft ................................ 3A-11
Piston and Connecting Rods ............... 3A-11
Camshaft and Drive ....................... 3A-11
Cylinder Head ............................. 3A-11
Valve Train ................................ 3A-11
Intake Manifold ........................... 3A-11
Lubrication System ........................ 3A-12
Bearing Failures .............................. 3A-13
Piston Failures ............................... 3A-13
Pre-Ignition ............................... 3A-13
Detonation ................................ 3A-14
Front Mount-MCM 305/350 CID Engines ...... 3A-15
Rear Mount/Flywheel Housing MCM
305/350 CID Engines ................. 3A-15
Front/Rear Mounts-MIE 305/350 CID
In-Line Transmission Engines .............. 3A-16
Front/Rear Mounts-MIE 305/350 CID
V-Drive Engines ........................... 3A-16
Flywheel Housing-MIE 305/350 CID
Engines ................................... 3A-17
Rocker Arm Cover ............................ 3A-17
Intake Manifold .............................. 3A-17
RockerArm/Push Rod ........................ 3A-19
Adjustment-Engine Stopped .............. 3A-20
Adjustment-Engine Running .............. 3A-20
Hydraulic Valve Lifters ........................ 3A-21
Locating Noisy Lifters ..................... 3A-21
Removal .................................. 3A-22
Disassembly .............................. 3A-22
Cleaning and Inspection ................... 3A-22
Reassembly ............................... 3A-23
Installation ................................ 3A-23
Page
Valve Stem Oil Seal/Valve Spring ............. 3A-23
Cylinder Head ............................... 3A-24
Removal ................................. 3A-24
Cleaning and Inspection .................. 3A-24
Installation ............................... 3A-24
Cylinder Head and Valve Conditioning ........ 3A-25
Disassembly ............................. 3A-25
Cleaning ................................. 3A-25
Inspection ............................... 3A-26
Rocker Arm Studs and Push Rod Guide
Repairs ............................... 3A-27
Valve Guide Bore Repair .................. 3A-28
Valve Seat Repair ......................... 3A-28
Valve Repair ............................. 3A-29
Reassembly .............................. 3A-30
Oil Pan ..................................... 3A-30
Removal ................................. 3A-30
Oil Pan Replacement Information .......... 3A-30
Installation ............................... 3A-32
Oil Pump ................................... 3A-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32
Disassembly ............................. 3A-33
Cleaning and Inspection .................. 3A-33
Reassembly .............................. 3A-33
Installation ............................... 3A-34
Torsional Damper ........................... 3A-34
Crankcase Front Cover/Oil Seal .............. 3A-35
Oil Seal Replacement (without Removing
Front Cover) .......................... 3A-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Installation ............................... 3A-35
Flywheel .................................... 3A-36
Oil Seal (Rear Main) ......................... 3A-38
Main Bearings ............................... 3A-40
Inspection ............................... 3A-41
Checking Clearance ...................... 3A-41
Replacement ............................. 3A-42
WithCrankshaft Removed ............. 3A-42
Without Crankshaft Removed .......... 3A-42
·?"''
ENGINE -3A
90-1 4499--1 887
Index
Page
Connecting Rod Bearings .................... 3A-43
Inspection and Replacement .............. 3A-43
Connecting Rod/Piston Assembly ............ 3A-44
Removal ................................. 3A-44
Disassembly ............................. 3A-44
Cleaning and Inspection .................. 3A-45
Reassembly .............................. 3A-46
Installation ............................... 3A-48
Crankshaft .................................. 3A-49
Removal ................................. 3A-49
Cleaning and Inspection .................. 3A-50
Installation ............................... 3A-50
Crankshaft Sprocket/Gear ................... 3A-50
Timing Chain/Sprockets-Left-Hand
(Standard) Rotation Engines .............. 3A-51
Removal ................................. 3A-51
Cleaning and Inspection .................. 3A-52
Engine Replacement Part Information ..... 3A-52
Installation ............................... 3A-52
Checking Timing Chain Deflection ........ 3A-52
Timing Gears-Right-Hand (Opposite)
Rotation Engines ......................... 3A-53
Removal .............................. 3A-53
Cleaning and Inspection ............... 3A-53
Installation ............................ 3A-53
Checking Backlash and Runout ........ 3A-53
0
90-1 4499--1 887
Page
Camshaft ................................... 3A-54
Measuring Lobe Lift ...................... 3A-54
Removal ................................. 3A-55
Inspection ............................... 3A-55
Installation ............................... 3A-55
Camshaft Bearings .......................... 3A-56
Removal ................................. 3A-56
Inspection ............................... 3A-56
Installation ............................... 3A-56
Cylinder Block .............................. 3A-57
Cleaning and Inspection .................. 3A-57
Repairs .................................. 3A-58
Replacement Part Information ............. 3A-60
Oil Filter By-Pass Valve and Adaptor
Assembly ................................ 3A-60
Inspection and/or Replacement ........... 3A-62
Remote Oil Filter Kit (92043A2)-Installation
Instructions .............................. 3A-63
NOTICE
The repair procedures in this manual can be
used for repairing Production Performance
engines. It is recommended that only mechanics
familiar with hi-performance engines attempt
the repairs.
ENGINE -3A
Torque Specifications
305 and 350 CID Engines
.. .. ..
305 and 350 CID 350 CID Production Performance
Fastener Location
Lbs. Ft. (N.m) Lbs. ln. (N.m) Lbs. Ft. (N.m) Lbs. ln. (N.m)
Alternator Brace to Alternator 192 (28) 192 (28)
Alternator Brace to Block 30 (41 ) 30 (41 )
Alternator to Mounting Bracket 35 (48) 35 (48)
Alternator Mounting Bracket 30 (41 ) 30 (41 )
Camshaft Sprocket/Gear 20 (27) 20 (27)
Carburetor 132 (15) 132 (1 5)
Connecting Rod Cap 45 (61 ) 45 (61 )
Coupler/Flywheel (MCM) See Page 3
Crankshaft Damper 60 (81 ) 70 (95)
Crankshaft Pulley 35 (48) 35 (48)
Cylinder Head 65 (88) 75 (1 02)
Distributor Hold Down 25 (34) 20 (27)
Exhaust Manifold 20 (27) 20 (27)
Flywheel (MIE) 60 (81 ) 60 (81 )
Flywheel Drive Plate (MIE) 35 (48) 35 (48)
Flywheel Housing to Block 30 (41 ) 30 (41 )
Flywheel Housing Cover 80 (9) 80 (9)
Front Mount Bracket 30 (41 ) 30 (41 )
Fuel Pump 30 (41 ) 30 (41 )
Intake Manifold 30 (41 ) 35 (48)
Intake Top (EFI) 6 (8)
Fuel Rail (EFI) 30 (3)
Main Bearing Cap Long Bolt 80 (109) 75 (1 02)
(Production Performance Only) 70 (95)
Short Bolt
Oil Filter Bypass Valve 80 (9) 80 (9)
Oil Pan Plug 20 (27) 20
Oil Pan Screw (1/4"-20) 80 (9) 80 (9)
Oil Pan Screw (5/1 6"-1 8) 165 (19) 165 (19)
Oil Pump 65 (88) 65 (88)
Oil Pump Cover 80 (9) 80 (9)
Power Steering Pump Brace
30 (41 ) 30 (41 )
to Block
90-14499--1 887 ENGINE -3A-1
305 and 350 CID 350 CID Production Performance
Lbs. Ft. (N.m)
30
Lbs. ln. (N.m) Fastener Location
Power Steering Pump Bracket
Lbs. Ft. (N.m)
30 (41 )
Lbs. ln. (N.m)
Rear Mount (MCM) 40 (54) 40 (54)
Rear Mount (MIE) 50 (68) 50 (68)
Remote Oil (1/2"-1 3)
Filter Adaptor (5/1 6"-1 8)
25 (34) 25 (34)
20 (27) 20 (27)
Rocker Arm Cover 50 (5.5) 60 (7)
Seawater Pump Brace 30 (41 ) 30 (41 )
Seawater Pump Bracket
Spark Plugs
30 (41 )
180 (20)
30
180 (20)
Starter Motor 50 (68) 50 (68)
Thermostat Housing 30 (41 ) 30 (41 )
Timing Chain or Gear Cover 80 (9) 80 (9)
Transmission to Housing 50 (68) 50 (68)
Water Circulating Pump 30 (41 ) 30 (41 )
Water Temp. Sender 20 (27) 20 (27)
IMPORTANT: Do not intermix stud/nut combinations.
A
16-32808
11 -33962
5/8" Hex ESNA
______,
..1 7/8"
16-98532
B c
11/16" Hex 11-98533
Crown lock 5/8" Hex Crownlock
269-H
a-45 Lbs. Ft. (61 N.m)
b-35 Lbs. Ft. (42 N.m)
c-40 Lbs. Ft. (54 N.m)
d-See Figure 2 for Coupler Wrench Modification
Engine Coupler/Flywheel
3A-2 -ENGINE
Engine Coupler Wrench, 91-35547, may not work on
the later couplers. Modify wrench as shown, so it will
work on both earlier and later style couplings.
a-Original 91-35547 Wrench
b -Heat and Bend as Shown
c-Grind Area Shown Slightly
d -Heat and Bend as Shown (This is What Wrench Should Look
Like When It's Done)
Modifying Engine Coupler Wrench
90-14499--1 887
Tools/Lubricants/Sealants LUBRICANTS/SEALANTS
92-32609-1
Quicksilver Loctite
92-34227
Quicksilver
MERCURY MARINE SPECIAL TOOLS
92-42649A1
Quicksilver Needle Bearing
91 -24697 Piston Expanders
Lubricant
91 -35547 Coupler Wrench
92-91 601 -1
Quicksilver RTV Sealer
91 -66273 Rocker Stoppers
KENT -MOORE SPECIAL TOOLS
Can be ordered from: Kent-Moore Tools, Inc.
29784 Little Mack
Roseville, Ml 48066
Phone: (31 3) 774-9500
J5892 Valve Spring Compressor
J8062 Valve
J8056 Valve Spring Tester
J81 01 Valve Guide Cleaner
J5830-2 Valve Guide Reamer
J7049-5 Valve Guide Reamer Set
J5802-01 Rocker Arm Stud Remover
J6880 Rocker Arm Stud Installer
J571 5 Rocker Arm Stud Hole Reamer
(.003" O.S.)
J6036 Rocker Arm Stud Hole Reamer
(.01 3" O.S.)
J8089 Carbon Remover Brush
J24086-100 Piston Pin Tool
J3936-03 Piston Ring Groove Cleaner
J8037 Piston Ring Compressor
J6305-1 Connecting Rod Bolt Guide Set
( 11 /32" Bolts)
J8369 Oil Pump Suction Pipe Installer
J6098-01
J23523-03
Camshaft Bearing Remover and
Installer Tool
Harmonic Balancer Removal and
Installer Tool
J23042 Crankcase Front Cover Seal Installer
J1619 Crankshaft Gear and Puller
J5590 Crankshaft Gear and
Sprocket Installer
90-1 4499--1 887 ENGINE -3A-3
Engine Specifications
UNIT OF MEASUREMENT
ln. (mm)
Bore
Stroke
Cubic Inch
Displacement
Compression
Ratio
Heads
Intake
Manifold
Block
Rods
Pistons
Crankshaft
200 230
MCM MCM
230TR
230 260 260TR
MIE MCM MCM
350
300
300TRS260
5.7 Ski MCMMIE MCM MCM
MCM MIE Alpha5.0 Litre 5.0 Litre 5.0 Litre 5.7 Litre 5.7 Litre 5.7 Litre Magnum
One Tempest
LX
3.74
(95)
3.38
(88.4)
305
(5L)
8.5:1
Tempest
4.00
(101 .6)
3.48
(88.4)
350 350 (5.7L) Produc(
5.7L) tion Performance
9.0:1
Cast Iron
Cast Iron
Aluminum
Hi-Rise
Cast Iron
Cast Iron (2 Bolt Main Bearings Caps (4 Bolt Main Bearing
Forged Steel
Cast Aluminum
Cast Iron
Caps on #2, 3, 4)
Forged Steel
Forged Aluminum
Forged Steel
FRONT FRONT
Firing Order
1-8-4-3-6-5-7-2
Left-Hand (Standard)
Rotation Engine
Firing Order
1-2-7-5-6-3-4-8
Right-Hand (Opposite)
Rotation Engine
3A-4 -ENGINE 90-1 4499--1 887
Engine 305 CID 350 CID 350 CID Production Performance
Cylinder Bore:
3.7350 -3.7385 3.9995 -4.0025
Diameter (94.8690 (
1 01 .5873 94.9579)
101 .6635)
Out of Production .001 (.025) Max.
Round Service .002 (.05) Max.
Thrust
.0005 ( .01 27) Max.
Produc-Side
Taper tion
Relief
Side
.001 (.025) Max.
Service
.001 (.025) Max.
Piston:
Production .0007 -.0017 (0.1 78 -.0432)
Clearance
Service .0027 (.07) Max.
Piston Ring:
c0
"iii UlQ)....a. E0(.)
Groove
Side
Clearance
Gap
Produc-
Top
tion 2nd
Service
.0012 -.0032 (.0305 -.081 3)
.0012 -.0032 (.0305 -.0813)
Hi Limit Production + .001 (.025)
Production
Top .010 -.020 (.25 -.5)
2nd .010 -.025 (.25 -.6)
Service Hi Limit Production + .01 0 (.25)
Groove
Side
Clearance
Production
Service
.002 -.007 (.05 -.15)
Hi Limit Production + .001 (.02) -·
0
Gap
Production .015 -.055 (.35 -1.35)
Service Hi Limit Production + .010 (.25)
Piston Pin:
Diameter .9270 -.9273 (23.5458 -23.5534)
Clearance
Production
Service
.00025 -.00035 (.00635 -.00889)
.001 (.02) Max.
Fit in Rod .0008 -.001 6 (.0203 -.0406) Interference
90-1 4499--1 887
ENGINE -3A-5
Engine 305 CID 350 CID 350 CID Production Performance
Crankshaft:
Diameter
«i
c:
....
:I
0
J
c:"iii
.. Taper
Out of
Round
No. 1
No. 2, 3, 4
No. 5
Production
Service
Production
Service
No. 1
Q)
u
c:«<
....
No. 2, 3, 4 «< Production
Q)
0
2.4484 -2.4493
(62.1 894 -62.2122)
2.4481 -2.4490
(62.1817 -62 .2046)
2.4479 -2.4488
(62.1 767 -62.1 995)
.0002 (.0051) Max.
.001 (.025) Max .
. 0002 (.0051) Max.
.001 (.025) Max .
. 0008 -.0020
(.0203 -.0508)
.001 1 -.0023
(.0279 -.0584)
Cl
c:
·;::
« Spring 1.70 [1-45/64] (U (1 03 -114 N. m) > 24-48437 Pressure (43.16)
(With 1 (Note 2)
Open @
Lavender 194 -206 Lbs. Ft.
Stripe)
1.25 [1-1/4]
(263 -279 N.m)
(31 .75)
Installed Height 1.593 [1-19/32] (40.5) ..... Free Length 1.86 [1 -55/64] (47.24) Q)a. E Approximate No. of Coils 4Cl30
NOTE 1: Refer to information under "Cylinder Heads", to determine which valve spring is being used. (' NOTE 2: Test spring pressure with damper removed.
90-1 4499--1 887 ENGINE -3A-9
General
Some repairs, that are listed in this section, must be
completed with engine removed from boat. Engine
removal depends upon type of repair and boat design.
Place engine on repair stand for major repairs.
Lubricate all moving parts (during reassembly) with
engine oil. Apply Perfect Seal on threads of and under
head of cylinder head bolts and on threads of all
cylinder block external bolts, screws and studs.
Engine Identification
The MerCruiser Model can be determined by looking at
the last two letters of the engine code stamped into the
cylinder block. This code number is stamped on all
MerCruiser Power Packages and replacement partial
engines but not replacement cylinder block assemblies.
If the engine serial number, and or model decals are
missing, the engine code letters may help in determining
the engine models. Following is a list of G.M.
engines and their respective code letters.
a -Engine Code (V06172WT)
b -Last Two Letters (WT)
a-Small Block V-8 -Front, Starboard Side, Near Cylinder Head
Mating Surfaces
3A-10-ENGINE
MCM Stern Drive Engines (All Are L.H. Rotation)
200-MX or PY
230-MY or PZ
260 -WT or AN
300 -WK
MIE Inboard Engines (Either Rotation)
L.H. Rotation
230 -MA or PA
260-WN or AB
R.H. Rotation
230-MB Or PB
260-WR or AR
Cylinder Head Identification Marks
(1 980 and Newer)
The identification mark is located on both ends of the
cylinder head.
305 CID Engines
350 CID Engines
90-1 4499--1 887
Engine Rotation
Engine rotation terminology at times has caused confusion.
To clarify, engine rotation is determined by
observing flywheel rotation from the rear (transmission
or stern drive end) of the engine looking forward
(water pump end).
PROPELLER ROTATION IS NOT NECESSARILY THE
SAME as engine rotation.
When ordering replacement engines, short blocks or
parts for engines, be certain to check engine rotation. Do
not rely on propeller rotation in determining engine rotation.
a-Left Hand Rotation (CCW) -All Stern Drive Engines, MIE Inboard
L.H. (Standard) Rotation
b-Right Hand Rotation (CW)-MIE Inboard R.H. (Opposite) Rotation
Crankshaft
The crankshaft is supported in the block by five insert
type bearings. Crankshaft end thrust is controlled by
flanges on the number five 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 of the
pistons to provide a gradual change in thrust pressure
against the cylinder wall as the piston travels its path.
Pins have a floating fit in the piston and a press fit in the
connecting rod (to hold them in place).
Connecting rods are made of forged steel and are connected
to the crankshaft thru insert type bearings.
Camshaft and Drive
Camshaft is supported by five bearings, which are
pressed into the block, and is driven at one-half crankshaft
speed by a timing chain and sprockets or by
timing gears.
Taper on lobes coupled with spherical foot on hydraulic
valve lifters, causes the valve lifters to rotate, thus
reducing wear. A helical gear on the aft end of the
camshaft drives the distributor and oil pump, while an
eccentric cam on the front of the camshaft actuates the
fuel pump.
Cylinder Head
The cylinder heads are made of cast iron and have
individual intake and exhaust ports for each cylinder.
Stainless steel or composition head gaskets are used
to retard corrosion.
Valve Train
The valves and valve springs are of a heavy-duty design
to withstand the high engine speeds encountered.
Valve tips have been hardened to extend valve life.
Exhaust valve rotators are used on some engines to
help extend valve life.
Hydraulic valve lifters ride directly on the camshaft
lobes and transmit the thrust of the lobes to the push
rods which in turn actuate the valves thru the rocker
arm.
In addition to transmitting thrust of the cam lobes, the
hydraulic lifters also serves to remove any clearance
(lash) from the valve train to keep all parts in constant
contact.
The valve lifters also are used to lubricate the valve
train bearing surfaces.
Intake Manifold
The manifold is of the double level design for efficient
fuel distribution. The upper level of passages feeds
cylinders 2, 3, 5 and 8 while the lower level passages
feed cylinders 1, 4, 6 and 7. All passages are of approximately
equal length to assure more even fuel-air mixture
to the cylinders.
90-14499--1 887 ENGINE-3A-11
Lubrication System
The engine lubrication system is of the force-feed type
in which oil is supplied under full pressure to the
crankshaft, connecting rods, camshaft bearings and
valve lifters, and is supplied under controlled volume to
the push rods and rocker arms. All other moving parts
are lubricated by gravity flow or splash.
A positive displacement gear-type oil pump is mounted
on the rear main bearing cap and is driven by an extension
shaft from the distributor (which is 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 assembly.
If screen should become clogged, a relief valve in the
screen will open and continue to allow oil to be drawn
into system. Once the oil reaches the pump, the pump
forces the oil thru the lubrication system. A spring
loaded relief valve in the pump limits the maximum
pump output pressure.
After leaving the pump, the pressurized oil flows thru a
full-flow oil filter. On engines with an engine oil cooler,
the oil also flows thru the cooler before returning to the
block. A bypass valve allows oil to bypass the filter and
oil cooler should they become restricted.
On 305 and 350 CID engines, some of the oil, after
leaving the oil cooler and/or filter, is routed to the No.5
crankshaft main bearing. The remainder of the oil is
routed to the main oil gallery, which is located directly
above the camshaft and runs the entire length of the
block. From the main oil gallery, the oil is routed thru
individual oil passages to an annular groove in each
camshaft bearing bore. Some of the oil is then used to
lubricate camshaft bearings. The remainder of the oil is
routed to the valve lifter oil galleries and No. 1, 2, 3, and
4 crankshaft main bearings by means of individual oil
passages which intersect with the annular grooves.
The camshaft bearings have holes which align with the
oil passages or annular grooves in the block and allow
oil to flow in between the bearings and the camshaft
journals. The oil that is forced out the front end of the
No. 1 camshaft bearing drains down onto camshaft
drive and keeps it lubricated.
The oil which reaches the crankshaft main bearings is
forced thru 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 thru grooves in the upper half of the
crankshaft main bearings and oil passages in crankshaft.
Oil which is forced out the ends of the connecting
rod bearings and crankshaft 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 lubricating 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 areating the oil in
the oil pan.
Oil which reaches the valve lifters oil galleries is forced
into each hydraulic valve lifter thru holes in the side of
the lifter. From here, the oil is forced thru the metering
valve in each of the lifters (which controls the volume of
oil flow) and then up thru the push rods to the rocker
arms. A hole in each rocker arm push rod seat allows
the oil to pass thru the rocker arm and lubricate the
valve train bearing surfaces. After lubricating valve
train, oil drains back to the oil pan thru oil returns holes
in the cylinder head and block.
The distributor shaft and gear also is lubricated by the
oil flowing thru the right valve lifter oil gallery. Fuel
pump push rod is lubricated by oil thrown off from the
camshaft eccentric.
3A-12-ENGINE 90-14499--1 887
Bearing Failures
('
..
SCRATCHED
BY DIRT
Dirt
Imbedded
into Bearing
Material
Overlay
Wiped Out
LACK OF OIL IMPROPER SEATING
Overlay Gone
from Entire Surface Radius Ride Craters or Pockets
TAPERED JOURNAL RADIUS RIDE FATIGUE FAILURE
Piston Failures
Pre-Ignition
Pre-ignition is abnormal fuel ignition, caused by combustion
chamber hot spots. Control of the start of ignition
is lost, as combustion pressure rises too early,
causing power loss and rough running. The upward
motion of 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.
Pre-Ignition Damage
Ignited by hot deposit .. . . regular ignition spark ..
PRE-IGNITION CAUSES
1.
Hot spots in the combustion chamber from glowing
deposits (due in turn to the use of improper oils
and/or fuels).
2.
Overheated spark plug electrodes (improper heat
range or defective plug).
3.
Any other protuberance in the combustion chamber,
such as an overhanging piece of gasket, an
improperly seated valve or any other inadequately
cooled section of material which can serve as a
source.
Engine failures, which result from the foregoing conditions,
are beyond the control of Mercury Marine,
therefore, no warranty will apply to failures which
occur under these conditions.
. . ignites remaining fuel ..
90-1 4499--1 887
ENGINE -3A-13
Spark occurs ... . . combustion begins .. . . . . continues .... . ... detonation .
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 damage to
the spark plugs, pistons, valves and, in severe cases,
results in pre-ignition.
Use of low octane gasoline is one of the most common
causes of detonation. Even with high octane gasoline,
detonation could occur if engine maintenance is neglected.
OTHER CAUSES of DETONATION
IMPORTANT: Use of improper fuels will cause engine
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 compression
ratio).
5.
Inadequate cooling of engine by deterioration of
cooling system.
Engine failures, which result from the foregoing conditions,
are beyond the control of Mercury Marine, therefore,
no warranty will apply to failures which occur
under these conditions.
Detonation Damage
3A-14-ENGINE
90-1 4499--1 887
Mount on
MCM 200,
230, 260
Only
not Be Replaced
FRONT MOUNT -MCM 305/350 CID Engines
Out with Press
a-Gasket used on MCM Engines Only
REAR MOUNT/FLYWHEEL HOUSING -MCM 305/350
CID Engines
FLYWHEEL HOUSING -MCM 350 CID Production
Performance
Press Mount Out
With Press
REAR MOUNT/TAILSTOCK ASSEMBLY -MCM 350
CID TRS Production Performance
90-14499--1 887 ENGINE -3A-15
Some
Models
Horizontal Rear
Mount -52158A20
FRONT/REAR MOUNTS -MIE 305/350 CID In-Line
Transmission Engines
Rubber Insert Can not Be
Removed
FRONT/REAR MOUNTS -MIE 305/350 CID
V-/Drive Engines
. -_,..
3A-1 6-ENGINE 90-1 4499--1 887
FLYWHEEL HOUSING -MIE 305/350 CID Engines
Rocker Arm Cover
Removal
On engines with Center Exhaust Outlet exhaust manifolds:
It may be necessary to remove exhaust manifold
before removing rocker arm cover. Also remove any
component that will interfere with the removal of the
manifold or rocker arm cover.
1.
Remove rocker arm cover attaching hardware.
2.
Disconnect crankcase ventilation hoses.
IMPORTANT: Do not pry rocker arm cover loose.
Gaskets, which adhere to cylinder head and rocker arm
cover, may be sheared by bumping end of rocker arm
cover from the rear with palm of hand or a rubber
mallet.
3.
Remove rocker arm cover.
Installation
1.
Clean sealing surfaces on cylinder head and rocker
arm cover with degreaser.
2.
Install rocker arm covers, as follows:
ROCKER ARM COVERS USING GASKETS:
a.
Place new rocker arm cover gasket in position in
rocker arm cover.
b.
Install rocker arm cover and secure with reinforcements
and attaching screws or nuts.
Torque to specifications.
90-14499--1 887
ROCKER ARM COVERS USING RTV SEALER:
a.
Apply a 3/16" (5mm) wide bead of RTV Sealer
all-the-way around sealing surface on cylinder
head, making sure to apply sealer on inboard
side of attaching screw holes or studs.
IMPORTANT: Be sure to install valve rocker arm cover
while sealer is still wet. Sealer dries in approximately 15
minutes.
b.
Install rocker arm cover and secure with attaching
screws or nuts. Torque to specifications.
3.
Reinstall exhaust manifolds, if removed.
4.
Reinstall any items which were removed from exhaust
elbows to allow removal of rocker arm covers.
5.
Connect crankcase ventilation hoses to valve
rocker arm covers.
6.
Start engine and check for oil leaks.
Intake Manifold
Removal
1.
Drain engine cooling system.
2.
Disconnect hoses from thermostat housing.
3.
Disconnect all electrical leads.
4.
Disconnect crankcase ventilation hoses from
rocker arm covers.
5.
Disconnect throttle cable. Remove fuel line running
between fuel pump and carburetor or fuel rails on
EFI.
ENGINE -3A-17
IMPORTANT: Do not crank engine over after distributor
has been removed.
6.
Remove distributor cap and mark position of rotor
on distributor housing. Also, mark position of distributor
housing on intake manifold. Remove distributor.
7.
Remove other ignition components.
8.
Remove oil sending unit.
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 screws, then remove intake
manifold.
NOTE: If intake manifold requires replacement, transfer
other related parts to new manifold.
Cleaning and Inspection
1.
Clean gasket material from all mating surfaces.
IMPORTANT: When cleaning cylinder head mating
surface, do not allow gasket material to enter engine
crankcase.
2.
Inspect manifold for cracks or scratches. Machined
surfaces must be clean and free of all marks, or
deep scratches or leaks may result.
3.
Check intake passages for varnish buildup or other
foreign material. Clean as necessary.
Installation
IMPORTANT: When installing intake manifold gaskets,
in next step, be sure to do the following:
•
Be sure to install gasket with marked side up. Both
gaskets are identical.
•
On 305 cu. in. engines with 2 barrel carburetor,
remove metal insert from manifold gasket to be
used on starboard (right} cylinder head to provide
clearance for heat pipe on intake manifold.
•
All MerCruiser V-8 G.M engines that have "automatic"
carburetor chokes must use an intake gasket
that has an opening for the exhaust crossover port
in the intake manifold. Without this opening the
"automatic" carburetor choke will not operate properly.
The choke will remain "ON" longer causing
rough engine operation and wasted fuel.
3A-18-ENGINE
a -Exhaust Crossover Port Opening in Gasket
b -Intake Valve Ports
1.
Apply Perfect Seal to intake manifold gaskets and
install gaskets on cylinder heads. Install front and
rear end seals on cylinder block and apply Perfect
Seal to areas where seals butt against gaskets.
IMPORTANT: If cylinder block rails do not have holes
for locating pins on end seals, RTV Sealer Must be used
instead of seals. Place a 3/16" (Smm} wide bead of RTV
Sealer. Extend the bead 1/2" (13mm} up each gasket to
seal and retain gaskets. RTV Sealer can be used
instead of end seals on all engines, if desired.
a -RTV Sealer
b -Intake Manifold Gaskets
90-1 4499--1 887
2. Carefully install manifold assembly and torque
bolts to specifications in sequence outlined.
14396
305/350 CID Manifold Torque Sequence Intake
EFI Base Included
Connect all electrical leads.
4.
Reconnect hoses to thermostat housing.
5.
Install fuel line to carburetor, and fuel pump. Connect
throttle cable fuel rails on EFI.
6.
Connect crankcase ventilation hoses to rocker arm
covers.
7.
Install distributor. Position rotor and housing to
align with marks made during removal, then install
distributor cap.
8.
Install other ignition components and reconnect
wires.
9.
Coat threads of oil pressure sending unit with Per-
feet Seal and install.
10. Reconnect any other items which
were disconnected
from manifold during the removal.
11. Start engine. Adjust ignition timing and carburetor.
Check hose connections, gaskets and seals for
leaks.
12.1nspect fuel line connections for fuel leaks.
Rocker Arm/Push Rod
Removal
1.
Remove rocker arm covers.
2.
Remove rocker arm components, rocker arms and
push rods.
IMPORTANT: Place rocker arms, rocker arm components
and push rods in a rack for reinstallation in the
same locations.
Cleaning and Inspection
1.
Clean parts with solvent and dry with compressed
air.
2.
Inspect all contact surfaces for wear. Replace all
damaged parts.
Installation
IMPORTANT: Push rods with a hardened tip end must
be installed with the hardened tip toward rocker arm.
Push rods without hardened tip must be installed with
large oil hole end toward rocker arms. Hardened tip
end or large hole end is marked with a blue stripe.
IMPORTANT: When installing rocker arms and rocker
arm balls, coat bearing surfaces of rocker arms and
rock arm balls with engine oil.
1.
Install push rods. Be sure push rods seat in lifter
socket.
2.
Install rocker arms, rocker arm balls and rocker arm
nuts. Tighten rocker arm nuts until all lash is eliminated.
3.
Valve lash can be adjusted either with engine
stopped or running.
90-14499--1 887
ENGINE -3A-19
Adjustment -Engine Stopped
With valve cover removed, adjust valves when lifter is
on low part of camshaft lobe, as follows:
1.
Crank engine with starter or turn over in normal
direction of rotation until mark on torsional damper
lines up with center "0" mark on timing tab, and
engine is in No. 1 firing position. This may be
determined by placing fingers on No. 1 valve as
mark on damper comes near "0" mark on timing
mark. If valves move as mark comes up to timing
tab, engine is in No. 6 firing position and should be
turned over one more time to reach No. 1 position.
2.
With engine in No. 1 firing position as determined
above, the following valves may be adjusted.
3.
MCM and MIE Left Hand {Standard) Rotation
Engines:
Exhaust -1-3-4-8 Intake -1-2-5-7
MIE Right Hand (Opposite) Rotation Engines:
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 upand-
down while turning adjusting nut until all play
is removed.
Valve Adjustment
3A-20 -ENGINE
5.
Hydraulic lifters now can be adjusted by tightening
adjustment nut an additional 1-turn. No other adjustment
is required.
6.
Crank engine one revolution until pointer "0" mark
and torsional damper mark are again in alignment.
This is No. 6 firing position. With engine 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 Engines:
Exhaust -3-4-6-8 Intake -2-5-6-7
Adjustment -Engine Running
Rocker Stoppers 91-66273
90-14499--1 887
Following procedure is performed with engine
running:
1.
After engine has been rechecked for normal operating
temperature, remove valve covers and install
rocker stoppers.
2.
With engine running at idle, back valve rocker arm
nuts off (one at a time) until valve rocker arm starts
to clatter.
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 1-turn from the zero lash
position. (3/4-turn from zero lash on performance
production models).
IMPORTANT: This preload adjustment must be done
slowly to allow lifter to adjust itself, thus preventing
possibility of interference between inlet valve head and
top of piston which might result in internal damage
and/or bent push rods.
5.
Repeat Steps 2-3-4 to adjust other valves.
6.
Remove rocker stoppers after all valves are adjusted.
7.
After valves have been adjusted, complete the
following:
a.
Install new gaskest (or RTV), and install covers.
Torque to specifications.
b.
Adjust carburetor idle speed and mixture.
c.
Start engine and check for leaks.
Hydraulic Valve Lifters
a -Lifter Body
b-Plunger Spring
c-Check Ball Retainer
d -Check Ball Spring
e-Check Ball
f-Plunger
g-Metering Valve
h -Push Rod Seat
i -Push Rod Seat Retainer
Hydraulic Valve Lifter Assembly
Hydraulic valve lifters require little attention. Lifters are
extremely simple in design. Normally, readjustments
are not necessary and servicing requires only that care
and cleanliness be exercised in the handling of parts.
Locating Noisy Lifters
Locate a noisy valve lifter by using a piece of garden
hose approximately 4 ft. (1 .2m) in length. Place one
end of hose near end of each intake and exhaust valve,
with other end of hose to the ear. In this manner, sound
is localized, making it easy to determine which lifter is
at fault.
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 seat.
General types of valve lifter noise are as follows:
1.
Hard rapping noise --Usually caused by plunger
becoming tight in bore of lifter body so that return
spring cannot push plunger back up to working
position. Probable causes are:
a.
Excessive varnish or carbon deposit, causing
abnormal stickiness.
90-14499--1 887
b. Galling or "pick-up" between plunger and bore
of lifter body, usually caused by an abrasive
piece of dirt or metal wedged between plunger
and lifter body.
ENGINE -3A-21
2.
Moderate rapping noise --Probable causes are:
a.
Excessively high leakdown rate.
b.
Leaky check valve seat.
c.
Improper adjustment.
3.
General noise throughout valve train--This will, in
most cases, be a definite indication of insufficient
oil supply or improper adjustment.
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 or
have a flat spot.
c.
Improper adjustment.
In most cases, where noise exists in one or more lifters,
all lifter units should be removed, disassembled,
cleaned in solvent, reassembled and reinstalled in
engine. If dirt, corrosion, carbon, etc, is shown to exist
in one unit, it more likely exists in all the units, thus it
would only be a matter of time before all lifters caused
trouble.
Removal
1.
Remove intake manifold.
2.
Remove valve mechanism.
3.
Remove valve lifters.
IMPORTANT: Keep push rod and hydraulic valve lifter
from each valve together as a matched set and mark
them so they can be reinstalled in the same location
later.
Disassembly
IMPORTANT: The internal parts of each hydraulic lifter
assembly are matched sets. Do not intermix the
parts.
1.
Hold plunger down with a push rod and remove
push rod seat retainer with the blade of a small
screwdriver.
2.
Remove push rod seat and metering valve.
3.
Remove the plunger, ball check valve assembly and
the plunger spring.
4.
Remove the ball check valve and spring by prying
the ball retainer loose from the plunger with the
blade of a small screwdriver.
a-Check Ball Retainer
Removing Ball Check Valve
Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent and
inspect them carefully. If any parts are damaged or
worn, entire lifter assembly should be replaced. If outer
lifter body wall is scuffed or worn, inspect cylinder
block lifter bore. If bottom of lifter is scuffed or worn,
inspect camshaft lobe. If push rod seat is scuffed or
worn, inspect push rod.
wsn 1hH?1'!i .!.'J G.HS.O'it..!?-att.. oi ..<'P1<)..f
3A-22 -ENGINE
90-14499--1 887
Reassembly
1. Place the check ball in small hole in bottom of the
plunger.
r' 2. Insert check ball spring on seat in ball retainer and
place retainer over ball so that spring rests on the
ball. Carefully press the retainer into position in
plunger with the blade of a small screwdriver.
IMPORTANT: Do not attempt to force or pump the
plunger.
6. Remove the 1/8" drift pin and refill assembly with
oil.
7. Install the metering valve, push rod seat and push
rod seat retainer.
8. Press down on the push rod seat with a push rod
and remove 1/16" drift pin from lifter. The lifter is
now completely assembled, filled with oil and ready
for installation.
Installation
IMPORTANT: Before installing lifters, coat the bottom
of the lifter with engine oil. If new lifters or a new
camshaft has been installed, an additive containing EP
lube should be poured over camshaft lobes before
installing lifters.
a -Check Ball Retainer
Installing Check Ball Valve
3. Place the plunger spring over the ball retainer and
slide the lifter body over the spring and plunger,
being careful to line up the oil feed hole in the lifter
body and plunger.
4. Fill the assembly with oil, then insert the end of a
1/8" drift pin into the plunger and press down on
checkball until hole in lifter body aligns with hole in
plunger.
5. Insert a 1/16" drift pin through both oil holes to hold
the plunger down against the lifter spring tension.
a -1 /8" Drift Pin
b -Oil Feed Hole
c -1 /16" Drift Pin
Oil Feed Holes Aligned and Drift Pin Installed
90-14499--1 887
1. Install hydraulic valve lifters.
2. Install intake manifold.
3. Install and adjust valve mechanism as outlined.
4. Install rocker arm cover.
5. Start engine and check for leaks.
Valve Stem Oil Seal/
Valve Spring
Removal
1. Remove rocker arm cover.
2. Remove spark plug, rocker arm and push rod on
cylinder(s) to be serviced.
3. Position piston (in cylinder to be serviced) at TDC,
to prevent valve from dropping out of valve guide.
4. Compress valve spring with J-5892 Tool. Remove
valve locks and all other components.
a -J-5892 Tool
b -Rocker Arm Nut
Compressing Valve Spring
ENGINE -3A-23
Installation
1.
If removed, install damper in valve spring.
2.
If engine has additional valve stem seal:
a.
Install intake valve seal.
b.
Do not install exhaust valve seal, discard.
3.
Set valve spring, damper, valve shield and cap in
place. Be sure to install valve cap with rotator on
exhaust valve. Compress spring with Tool J-5892
and install oil seal into lower groove of valve stem.
NOTE: A light film of oil will help prevent twisting of the
seal.
4.
Install valve locks and release pressure of tool,
being sure that locks are in place. Grease may be
used to help hold locks while removing pressure
from tool.
IMPORTANT: Compress valve spring only enough to
install valve locks in next step. Excess compression
could cause damage to seal.
Install spark plug(s) and torque to specifications.
Install and adjust valve mechanism.
Install rocker arm cover and torque to specifica
tions.
Start engine and check for leaks.
Cylinder Head
Removal
1.
Drain engine cooling system.
2.
Remove exhaust manifolds.
3.
Remove intake manifold.
4.
Remove valve mechanism.
NOTE: Remove any component attached to front or aft
end of cylinder head to be removed.
5.
Remove spark plugs.
6.
Remove spark plug wire retainers from cylinder
head.
7.
Remove cylinder head bolts, cylinder head and
gasket.
8.
Place cylinder head on 2 blocks of wood to prevent
damage.
Cleaning and Inspection
For cleaning and inspection, refer to "Cylinder Head
and Valve Conditioning".
3A-24 -ENGINE
Installation
A CAUTION
Gasket surfaces on both head and block must be clean
of any foreign matter and free of nicks or deep
scratches. Cylinder bolt threads in block and threads
on cylinder head bolts must be clean (Dirt will affect
bolt torque).
1.
On engines using a stainless steel gasket, coat both
sides of new gasket with Perfect Seal. Spread sealer
thin and even. Too much sealer may hold gasket
away from head or block.
A CAUTION
Use no sealer on engines which have a composition
steel asbestos gasket.
2.
Place gasket in position over dowel pins.
3.
Carefully guide cylinder head into place over dowel
pins and gasket.
4.
Coat threads of cylinder head bolts with Perfect
Seal and install bolts finger-tight.
5.
Tighten each cylinder head bolt a little at a time in
sequence shown in torque sequence chart until
specified torque is reached.
6.
Install exhaust manifolds as outlined.
7.
Install intake manifold as described.
8.
Install and adjust valve mechanism as outlined.
9.
Install valve covers.
1 O.lnstall spark plugs. Torque spark plugs to specifications.
11.1nstall spark plug wire retainers.
NOTE: Install any component that was removed from
the front or aft end of cylinder head.
12. Run engine, adjust timing and check for leaks.
0
Cylinder Head Torque Sequence
90-1 4499--1 887
Cylinder Head and Valve
Conditioning
/""
Review "Cylinder Head Assemblies" BEFORE
Starting Repair.
Disassembly
1.
With cylinder head removed, remove rocker arms
and components (if not previously done).
2.
Compress valve springs with J-8062 tool and remove
valve retainers. Release compressor tool and
remove all valve components.
3.
Remove valves from cylinder head and place valves
in a rack in their proper sequence for reassembly in
their original positions.
a-J-8062 Tool
Compressing Valve Spring
90-14499--1 887
Cleaning
1.
Clean all carbon from combustion chambers and
vale ports with J-8089 tool.
a-J-8089 Tool
Cleaning Combustion Chambers
2.
Thoroughly clean valve guides with J-8101 tool.
3.
Clean all carbon and sludge from push rods, rocker
arms and push rod guides.
4.
Clean carbon from valves on a buffing wheel.
5.
Clean carbon deposits and gasket material from
cylinder head mating surfaces.
a-J-8101 Tool
Cleaning Valve Guides
ENGINE-3A-25
Inspection
1.
Inspect cylinder head for cracks in the exhaust
ports, combustion chambers (especially around
spark plug holes and valve seats) and for cracks in
external surface of water jacket. Replace head if
cracked.
2.
Inspect cylinder head gasket surface for burrs,
nicks, erosion or other damage. Also, check flatness
of cylinder head gasket surface, using a
machinists straight edge and feeler gauges as
shown. Refer to "Specifications".
a -Straight Edge
b -Feeler Gauge
c-Take Measurements Diagonally Across Head (Both Ways) and
Straight Down Center Head
Checking Gasket Surface of Cylinder Head for
Flatness
IMPORTANT: Cylinder head to block gasket surface
should be resurfaced if out-of-flat more than specified.
When resurfacing gasket surface, cylinder head to
intake manifold gasket surface also must be milled to
provide proper alignment between manifold and head.
3.
Inspect valves for burned heads, cracked faces or
damaged stems.
IMPORTANT: Excessive valve stem to bore clearance
will cause excessive oil consumption and possible
valve breakage. Insufficient clearance will result in
noisy and sticky functioning of valve and disturb
engine smoothness.
4.
Measure valve stem clearance as follows: Clamp a
dial indicator on one side of cylinder head rocker
arm cover gasket rail, locating indicator so that
movement of valve stem from side-to-side (crosswise
to the head) will cause a direct movement of
indicator stem. Indicator stem must contact side of
valve stem just above valve guide. With valve head
dropped about 1/16" (2mm) off valve seat, move
valve stem from side-to-side, using light pressure to
obtain a clearance reading. If clearance exceeds
specifications, it will be necessary to ream valve
guides for oversize valves, as outlined under "Valve
Guide Bores".
a -Valve Stem
b -Dial Indicator
c -Valve Guide
Measuring Valve Stem Clearance
3A-26 -ENGINE
90-1 4499--1 887
5. Check valve spring tension with J-8056 spring
tester.
IMPORTANT: Springs should be compressed to specified
height and checked against specification. Springs
should be replaced if not within 10 lbs. of specified
load.
6. Inspect rocker arm studs for wear or damage.
Inspect push rod guides for wear or damage.
Checking Valve Spring Tension
Rocker Arm Studs and Push Rod Guide
Repairs
1. Rocker arm studs, which are replaced because of
wear or looseness, should be replaced with oversize
studs.
a -Large Sleeve
b-3/8 x 24 Nut -Turn until Nut Bottoms Out on Stud Threads,
Then Remove Nut
Using J-5802-01 Tool
90-14499--1 887
2. Use Tool J-5802-01 to remove old stud by placing
tool, flat washer and nut over stud, then turning nut.
3. Ream stud hole, whenever installing an oversize
stud, using appropriate reaming tool.
4. Install new stud with Tool J-6880 or similar stud
installing tool made for press-in type studs. Follow
instructions with tool.
a -Install Small Sleeve
b-Turn Nut to Remove Stud
Removing Stud
Installing Stud Tool J-6880
ENGINE -3A-27
Valve Guide Bore Repair
IMPORTANT: Be sure to measure valve stem diameter
of both the intake and exhaust valve, as valve stem
diameter may or may not be the same for both valves.
If .015" oversize valves are required ream valve guide
bores for oversize valves, as follows:
1.
Measure valve stem diameter of old valve being
replaced and select proper size Valve Guide Reamer
from chart below.
2.
Ream valve guide bores, as shown.
3.
Remove the sharp corner created by reamer at top
of valve guide.
Standard Valve Reamer Required
Stem Diameter for Oversize Valve
.341 J-5830-2
.372 J-7049-5
Reaming Valve Guides
Valve Seat Repair
Valve seat reconditioning is very important, since seating
of valves must be perfect for engine to deliver maximum
power and performance.
Another important factor is valve head cooling. Good
contact between each valve and its seat in head is
important to insure that heat in valve head will be properly
dispersed.
Several different types of equipment are available for
reseating valve seats. Equipment manufacturer's recommendations
should be followed carefully to attain
proper results.
Regardless of type of equipment, however, it is essential
that valve guide bores be free from carbon or dirt to
insure proper centering of pilot in valve guide.
1.
Install expanding pilot in valve guide bore and
expand pilot.
2.
Place roughing stone or forming stone over pilot
and clean up valve seat only. Use a stone that is cut
to specifications.
3.
Remove roughing stone or forming stone from
pilot, place finishing stone (cut to specifications)
over pilot and cut just enough metal from seat to
provide a smooth finish. Refer to "Specifications".
4.
Narrow down valve seats to specified width by
grinding with a 30° stone to lower seat and a 60°
stone to raise seat.
a-Top Edge "Approach Angle" (30°)
b -Seat Angle
c -Seat Width
d -Bottom Edge (60° )
Valve Seat In Cylinder Head
3A-28 -ENGINE
90-14499--1 887
5.
Remove expanding pilot and clean cylinder head
carefully to remove all chips and grindings from
above operations.
6. Measure valve seat width. See "Specifications".
7. Measure valve seat "out-of-round" See 'Specifica
tions".
05024
Measuring Valve Seat Concentricity
Valve Repair
Pitted valves can be refaced to proper angle on a valve
grinder, thus insuring correct relation between cylinder
head seat and valve mating surface. Replace
valves with excessive wear on stems or valves which
are warped excessively. When an excessively-warped
valve head is refaced, a knife edge will be ground on
part or all of the valve head, due to amount of metal that
must be removed to completely reface. Knife edges
lead to breakage, burning or pre-ignition caused by
heat localizing in this knife edge. If edge of valve head
is less than 1/32" (.8mm) thick after grinding, replace
the valve.
Various equipment is available for refacing valves.
Manufacturer's recommendations should be carefully
followed to attain proper results.
1.
If necessary, dress the valve refacing machine
grinding wheel to make sure it is smooth and true.
Set chuck at angle specified for valve. Refer to
"Specifications".
2.
Continue grinding until valve face is true and
smooth all around the valve. If this makes valve
head thin [1/32" (.8mm) minimum]. valve must be
replaced, or valve will overheat and burn.
3.
Remove valve from chuck and place stem in "V"
block. Feed valve squarely against grinding wheel
to grind any pit from rocker arm end of stem.
IMPORTANT: Only extreme end of valve stem is hardened
to resist wear. Do not grind end of stem excessively.
4.
After cleaning valve face and cylinder head valve
seat of grinding particles, make pencil marks about
1/4" (6mm) across the valve face, place valve in
cylinder head and give valve 1/2-turn in each direction
while exerting firm pressure on head of valve.
5.
Remove valve and check face carefully. If all pencil
marks have not been removed at point of contact
with valve seat, repeat refacing operation and again
recheck for proper seating.
Refer to
Specifications
for Minimum
Dimension
Check for
Bent Stem
Diameter
For Dimensions, Valve
Refer to Face
Specifications Angle This Line
Parallel
with
1/32" Minimum Valve Head
Critical Valve Dimensions
90-14499--1 887
ENGINE -3A-29
Reassembly
•
Lubricate valve guides and valve stems with engine
oil.
•
Install each valve in the port from which it was
removed or to which it was fitted.
•
Install valve stem oil seal, valve spring(s) and
related parts on each valve as explained under
"Valve Stem Oil Seal and/or Valve Spring".
•
Compress valve spring with Tool J-8062.
•
Check installed height of the valve springs with a
narrow, thin scale. A cutaway scale will help. Measure
from top of spacer (spring seat) to top of valve
spring. If this exceeds specified height, install a
valve spring seat shim approximately 1/16" (1.6mm)
thick. At no time should spring be shimmed to give
an installed height under minimum specified.
05037
Cutaway Scale
Measuring Valve Spring Installed Height
4.
Install new front and rear seals, being sure ends of
seals are butted properly against side gaskets.
5.
Apply a 1/8" (3mm) bead of RTV Sealer to outer
surface of seals. This is extremely important on
inboard and V-drive engines which have aluminum
oil pans.
Oil Pan
Removal
1.
Drain coolant.
2.
Drain crankcase oil.
3. Remove oil dipstick and tube, if required.
4. Remove oil pan and discard gaskets.
Oil Pan Replacement Information
Early cylinder blocks had the oil dipstick tube mounting
hole on the port (left) side. Later cylinder blocks
had the mounting hole on the starboard (right) side.
IMPORTANT: MIE engines normally have mounting
hole plugged, however, this information applies to
those engines also.
Front
a-Port Side
b -Starboard Side
Oil Dipstick Tube Mounting Holes
OIL PAN BAFFLE
MCM 200 engine: Baffle is part of oil pan.
All other engines: Determine which side of engine oil
dipstick tube mounting hole is on and use appropriate
one. Refer to Parts Manual.
OIL PAN
Determine which side of engine oil dipstick tube
mounting hole is on and use appropriate one. Refer to
Parts Manual.
OIL PAN GASKET
Determine which side of engine oil dipstick tube
mounting hole is on and use appropriate one. Refer to
Parts Manual.
3A-30 -ENGINE
90-14499--1 887
OIL DIPSTICK and TUBES
Refer to Parts Manual for part numbers.
a-92163A2 -Tube (All Listed Below)
b -96822A 1 -Dipstick (MCM 200)
c-96418A1 -Dipstick (MCM 230/260/300)
d-12394 -Dipstick (MIE 5.7 Ski)
Used On: MCM 200/230/260/300
MIE 5.7 Ski
a-86890A 1 -Tube
b -87353 -Dipstick
c -49457 -Dipstick (MCM 230/260 V-Drive
Engines and Engines That are Mounted
Near Horizontal)
Used on: MIE 230 -All
MIE 260 -All
MIE 305 and 350 CID Engines
90-14499--1 887
23-U/32(593rnml
fULL 15132ADD-1
0
21 " ($33MMI
FUll ADO
FULL
ADD
33164"'(13mm)
27"(6a6mm)
''i$33mml
ENGINE-3A-31
Installation
1.
Thoroughly clean gasket and seal surfaces on oil
pan, cylinder block, rear main bearing cap and
crankcase front cover.
2.
Coat both sides of oil pan side gaskets with Perfect
Seal and place gaskets in position on each side of
cylinder block.
3.
Apply a 1/8" (3mm) bead of RTV Sealer to front and
rear seal mating surfaces on cylinder block rear
main bearing cap, front cover and gaskets.
IMPORTANT: RTV Sealer sets up in about 15 minutes.
Be sure to complete assembly promptly.
4.
Install new front and rear seals, being sure ends of
seals are butted properly against side gaskets.
5.
Apply a 1/8" (3mm) bead of RTV Sealer to outer
surface of seals. This is extremely important on
inboard and V-drive engines which have aluminum
oil pans.
14446
a -Coat Both Sides with Perfect Seal
b-Apply RTV to Mating Surfaces
c -Apply RTV to Outer Surface of Seals
Typical Oil Pan Gasket and Seal Locations
6.
Carefully position oil pan against the block, being
careful not to disturb gaskets and seals. Install oil
pan attaching screws and washers. Torque screws
to specifications, starting from center and working
outward in each direction.
7.
Install oil dipstick tube and dipstick.
8.
Install engine in boat. Fill engine with oil, start
engine and check for leaks.
Oil Pump
1 -Shaft Extension
2-Shaft Coupling
3-Pump Body
4 -Drive Gear and Shaft
5-Idler Gear
6-Pickup Screen and Pipe
7-Pump Cover
8-Pressure Regulator Valve
9-Pressure Regulator Spring
10 -Washer
11 -Retaining Pin
12 -Screws
Oil Pump Assembly
The oil pump consists of 2 gears and a pressure regulator
valve enclosed in a 2-piece housing. Oil pump is
driven by distributor shaft which is driven by a helical
gear on camshaft.
A baffle is incorporated on pickup screen to eliminate
pressure loss and engine oil pump tubes are bent at
special angles.
Removal
1.
Remove oil pan.
2.
Remove pump to rear main bearing cap bolt and
remove pump and extension shaft.
3A-32 -ENGINE
90-1 4499--1 887
Disassembly
1. Remove pump cover attaching screws and pump
cover.
/' IMPORTANT: Mark gear teeth for reassembly with
same teeth indexing.
2. Remove idler gear, drive gear and shaft from pump
body.
3. Remove retaining pin, pressure regulator valve and
related parts.
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 replacement,
mount pump in a soft jawed vise and extract
pipe from pump.
Cleaning and Inspection
1. Wash all parts in cleaning solvent and dry with
compressed air.
2. Inspect pump body and cover for cracks or excessive
wear.
3. Inspect pump gears for damage or 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 or pipe.
7. Check pressure regulator valve for fit.
IMPORTANT: Pump gears and body are not serviced
separately. If pump gears or body are damaged or
worn, replacement of entire oil pump assembly Is
necessary.
90-14499--1 887
Reassembly A CAUTION
Be careful of twisting, shearing or collapsing pipe
while installing in pump. Pickup screen must be parallel
to oil pan rails when oil pump is installed.
If pickup screen and pipe assembly was removed,
mount pump in a soft-jawed vise, apply Perfect Seal to
end of new pipe and using Tool (J-8369), tap the pipe in
place with a hammer.
NOTE: Tool will have to be modified to fit later engines.
IMPORTANT: Oil Internal parts liberally before installation.
1. Install pressure regulator valve and related parts.
2. Install drive gear and shaft 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. Install pump cover and torque attaching screws to
specifications.
5. Turn drive shaft by hand to check for smooth operation.
14447
a-J-8369 Tool
Installing New Pickup Screen and Pipe Assembly
ENGINE -3A-33
remove torsional damper (in next step) as outside ring
of damper is bonded in rubber to the hub and use of
claw type puller may break the bond.
3. Remove damper with Tool J-23523-03.
3A-34 -ENGINE
a-J-23523-03 Tool
Installing Torsional Damper
d. Remove tool from install
90-1 4499--1 887
Installation
1.
Assemble pump and extension shaft to rear main
bearing aligning slot on top end of extension shaft
with drive tang on lower end of distributor drive
shaft.
2.
Install pump to rear main bearing cap and torque to
specifications.
IMPORTANT: Oil pump screen is installed with bottom
edge parallel to oil pan rails.
3.
Install oil pan as outlined.
Torsional Damper
Removal
1.
Remove drive belts.
2.
Remove drive pulley, then remove damper retaining
bolt.
IMPORTANT: Do not use a universal claw type puller to
a-J-23523-03 Tool
Removing Torsional Damper
Installation
IMPORTANT: The inertia weight section of torsional
damper is assembled to the hub with a rubber 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.
Coat front cover seal contact area (on damper) with
engine oil.
2.
Pull damper onto crankshaft, using Tool J-23523,
as follows:
a.
Install appropriate end of threaded rod into
crankshaft.
IMPORTANT: Be sure to install threaded rod in crankshaft
so that at least 1/2" (13mm) of thread engagement
is obtained to prevent damage to threads.
b.
Install plate, thrust bearing, washer and nut on
rod.
c.
Pull damper onto crankshaft (by turning nut)
until it bottoms-out.
crankshaft, then,
damper retaining bolt and torque to specifica
tions.
3.
Install drive pulley(s).
4.
Install and adjust drive belts.
Crankcase Front Cover/Oil
Seal
Oil Seal Replacement (Without
Removing Front Cover)
1.
Remove torsional damper.
2.
Pry seal out of cover from the front with a large
screwdriver, being careful not to distort front cover
or damage crankshaft seal surface.
3.
Install new seal with open end of seal inward, using
Tool J-23042 on 305 and 350 CID engines. Drive
seal in until it just bottoms out. Do not use excessive
force.
4.
Reinstall torsional damper.
a-J-23042 Tool
305 and 350 CID Engines
Removal
1.
Remove engine from boat.
2.
Remove torsional damper and oil pan.
3.
Remove water circulating pump.
4.
Remove crankcase front cover attaching screws
and remove cover. Remove and discard cover
gasket.
5.
If damaged, drive oil seal out of front cover (from
the rear) with a punch.
Installation
IMPORTANT: Correct rotation oil seal must be used to
prevent oil leak.
a-MCM and MIE (L.H.) Rotation Engines
b-MIE (R.H.) Rotation Engines
c-Seal Lip Toward Inside of Engine
d-Rotation of Crankshaft as Viewed From Flywheel End Looking
Forward
Front Seals WITH Helical Grooves
a -Can Be Used On Any Rotation Engine b-Seal Lip Toward Inside of Engine
Front Seat WITHOUT Helical Grooves
90-14499--1 887
ENGINE -3A-35
1.
Clean front cover in solvent and dry with compressed
air. Clean old gasket material and sealer
from mating surfaces on cover and cylinder block.
Check gasket surface on front cover for distortion
and true if necessary. Surfaces must be clean and
flat or oil leakage may result.
2.
Install oil seal in cover with lip of seal toward inside
of engine, using Tool J-23042. Support cover
around seal area with appropriate tool as shown.
3.
Coat both sides of front cover gasket with Perfect
Seal and place in position on engine.
4.
Install front cover, making sure holes in cover
align with dowel pins in block. Torque front cover
attaching screws to specifications.
5.
Install oil pan and torsional damper as outlined.
6.
Install water circulating pump.
7.
Reinstall engine in boat.
8.
Fill crankcase with engine oil.
9.
Start engine and check for water and oil leaks.
a-J-23042 Tool
b-Support (To Prevent Distorting Cover)
Flywheel
Removal
1.
Remove engine from boat.
2.
Remove transmission, if so equipped.
3.
Remove flywheel housing and related parts, if
applicable.
4.
On 1-Drive Engines: Remove flywheel and coupler
attaching hardware and remove coupler and flywheel.
3A-36 -ENGINE
a-Old Style (Flywheel Stud Mounted)
b-New Style
Alpha One Couplers
5.
On Engines with Borg-Warner Transmission: Remove
drive plate attaching screws and washers and
remove drive plate, then remove flywheel attaching
screws and washers and remove flywheel.
IMPORTANT: 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
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.
Inspection
1.
Inspect drive plate for wear, on engines so
equipped.
2.
Check flywheel ring gear for worn or missing teeth.
3.
Inspect engine coupler, on engines so equipped.
Installation
1.
Clean mating surfaces of flywheel and crankshaft.
305 and 350 CID Engines
90-1 4499--1 887
2.
On !-Drive Engines:
a.
If removed, apply Loctite 35 to threads of studs
and install in crankshaft.
.
b. Align dowel hole in flywheel with dowel hole or
dowel in crankshaft flange and place flywheel in
. "--'
position on flange.
c.
Install coupler and secure it and flywheel with
washers and elastic stop nuts. Torque nuts to
specifications.
On Engines with Borg-Warner Transmission:
a.
Align dowel hole in flywheel with dowel or dowel
hole in crankshaft flange and place flywheel in
position on flange.
b.
Secure flywheel with screws and lockwashers.
Torque screws to specifications.
c.
Install drive plate and torque to specifications.
Check flywheel runout by mounting dial indicator
on machined surface of flywheel.
5.
Runout should not exceed .008" (.203mm). If excessive,
remove flywheel and check for burrs or replace
flywheel.
('
a-.008" (.203mm) Max. Runout
b -Hold Flywheel and Crankshaft Forward or Rearward
As Far As It Will Go When Taking Reading
Checking Flywheel Runout
6.
Install flywheel housing and related parts, if so
equipped. Torque flywheel housing screws to specifications.
7.
Torque flywheel housing cover screws to specifications.
8.
Install transmission, if so equipped.
9.
Install engine in boat.
Oil Seal (Old Style Rear Main)
Replacement
Rear main bearing oil seal can be replaced (both
halves) without removing crankshaft.
IMPORTANT: Always replace upper and lower seal as a
unit. Install with lip facing toward front of engine.
1.
Remove oil pan and oil pump.
2.
Remove rear main bearing cap.
3.
Remove lower half of oil seal from the bearing cap
by prying from the bottom with a small screwdriver.
Be careful not to damage seal seating surface.
Removing Lower Half of Oil Seal
4.
Using a hammer and a soft metal pin punch, tap
upper half of oil seal on one end until it protrudes far
enough on the other end to remove it with a pliers.
Removing Upper Half of Oil Seal
5.
Clean, rear main bearing cap, cylinder block and
crankshaft with solvent and blow dry with compressed
air. Be sure all of the old sealer is removed
from bearing cap and cylinder block mating surfaces.
90-14499--1 887
ENGINE -3A-37
Installation
IMPORTANT: Correct rotation oil seal must be used to
prevent oil leak.
541-H
542-H
a-MCM and MIE (L.H.) Rotation Engines
b-MIE (R.H.) Rotation Engines
c-Seal Lip Toward Inside of Engine
d -Rotation of Crankshaft as Viewed From Flywheel End Looking
Forward
Rear Seals WITH Helical Grooves
Extreme care must be exercised when installing seal to
prevent damage to sealing bead, located in the channel
on outside diameter of the seal. To protect this bead,
installation tool must be used. Construct tool using
.004" (.1 mm) shim stock, if tool is not supplied with
seal.
Engine
Block
Grind Away
.004" Feeler Gauge
:;...:. -1;2;;
(13mm)
.t
..t
11/64"
(4mm)
540-H Installing Rear Main Seal -Cylinder Block Inverted
a-Can Be Used On Any Rotation Engine
b-Sealed Lip Toward Inside of Engine
Rear Seal WITHOUT Helical Grooves
1. Coat lips and sealing bead on new rear oil seal with
engine oil. Keep oil off of seal parting surfaces.
IMPORTANT: Be sure to install oil seal with lip facing
toward inside of engine.
2. Install upper half of oil seal:
a. Position tip of installation tool between crankshaft
and seal seating surface in cylinder block.
b. Position upper half of seal between crankshaft
and tip of installation tool so that seal bead contacts
tip of tool.
c. Roll upper half of seal around crankshaft using
installation tool as a "shoe-horn" to protect seal
bead from sharp corner of seal seating surface.
0.
<>'. \
.. W.l.'tti'W.':;tlQ1'1t3l;C!f'tll'J;1i1'N'I(B 9Ui)'Fii"
.
. ...O.)if
3A-38 -ENGINE 90-14499--1 887
IMPORTANT: Installation tool must remain In position
until seal is properly positioned with both ends flush
with block.
d. After both ends of seal half are flush with block,
remove installation tool.
a-Installation Tool
b-Roll Seal Into Place In This Direction
Installing Upper Half of 011 Seal
3. Install lower half of oil seal:
a. Position oil seal half in rear main bearing cap so
that one end is slightly below mating surface and
seal lip is facing toward bearing. Do not allow
sealing bead on other end of seal half to contact
seal seating surface.
b. Insert installation tool in between sealing bead
and seal seating surface, then, using tool as a
"shoe-horn" to protect sealing bead from sharp
corner of seal seating surface, roll seal into
place. Seal is properly positioned when both
ends are flush with cap.
c. Remove installation tool.
a-Installation Tool
b-Roll Seal Half Into Position In This Direction
Installing Lower Half of Oil Seal
90-14499--1 887
14513
4. Make sure that bearing cap and cylinder block mating
surfaces and oil seal parting surfaces are clean
and free of oil, then apply Perfect Seal to block at
locations shown. Do not get sealer on seal parting
surfaces or on surfaces adjacent to main bearing
inserts.
a -Apply Perfect Seal to Outlined Area Only
Applying Sealer to Block
5. Install rear main bearing cap and torque attaching
bolts to 10-12 ft. lbs. (13-16 N.m). Tap crankshaft
first rearward and then forward with a lead hammer
to line up rear main bearing thrust surfaces. With
crankshaft in forward position, torque rear main
bearing cap attaching bolts evenly (alternating
from side to side) to specifications.
6. Install oil pump and oil pan as outlined.
Oil Seal {New Style Rear)
The new style rear crankshaft oil seal can be replaced
without removing the oil pan or rear main bearing cap
from engine.
Removal
1. Remove seal by prying out by the three slots located
in the seal retainer.
ENGINE-3A-39
..-....
a-Rear Seal
b -Seal Retainer
c-Slots (Three)
Removing Rear Crankshaft Seal
2.
Clean crankshaft/seal running surface and seal
retainer.
Installation
1.
Apply Perfect seal to seal retainer mating surface.
Apply grease to seal lips.
2.
Install seal with Kent Moore tool J-26817-A.
a-Kent Moore Tool J-2681 7-A
Installing Seal
3A-40 -ENGINE
Main Bearings
Main bearings are precision insert type and do no utilize
shims for adjustment. If clearances are excessive, a
new bearing (both upper and lower halves) will be
required. Bearings are available in standard size and
undersize. Selective fitting of both rod and main bearing
inserts is necessary in production to obtain close
tolerances. Consequently, one half of a standard insert
may have one half of a .001 " undersize insert which will
decrease clearance .005" from using a full standard
bearing.
When a production crankshaft cannot be precision fitted
by this method, it then is ground .009" (.229mm)
undersize on main journals only. A .009" undersize
bearing and .01 0" undersize bearing may be used for
precision fitting in the same manner as previously described.
Any engine fitted with a .009" undersize
crankshaft will be identified by the following markings:
•
".009" will be stamped on crankshaft counterweight
forward of center main journal.
•
A figure "9" will be stamped on block at left front oil
pan rail.
•
A crankshaft with an undersize journal will be
painted with light green on each side of the affected
journal.
IMPORTANT: If crankshaft has an undersize journal
and a new bearing is required, journal must be reconditioned
to accept a .01 0" or a .020" undersize bearing as
.009" undersize bearings are not available for service.
Inspection
In general (except No.2 bearing), lower half of bearing
shows a greater wear and most distress from fatigue.
After inspection, if lower half is suitable for use, it can
be assumed that the upper half also is satisfactory. If
lower half is worn or damaged, both upper and lower
halves should be replaced. Never replace one half
without replacing the other.
90-1 4499--1 887
Checking Clearance
To obtain best results, use Plastigage (or its equivalent),
a wax-like plastic material which will compress
evenly between bearing and journal surfaces without
damaging either surface. With engine upside-down,
crankshaft will rest on upper bearings, and total clearance
can be measured between lower bearing and
journal.
IMPORTANT: To assure proper seating of crankshaft,
all bearing cap bolts should be at their specified
torque. In addition, surface of crankshaft journal and
bearing should be wiped clean of oil before checking fit
of bearings. Remove oil seal from rear main bearing
cap prior to checking clearance.
1.
With oil pan, baffle (some engines) and oil pump
removed (starting with rear main bearing), remove
bearing cap and wipe oil from journal and bearing
cap.
2.
Place a piece of gauging plastic full width of bearing
(parallel to crankshaft) on journal.
IMPORTANT: Do not rotate crankshaft while gauging
plastic is between bearing and journal.
3.
Install bearing cap and torque retaining bolts
evenly to specifications.
Gauging Plastic on Journal
4.
Remove bearing cap. Flattened gauging plastic will
be found adhering to either bearing shell or journal.
5.
Use graduated scale (correlated in thousandths of
an inch) on edge of gauging plastic envelope. Without
removing gauging plastic, measure its compressed
width (at widest point) with graduations on
gauging plastic envelope.
90-1 4499--1 887
Measuring Gauging Plastic
IMPORTANT: Main bearing journals usually wear
evenly and are not out-of-round. However, if a bearing
is being fitted to an out-of-round journal (.001 "
[.25mm] maximum), be sure to fit to maximum diameter
of journal. If bearing is fitted to minimum diameter,
and journal is out-of-round .001 ", interference between
bearing and journal will result in rapid bearing
failure. If flattened gauging plastic tapers toward middle
or ends, there is a difference in clearance indicating
taper, low spot or other irregularity of bearing or journal.
Be sure to measure journal wiht a micrometer if
flattened gauging plastic indicates more than .001 "
difference.
6.
If bearing clearance is within specifications, bearing
insert is satisfactory. If clearance is not within
specifications, replace the insert. Always replace
both upper and lower insert as a unit.
IMPORTANT: If a new bearing cap is being installed
and clearance is less than .001 ", inspect for burrs or
nicks.
7.
A standard .001 " or .002" undersize bearing may
produce proper clearance. If not, regrind crankshaft
journal for use with next undersize bearing.
8.
Proceed to next bearing. After all bearings have
been checked, rotate crankshaft to see that excessive
drag does not exist.
9.
Install front 4 main bearing caps and torque evenly
to specifications.
10. 1nstall rear main bearing cap and torque attaching
bolts to 10-12 lbs. ft. (13-16 N.m) Tap end of crankshaft
first rearward and then forward with a hammer
to align rear main bearing thrust surfaces. With
crankshaft in forward position, torque rear main
bearing attaching bolts evenly (alternating from
side to side) to specifications.
ENGINE -3A-41
11. Measure crankshaft end play with a feeler gauge by
forcing crankshaft forward and measuring clearance
between the front of the rear main bearing and
the crankshaft. If clearance is excessive rear main
bearing and/or crankshaft must be replaced.
12. 1nstall a new rear main bearing oil seal in cylinder
block and main bearing cap, as outlined.
a-Lower Bearing Insert (Install in Cap)
b-Upper Bearing Insert (Install in Block)
c-Oil Groove
Main Bearing Inserts
WITH CRANKSHAFT REMOVED:
a -Force Crankshaft Forward
Measuring Crankshaft End Play
Replacement
NOTE: Main bearings may be replaced with or without
removing crankshaft.
1.
Remove and inspect crankshaft.
2.
Remove main bearings from cylinder block and
main bearing caps.
3.
Coat bearing surfaces of new, correct size, main
bearings with oil and install in cylinder block and
main bearing caps.
4.
Install crankshaft.
WITHOUT CRANKSHAFT REMOVED:
1.
With oil pan, baffle (some engines), oil pump and
spark plugs removed, remove cap on main bearing
requiring replacement and remove bearing from
cap.
2.
Replace main bearing upper half as follows:
a.
Install main bearing removing and installing tool
in crankshaft journal oil hole.
NOTE: If tool is not available, bend a cotter pin.
b.
Rotate crankshaft clockwise (as viewed from
front of engine). This will roll upper bearing out
of block.
c.
Oil new selected size upper bearing and insert
plain (unnotched) end between crankshaft and
notched side of block. Rotate bearing into place
and remove tool from oil hole in crankshaft
journal.
3.
Oil new lower bearing and install in bearing cap.
4.
Install main bearing cap with arrows pointing toward
front of engine.
5.
Torque main bearing cap bolts to specifications.
Connecting Rod Bearings
Connecting rod bearings are precision insert type and
do not utilize shims for adjustment. Do not file rods or
rod caps. If clearances are found to be excessive, a new
bearing will be required. Bearings are available in
standard size and undersize for new and used standard
size crankshafts and reconditioned crankshafts.
3A-42 -ENGINE
90-14499--1 887
Inspection and Replacement
1.
With oil pan and oil pump removed, remove connecting
rod cap and bearing.
2.
Inspect bearing for wear or damage and replace
unsatisfactory bearings.
3.
Wipe bearings and crankpin clean of oil.
4.
Measure crankpin for out-of-round or taper with a
micrometer. If not within specifications, replace or
recondition crankshaft. If within specifications, and
a new bearing is to be installed, measure maximum
diameter of crankpin to determine new bearing size
required.
5.
Measure new or used bearing clearances with Plas
tigage or its equivalent.
IMPORTANT: If a bearing Is being fitted to an outof-
round crankpln, be sure to fit to maximum diameter
of crankpin. If bearing Is fitted to minimum diameter,
and crankpln Is out-of-round .001" (.025mm) or more,
interference between bearing and crankpin will result
in rapid bearing failure.
a.
Install bearing in connecting rod and cap.
b.
Place a piece of gauging plastic the full width of
crankpin (parallel to crankshaft).
Gauging Plastic on Crankpln
c.
Install bearing cap and torque nuts evenly to
specifications.
IMPORTANT: Do not turn crankshaft with gauging
plastic Installed.
d.
Remove bearing cap and, using scale on gauging
plastic envelope, measure gauging plastic
width at the widest point.
6.
If clearance exceeds specifications, select a new,
correct size bearing and recheck clearance.
7.
Coat bearing surface with oil, install rod cap and
torque nuts to specifications.
8.
When all connecting rod bearings have been installed,
tap each rod lightly (parallel to crankpin) to
make sure they have clearance.
9.
Measure all connecting rod side clearances (see
specifications) between connecting rod caps.
Measuring Gauging Plastic
Measuring Connecting Rod Side Clearance
90-14499--1 887
ENGINE -3A-43
Connecting Rod/Piston
Assembly
Removal
1.
With oil pan, baffle (some engines), oil pump and
cylinder head removed, use a ridge reamer to
remove any ridge and/or deposits from upper end
of cylinder bore.
IMPORTANT: Before ridge and/or deposits are removed,
turn crankshaft until piston is at bottom of
stroke and place a cloth on top of piston to collect
cuttings. After ridge and/or deposits are removed, turn
crankshaft until piston is at top of stroke, then remove
cloth and cuttings.
2.
Mark connecting rod and bearing caps left bank 1,
3, 5 and 7; right bank 2, 4, 6 and 8 from front to rear
on same side as piston thrust.
3.
Remove connecting rod cap and install tool J-5239
(3/8") on bolts. Push connecting rod and piston
assembly out of top of cylinder block.
NOTE: It will be necessary to turn crankshaft slightly to
disconnect and remove some connecting rod and piston
assemblies.
Removing Piston Assembly
Disassembly
1.
Use Tool Kit (J-24086-100), shown.
2.
Position connecting rod onto tool rod support with
rod support inserted between connecting rod end
and piston. Align piston pin with hole located in top
of arched base.
3A-44 -ENGINE
3.
Insert pin remover thru hole (located in top of
arched base) and into piston pin hole. Press on pin
remover to remove piston pin.
a -Arched Base
b -Rod Support
c -Adjustable Installer
d -Piston Pin Guide
e-Piston Pin Remover
Tool (J-24086-100) Parts Identification
a -Piston Pin Remover
b -Arched Base
c-Piston
d -Connecting Rod
e -Rod Support
Removing Piston Pin
90-14499--1 887
Cleaning and Inspection
CONNECTING RODS
1.
Wash connecting rods in cleaning solvent and dry
with compressed air.
2.
Check for twisted or bent rods and inspect for nicks
or cracks. Replace damaged connecting rods.
PISTONS
1.
Clean varnish from piston skirts and pins with a
cleaning solvent. DO NOT WIRE BRUSH ANY
PART OF PISTON. Clean ring grooves with a
groove cleaner and make sure oil ring holes and
,
•
slots are clean.
2.
Inspect piston for cracked ring lands, skirts or pin
bosses, wavy worn ring lands, scuffed or damaged
skirts or eroded areas at top of piston. Replace
pistons which are damaged or show signs of excessive
wear.
3.
Inspect grooves for nicks or burrs that might cause
rings to hang up.
4.
Measure piston skirt and check clearance as outlined
under "Piston Selection -Cylinder Block".
PISTON PINS
1.
Piston pin clearance is designed to maintain adequate
clearance under all engine operating conditions.
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 or 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 " (.025mm) wear limit, replace
piston and piston pin assembly.
PISTON RINGS
All compression rings are marked on upper side of
ring. When installing compression rings, make sure
that marked side is toward top of piston.
Oil control rings are a 3-piece type, consisting of 2
segments (rails) and a spacer.
1.
Select rings comparable in size to piston being
used.
2.
Slip compression ring in cylinder bore, then press
ring down into cylinder bore about 1/4" (6mm)
(below ring travel). Be sure that ring is square with
cylinder wall.
3.
Measure gap between ends of ring with a feeler
gauge.
90-1 4499--1 887
4.
If gap between ends of ring is below specifications,
remove ring and try another for fit.
5.
Fit each compression ring to cylinder in which it is
going to be used.
6.
Clean and inspect pistons, if not previously done.
7.
Slip outer surface of top and second compression
ring into respective piston ring groove and roll ring
entirely around the groove to make sure that ring is
free. If binding occurs at any point, determine
cause. If caused by ring groove, remove by dressing
with a fine cut file. If binding is caused by a distorted
ring, check a new ring.
8.
Install piston ring as shown. Use 91-24697 piston
ring expanders for compression ring installation.
a.
Install oil ring spacer in groove and insert antirotation
tang in oil hole.
b.
Hold spacer ends butted and install lower steel
oil ring rail with gap properly located.
c.
Install upper steel oil ring rail with gap properly
located.
d.
Flex the oil ring assembly to make sure ring is
free. If binding occurs at any point, the cause
should be determined and, if caused by ring
groove, remove by dressing groove with a fine
cut file. If binding is caused by a distorted ring,
check a new ring.
e.
Install lower compression ring, using ring expander,
and check location of gap.
f.
Install top compression ring with gap properly
located.
Checking Ring Gap
ENGINE -3A-45
14504
Rolling Ring in Ring Groove
.. ENGINE LEFT ENGI*ONT ENGINE RIGHT t CYLINDER BLOCK NOTCHES
1-3-5-7 cyl.
"'A" Oil RING SPACER GAP
(Tong in Hole or Slot within Arc )
''8"'OIL RING RAIL GAPS
"C"' 2ND COMPRESSION RING GAP
"0" TOP COMPRESSION RING GAP
Ring Gap Location
3A-46 -ENGINE
9. Proper clearance of piston ring in its piston ring
groove is very important to provide proper ring
action and reduce wear. Therefore, when fitting
new rings, clearances between ring and groove surfaces
should be measured. See "Specifications".
Checking Groove Clearance
Reassembly
IMPORTANT: When reassembling pistons and connecting
rods, the following must be kept in mind. • Piston and pin are machine fitted to each other and
must remain together as a matched 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 removed. • Connecting rod bearing tangs are always toward
outside of cylinder block.
90-14499--1 887
• Reference mark on piston, must be positioned correctly
for engine that Is being repaired. • To determine if engine Is left-hand (standard) rotation
or right-hand (opposite) rotation, inspect camshaft
drive. If engine has a timing chain, engine is
left-hand rotation. If engine has timing gears, engine
is right-hand rotation. All MCM engines are
left-hand rotation.
a-Connecting Rod Bearing Tangs Must Face Toward Outside
of Cylinder Block
Connecting Rod
90-14499--1 887
0
FRONT OF ENGINE
a-Notch
b-MCM and MIE L.H. Rotation Engines -Notch Toward Front
of Engine
c-MIE R.H. Rotation Engines -Notch Toward Rear of Engine
305 CID Engines
0
FRONT OF ENGINE
a-Notch
b-MCM and MIE L.H. Rotation Engines -Notch Toward Front
of Engine
c-MIE A.H. Rotation Engines -Notch Toward Rear of Engine
350 CID Engines
17758
17755
ENGINE -3A-47
1. Install piston pin with Tool Kit J-24086-1 00. Refer to
chart (furnished with Tool) and select proper size
piston pin guide for specific engine being worked
on.
2. Lubricate piston pin, piston pin hole in piston and
hole in rod end with a light coat of engine oil.
a-Jam Nut
b -Adjustable Installer
c -Arched Base
d-Piston
e -Connecting Rod
f -Piston Pin
g -Rod Support
Installing Piston Pin
3. Position rod onto rod support and piston onto rod
end. Insert piston pin guide thru bottom piston pin
hole and into connecting rod. Place piston pin thru
top side of piston.
4. Adjust adjustable installer to setting specified on
chart (which came with tool) for particular piston
installation. Lock adjustable installer with jam nut.
3A-48 -ENGINE
5. Insert adjustable installer thru hole (located on top
of arched base) and into piston pin hole. Carefully
press on adjustable installer until installer bottomsout
on arched base to install piston pin.
6. Check piston for freedom of movement in piston pin
bores by moving connecting rod back-and-forth
and up-and-down. Connecting rod should move
freely (with no resistance) in both directions. If it
does not, piston pin is tight in piston pin bores and
piston and pin assembly must be replaced.
7. If a new connecting rod has been installed, mark
connecting rod and cap (on side of rod and cap with
slots for connecting rod bearing tangs) with cylinder
number in which it will be installed.
Installation
IMPORTANT: Cylinder bores must be clean before piston
installation. Clean with a light honing, as necessary.
Then clean with hot water and detergent wash.
After cleaning, swab bores several times with light
engine oil and a clean cloth, then wipe with a clean dry
cloth.
1. Lubricate connecting rod bearings and install in
rods and rod caps.
2. Lightly coat pistons, rings and cylinder walls with
light engine oil.
3. With bearing caps removed, install tool J-5239
(3/8") on connecting rod bolts.
a-Connecting Rod Bearing Tangs Toward Outside of Cylinder
Block
Connecting Rods -Installed Position
90-14499--1 887
"Connecting Rod Bearings".
90-1 4499--1 887 ENGINE -3A-49
Installing Connecting Rod and Piston Assemblies
IMPORTANT: Be sure ring gaps are properly positioned
as previously outlined.
4.
Install each connecting rod and piston assembly in
its respective bore. Install with connecting rod
bearing tangs toward outside of cylinder block. Use
tool J-8307 to compress rings. Guide connecting
rod into place on crankshaft journal with tool
J-5239. Use a hammer handle with light blows to
install piston into bore. Hold ring compressor firmly
against cylinder block until all piston rings have
entered cylinder bore.
IMPORTANT: Be sure to install new pistons in same
cylinders for which they were fitted, and used pistons
in same cylinder from which they were removed. Each
connecting rod and bearing cap should be marked,
beginning at front of engine (1, 3, 5 and 7 in left bank
and 2, 4, 6 and 8 in right bank). Numbers on connecting
rod and bearing cap must be on same side when
installed in cylinder bore. If a connecting rod is ever
transposed from one block or cylinder to another, new
bearings should be fitted and connecting rod should
be numbered to correspond with new cylinder number.
5.
Remove tool J-5239.
6.
Install bearing caps and torque nuts to specification.
7. Check connecting rod side clearance.
NOTE: If bearing replacement is required, refer to
('
8.
Install the following items:
a.
Oil Pump
b.
Baffle (if equipped)
c.
Oil Pan
d.
Cylinder Head
9.
Install engine in boat.
10. Fill crankcase with oil.
11. Start engine, adjust timing and check for leaks.
Crankshaft
Removal
1.
Remove engine from boat.
2.
Drain coolant and crankcase oil. Disconnect all
hoses.
3.
Remove starter motor, flywheel housing and flywheel.
Place engine in repair stand.
4.
Remove belts, crankshaft pulley and water pump.
5.
Remove torsional damper and crankcase front
cover.
6.
Remove spark plugs.
7.
Remove camshaft sprocket and timing chain. (Lefthand
rotation engines only.)
8.
Remove oil pan and oil pump.
9.
Make sure all bearing caps (main and connecting
rods) are marked so they can be installed in their
original locations.
10. Remove connecting rod bearing caps, then push
piston and rod assemblies toward heads.
11. Remove main bearing caps and carefully lift crankshaft
out of cylinder block. Remove rear main bearing
oil seal from cylinder block and rear main bearing
cap.
12. 1f new main and/or connecting rod bearings are to
be installed, remove main bearing inserts from
cylinder block and bearing caps, and/or connecting
rod bearing inserts from connecting rod and caps.
Install new bearings following procedures outlined
in this section. (See "Index".)
2. Install a new rear main bearing oil seal in cylinder
block and rear main bearing cap.
3. Carefully lower crankshaft into place. Be careful
not to damage bearing surface.
4. Check clearance of each main bearing, following
procedure outlined under "Main Bearing"; see
"Index". If bearing clearances are satisfactory,
apply a light coat of engine oil to journals and
bearings.
5. Install all bearing caps and bolts. Torque all main
bearing cap bolts to specifications. When tightening
rear main bearing cap. Follow procedure outlined
under "Main Bearing"; see "Index".
6. Check clearance for each connecting rod bearing,
following procedure under "Connecting Rod Bearings";
see "Index". If bearing clearances are satisfactory,
apply a light coat of engine oil to journals
and bearings.
3A-50 -ENGINE
2. Remove camshaft timing chain as outlined.
3. Using tool shown in chart, remove sprocket or gear.
'-....../
350 CID ENGINE J-1619
J-1619 Puller
90-14499--1 887
Cleaning and lnspeciton
1.
Wash crankshaft in solvent and dry with compressed
air.
2.
Measure main bearing journals and crankpin dimensions
with a micrometer for out-of-round, taper or
undersize (see "Specifications").
3.
Check crankshaft for runout (by supporting at front
and rear main bearings journals in "V" blocks) and
check at front and rear intermediate journals with a
dial indicator (see "Specifications").
4.
Replace or recondition crankshaft if not meeting
specifications.
Installation
1.
If a new crankshaft is being installed, proceed as
follows:
a.
Remove timing sprocket or gear from old crankshaft
and reinstall on new crankshaft.
b.
Oni-Drive Engines: Remove flywheel attaching
studs from old crankshaft, using heat if necessary.
Reinstall studs in new crankshaft with Loctite
35 applied to threads.
IMPORTANT: Be sure that all bearings and crankshaft
journals are clean.
7.
Install all rod caps and torque nuts to specifications.
8.
Check crankshaft end play. Follow procedure outlined
under "Main Bearing"; see "Index".
9.
Install oil pump and pan as outlined.
10. 1nstall camshaft sprocket and timing chain. (Lefthand
rotation engines only.)
11. 1nstall crankcase front cover and torsional damper.
12. Remove engine from repair stand and install water
pump, flywheel, flywheel housing and starter
motor.
13.1nstall crankshaft pulley and belts.
14. 1nstall spark plugs.
15. 1nstall
engine in boat, fill crankcase and install
hoses.
Crankshaft Sprocket/Gear
Removal
1.
Remove torsional damper and crankcase front
cover as outlined.
Installation
1.
Using correct tool as shown, install sprocket or
gear.
r--2. Install camshaft timing chain as outlined.
3.
Install crankcase front cover and torsional damper
as outlined.
a-Tool J-5590
305/350 CID Engines
Timing Chain/Sprockets Left
Hand (Standard) Rotation
Engines
Removal
1. Remove torsional damper and crankcase front
cover as outlined.
2.
Crank engine until marks on camshaft and crankshaft
sprockets are in alignment.
3. Remove camshaft sprocket to camshaft bolts.
90-14499--1 887
ENGINE -3A-51
4.
Remove camshaft sprocket and timing chain together.
Sprocket is a light press fit on camshaft. If
sprocket does not come off easily, a light blow on
lower edge of sprocket (with a plastic mallet)
should dislodge the sprocket.
5.
If crankshaft sprocket has to be replaced, remove as
outlined in "Crankshaft Sprocket/Gear".
a -Timing Marks Aligned
b -Locating Pin
305/350 CID Engines Aluminum/Nylon Camshaft
Sprocket
a -Timing Marks Aligned
b -Locating Pin
305/350 CIO Engines All Metal Camshaft Sprocket
Cleaning and Inspection
1.
Clean all parts in solvent and dry with compressed
air.
2.
Inspect timing chain for wear or damage.
3.
Inspect sprockets for wear or damage.
Replacement Part Information
Some engines were originally equipped with link type
timing chain and timing sprockets that have nylon
teeth. If any of these components require replacement,
a new timing chain assembly (35378A 1) must be used.
The timing chain assembly consists of a new roller type
timing chain, an all-metal camshaft timing sprocket
and a new crankshaft timing sprocket. The original
components cannot be used in any combination with
these replacement components.
Installation
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 and
orient to align marks on camshaft and crankshaft
sprockets.
IMPORTANT: Do not attempt to drive sprocket on
camshaft, as welsh plug at rear of engine can be dislodged.
3.
Draw camshaft sprocket onto camshaft, using the 3
mounting bolts. Torque to specifications.
4.
Lubricate timing chain with engine oil. Install crankcase
front cover and torsional damper as outlined.
Checking Timing Chain Deflection
With timing chain and sprockets installed, check timing
chain deflection, as follows:
1.
Rotate camshaft (in either direction) to place tension
on one side of the chain.
2.
Establish a reference point on the block (on taut
side of chain) and measure from this point to the
chain.
3.
Rotate camshaft in the opposite direction to slacken
the chain, then force chain out with fingers and
again measure the distance between reference
point and timing chain.
4.
The deflection is the difference between these two
measurements. If the deflection exceeds specifications,
timing chain should be replaced.
a-Reference Point
Checking Timing Chain Deflection
3A-52 -ENGINE
·.. · .. --., .;-:_,.,.;,.y.;·. ,
90-1 4499--1 887
Timing Gears Right-Hand
(Opposite) Rotation Engines
f' Removal
·.. ""--../
1.
Remove oil pan, torsional damper and crankcase
front cover as outlined.
2.
Crank engine over until timing mark on camshaft
timing gear aligns with timing mark on crankshaft
timing gear.
a -Timing Marks
b-Screws
c-Locating Pin
Timing Marks Aligned
3.
Remove camshaft timing gear attaching screws
(and washers if so equipped) and remove gear. If
gear does not come off easily, a light blow on the
lower edge of the gear with a plastic mallet should
dislodge the gear.
4.
If crankshaft timing gear requires replacement,
remove as outlined in "Crankshaft Sprocket/Gear"
(see "Index").
Cleaning and Inspection
1.
Clean all parts in solvent and dry with compressed
air.
2.
Inspect timing gears for worn or damaged teeth.
3.
Inspect camshaft gear to cylinder block contact
surfaces for damage.
Installation
1.
If removed, install crankshaft timing gear as outlined
in "Crankshaft Sprocket/Gear".
('
2.
Position camshaft timing gear so that timing mark
aligns with timing mark on crankshaft timing gear,
then align camshaft dowel with hole in camshaft
gear and install gear on camshaft.
3.
Install 3 camshaft timnig gear attaching screws
(and washers if so equipped) and draw sprocket
onto camshaft. After sprocket is in place, torque
screws to specifications.
IMPORTANT: Do not attempt to drive gear on camshaft,
as welsh plug at rear of engine can be dislodged.
4.
Check timing gear backlash and runout as explained
under "Checking Backlash and Runout".
5.
Lubricate timing gears with engine oil.
6.
Install crankcase front cover, oil pan and torsional
damper as explained.
Checking Backlash and Runout
1.
Remove fuel pump and fuel pump push rod.
2.
Loosen rocker arm nuts (to relieve tension on
hydraulic valve lifters).
3.
With timing gears installed, check camshaft to
crankshaft gear backlash, as follows:
a.
Mount a dial indicator on engine so that indicator
stem contacts one of the teeth on camshaft
gear. Indicator stem should be as perpendicular
to gear tooth surface as possible.
b.
Check the backlash between the camshaft gear
and crankshaft gear while applying inward pressure
on camshaft gear.
c.
If backlash is not within specifications, check for
improperly machined parts or for worn camshaft
or crankshaft bearings. If bearings check out
good, replace both timing gears.
Checking Backlash
90-14499--1 887
ENGINE -3A-53
4. With timing gear installed, check camshaft and
crankshaft timing gear runout, as follows:
a. Mount dial indicator on block so that indicator
stem is perpendicular to camshaft timing gear
and contacts gear surface just adjacent to teeth.
b. Apply inward pressure on timing gear and zero
indicator, then turn crankshaft as shown. Check
gear runout through one complete revolution of
camshaft gear.
c. If not within specifications, check for burrs or
foreign material between gear and camshaft
joining surfaces. If none is found, replace both
timing gears.
d. Check crankshaft timing gear runout in same
manner. Runout should not exceed specifications.
Replace both gears, if run out is excessive.
5. Adjust rocker arm nuts.
6. Install fuel pump push rod and fuel pump.
a -Turn Crankshaft In This Direction
Checking Gear Runout
3A-54 -ENGINE
Camshaft
Measuring Lobe Lift
NOTE: Procedure is similar to checking valve timing. If
improper valve operation is indicated, measure lift of
each push rod in consecutive order and record
readings.
1. Remove valve mechanism as outlined.
2. Position indicator with ball socket adapter Tool J-
8520-1 on push rod. Be sure that push rod is in lifter
socket.
Measuring Camshaft Lobe Lift
3. Rotate crankshaft damper slowly in direction of
rotation until lifter is on heel of cam lobe. At this
point, push rod will be in its lowest position.
4. Set dial indicator on zero, then rotate balancer
slowly (or attach an auxiliary starter switch and
"bump" engine over) until push rod is in fully raised
position.
5. Compare total lift, recorded from dial indicator,
with "Specifications".
6. Continue to rotate engine until indicator reads zero.
This will be a check on accuracy of original indicator
reading.
7. If camshaft readings for all lobes are within specifications,
remove dial indicator assembly.
8. Install and adjust valve mechanism as outlined.
90-14499--1 887
Removal
1.
Remove valve lifters as outlined.
2.
Remove crankcase front cover as outlined.
3.
Remove fuel pump and fuel pump push rod.
4.
Remove camshaft as follows:
MCM and MIE L.H. Rotation Engines:
a.
Refer to "Timing Chain/Sprockets, Left-Hand
(Standard) Rotation Engines" to remove chain
and sprocket.
b.
Install two 5/16-18 bolts in camshaft sprocket
bolt holes and carefully remove camshaft.
Removing Camshaft
MIE R.H. Rotation:
a.
Refer to "Timing Gears, Right-Hand (Opposite)
Rotation Engines" to remove timing gear.
b.
Install two 5/16-18 bolts in camshaft gear bolt
holes and carefully remove camshaft.
Inspection
Measure camshaft bearing journals with a micrometer
for out-of-round condition. If journals exceed .001 "
(.025mm) out-of-round, camshaft should be replaced.
Also check camshaft for alignment with "V" blocks and
dial indicator which indicates exact amount camshaft
is out-of-true. If out more than .002" (.051 mm) (dial
indicator reading) camshaft should be replaced.
On engines with timing gears, inspect camshaft gear
and thrust plate for wear or damage.
Checking Camshaft Alignment
Installation
1.
Install camshaft as follows:
MCM and MIE L.H. Rotation Engines:
a.
Install two 5/16-18 bolts in camshaft bolt holes,
then lubricate camshaft journals with engine oil
and install camshaft, being careful not to damage
bearings. Remove the two 5/16-18 bolts.
b.
Install timing chain and sprocket as outlined in
"Timing Chain/Sprockets, Left-Hand (Standard)
Rotation Engines".
MIE R.H. Rotation Engines:
a.
Install two 5/16-18 bolts in camshaft bolt holes,
then lubricate camshaft journals with engine oil
and install camshaft, being careful not to damage
bearings. Remove the two 5/16-18 bolts.
b.
Install timing gear as outlined in "Timing Gears,
Right-Hand (Opposite) Rotation Engines".
2. Lubricate camshaft drive system with engine oil.
3. Install fuel pump push rod and fuel pump.
4.
Install crankcase front cover and valve lifters as
outlined.
90-1 4499--1 887
ENGINE -3A-55
Camshaft Bearings
Removal
Camshaft bearings can be replaced while engine is
disassembled for overhaul or without complete disassembly.
To replace bearings without complete disassembly,
remove camshaft and crankshaft, leaving cylinder
heads attached and pistons in place. Before
removing crankshaft. Fasten connecting rod against
sides of engine so that they will not interfer while
replacing camshaft bearings.
1.
With camshaft and crankshaft removed, drive camshaft
rear plug from cylinder block.
NOTE: This procedure is based on removal of bearings
center of engine first, thus requiring a minimum
amount of turns to remove all bearings.
2.
Using tool set J-6098-01 (with nut and thrust washer
installed 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.
4.
Using 2 wrenches, hold puller screw while turning
nut. When bearing has been pulled from bore,
remove tool and bearing from puller screw.
5.
Remove remaining bearings (except front and rear)
in same manner. It will be necessary to position
pilot in rear camshaft bearin g to remove rear inter
_
mediate bearing.
Replacing Camshaft Bearings
6.
Assemble remover tool on driver handle and remove
front and rear camshaft bearings by driving
toward center of cylinder block.
Replacing Front and Rear Camshaft Bearings
Inspection
Clean camshaft bearing bores in cylinder block with
......____,
solvent and blow out with compressed air. Be sure
grooves and drilled oil passages are clean.
Installation
Front and rear bearings must be installed last as pilot
will not fit into bearing bores if bearings are installed.
3A-56 -ENGINE
90-1 4499--1 887
(
Lubricate outer surface of new camshaft bearings with
engine oil to ease installation.
IMPORTANT: All camshaft bearings are not the same.
Be sure to install bearing in proper location (indicated
by bearing manufacturer) and to position bearings as
follows: (Directional references are in reference to
engine in its normal operating position.)
•
Front bearing must be positioned so that oil holes
are equal distance from 6 o'clock position in the
block. Intermediate and center bearings must be
positioned so that oil holes are at the 5 o'clock
position (toward left side of block and at a position
even with bottom of cylinder bore). Rear bearing
must be positioned so that oil hole is at the 12
o'clock position.
Cylinder Block
Cleaning and Inspection
1.
Remove all engine components as previously outlined.
2.
Wash cylinder block thoroughly in cleaning solvent
and clean all gasket surfaces.
3.
Remove oil gallery plugs and clean all oil passages.
NOTE: These plugs may be removed with a sharp
punch, or they may be drilled and pried out.
4.
Clean and inspect water passages in cylinder block.
5.
Inspect cylinder block for cracks in cylinder walls,
water jacket valve lifter bores and main bearing
Installing Intermediate and Center Bearings:
webs.
Install nut and thrust washer all-the-way onto
puller screw, then position pilot in front camshaft
bearing bore and insert screw thru pilot.
Index center camshaft bearing, then position
appropriate size remover and installer tool in
bearing and thread puller screw into tool. Be
sure at least 1/2" (13mm) of threads are engaged.
6.
Measure cylinder walls for taper, out-of-round or
excessive ridge at top of ring travel. This should be
done with a dial indicator or inside micrometer.
Carefully work gauge up and down cylinder to
determine taper and turn it to different points
around cylinder wall to determine out-of-round
condition. If cylinders exceed specifications, boring
and/or honing will be necessary.
c.
Using 2 wrenches, hold puller screw and turn
nut until bearing has been pulled into position.
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 camshaft bearing
bore to install rear intermediate bearing.
2.
Installing Front and Rear Bearings:
a.
Install appropriate size remover and installer
tool on drive handle.
b.
Index front bearing (as explained in "lmportant"),
and drive it into position with tool. Check
position of oil hole(s) in bearing to ensure bearing
is positioned correctly.
-Center Line of Engine
"A" = At right angle to centerline of engine
"B" = Parallel to centerline of engine
"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.
Cylinder Measurement
Install rear bearing in same manner, being sure
to index bearing correctly.
3.
Install a new camshaft rear plug.
IMPORTANT: Plug must be installed flush to 1/32"
(.8mm) deep and must be parallel with rear surface of
cylinder block.
4.
Install crankshaft and camshaft as outlined.
90-14499--1 887
ENGINE -3A-57
Measuring Cylinder Bore
Measuring Cylinder Bore
7.
Check cylinder head gasket surfaces for warpage
with a machinists straight edge and a feeler gauge,
as shown Take measurements diagonally across
surfaces (both ways) and straight down center. If
surfaces are out-of-flat more than .003" (.07mm) in
a 6" area or .007" (.2mm) overall, block must be
resurfaced by an automotive machine shop.
a -Machinists Straight Edge
b -Feeler Gauge
c -Take Measurements Diagonally Across Surface and Straight
Down Center
Checking Cylinder Head Gasket Surfaces for Warpage
Repairs
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" (.127mm) taper or
wear, they can be conditioned with a hone and fitted
with high limit standard size piston. A cylinder bore
of less than .005" wear or taper may not clean up
entirely when fitted to a high limit piston. To entirely
clean up the bore, it will be necessary to rebore for
an oversize piston. If more than .005" taper or wear,
bore and hone to smallest oversize that will permit
complete resurfacing of all cylinders.
4.
When pistons are being fitted and honing is not
necessary, cylinder bores may be cleaned with a
hot water and detergent wash. After cleaning, swab
cylinder bores several times with light engine oil
and a clean cloth, then wipe with a clean dry cloth.
3A-58 -ENGINE
90-14499--1 887
CYLINDER BORING
1.
Before using any type boring bar, file off top of
cylinder block to remove dirt or burrs. This is very
important to prevent boring bar tilt, with result that
rebored cylinder wall is not at rightangles to crankshaft.
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 diameter
as piston and hone to give specified clearance.
NOTE: Hone cylinders as outlined under "Cylinder
Honing" and "Piston Selection", following.
3.
Carefully observe instructions furnished by manufacturer
of equipment being used.
CYLINDER HONING
1.
Follow hone manufacturer's recommendations for
use of hone and cleaning and lubrication during
honing.
2.
Occasionally, during the honing operation, thoroughly
clean cylinder bore and check piston for
correct fit in cylinder.
3.
When finish-honing a cylinder bore to fit a piston,
move hone up-and-down at a sufficient speed to
obtain very fine uniform surface finish marks in a
cross-hatch pattern of approximately 30° 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 cylinder 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 extremely
essential that a good cleaning operation be performed.
If any abrasive material remains in cylinder
bores, it will rapidly wear new rings and cylinder
bores in addition to bearings lubricated by the contaminated
oil. Swab bores several times with light
engine oil on a clean cloth, then wipe with a clean
dry cloth. Cylinder should not be cleaned with
kerosene or gasoline. Clean remainder of cylinder
block to remove excess material spread during honing
operation.
PISTON SELECTION
1.
Check used piston to cylinder bore clearance as
follows:
a.
Measure "cylinder bore diameter" with a telescope
gauge 2-1/2" (64mm) from top of cylinder
bore.
b.
Measure "piston diameter" at skirt across center
line of piston pin.
c.
Subtract piston diameter from cylinder bore
diameter to determine "piston-to-bore clearance".
d.
Determine if "piston-to-bore clearance" is in
acceptable range shown in "Specifications".
2.
If used piston is not satisfactory, determine if a new
piston can be selected to fit cylinder bore within
acceptable range.
3.
If cylinder bore must be reconditioned, measure
new piston diameter (across centerline of piston
pin), then hone cylinder bore to correct clearance
(preferable range).
4.
Mark piston to identify cylinder for which it was
fitted.
Measuring Cylinder Bore
90-1 4499--1 887
ENGINE -3A-59
Measuring Piston
Replacement Part Information
If replacement of cylinder block is necessary, the following
must be performed:
1. Retain double-ended main bearing cap attaching
screws (used to support oil splash plate) for use
with new engine. New engines are shipped with
regular (single-ended) bolts only.
2. Retain oil filter by-pass valve and adaptor assembly
and related parts for use with new engines.
3. If engine being replaced has a remote oil filter,
check the cylinder block being replaced to determine
method used to attach oil hoses to cylinder
block Refer to "Oil Filter By-Pass Valve and Adaptor
Assembly". If it uses the older style adaptor that is
secured to the block with one 1/2-13 bolt, a Remote
Oil Filter Adaptor Kit (90783A9) is required to adapt
the remote oil filter to new block. All new blocks are
machined to accept new style oil hoses to cylinder
block adaptor which is secured to block with two
5/16-18 screws.
3A-60 -ENGINE
Oil Filter By-Pass Valve and
Adaptor Assembly
52731
14527
Oil Filter By-Pass Valve and Adapator Assembly for
Engines with Block Mounted Oil Filter
90-14499--1 887
a-One 1/2"-13 Adaptor Attaching Bolt
14529
a-Two 5/16"-18 Adaptor Attaching Bolts
14528 Engines With Remote Oil Filter Adaptor (5/16"-18) Bolt
Engines With Remote Oil Filter Adaptor (1/2"-13) Bolt
90-14499--1 887 ENGINE -3A-61
Inspection and/or Replacement
Oil by-pass valve and adaptor assembly should be
inspected whenever engine is disassembled for major
repair or whenever inadequate oil filteration is suspected.
Refer to "Engine Parts List" when ordering parts for oil
filter by-pass valve, adaptor assembly or remote oil
filter parts.
1.
Remove oil filter (on engines with block mounted
filter) or cylinder block adaptor (on engines with
remote oil filter) and remove by-pass valve and
adaptor assembly.
2.
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 questionable, bypass
valve and adaptor assembly should be replaced.
4.
Wipe out valve chamber in cylinder block to remove
any foreign material.
5.
Install by-pass valve and adaptor assembly and oil
filter or cylinder block adaptor and secure as
shown. Be sure to torque bolts or screws to specifications.
a-Fiber Valve (Be Sure Valve Fits Tightly Against its Seat)
Typical By-Pass Valve and Adaptor Assembly
. ..
3A-62 -ENGINE
90-14499--1 887
Remote Oil Filter Kit
(92043A2) Installation
Instructions
IMPORTANT: Retain existing parts unless stated otherwise.
IMPORTANT: If installing kit on engine equipped with
2 studs (16-34713) must be ordered.
A CAUTION
Water MUST BE drained from exhaust manifold to prevent
water from entering combustion chamber when
hose is removed.
MODIFY PORT EXHAUST ELBOW
1.
If equipped with standard cooling system, remove
hose clamp, hose and straight fitting from front of
exhaust elbow. Discard fitting only. If equipped
with Closed Cooling System, proceed with Step 2.
2.
Coat threads of 45° fitting (from kit) with Quicksilver
Perfect Seal.
3.
Insert fitting in elbow opening and tighten securely.
Position fitting to point toward engine. Replace
hose and tighten hose clamp.
4.
Remove front 2 exhaust elbow attaching nuts,
washers and studs. Discard studs.
..
90-1 4499--1 887 ENGINE -3A-63
MODIFY OIL FILTER OPENING IN
CYLINDER BLOCK
1.
Remove and discard existing filter, 2 screws and
filter valve.
INSTALL REMOTE OIL FILTER
ASSEMBLY
1.
Remove oil filter adaptor cover and mount adaptor
body with 2 screws provided. Be sure cover seal and
adaptor "0" ring are in place. Torque to 20-25 1bs. ft.
(27-34 N.m).
2.
Route hoses up and between exhaust manifold and
engine.
A CAUTION
Hoses must not contact hot spots on exhaust manifold.
3.
Install oil filter bracket on front of exhaust elbow.
Where elbow is fastened to manifold or 6" (152mm)
riser, use 2 screws (from kit) and original washers.
Discard original nuts. Torque to 20-25 1bs. ft. (27-34
N.m).
NOTE: If installing kit on engine equipped with 3"
(76mm) risers and replacement studs, use original
washers and nuts. Discard 2 screws from kit.
4.
Run engine until warm. Stop engine and wait 5
minutes. Check crankcase oil level and add oil if
necessary.
ENGINE
V-8 GM 454/482/540 CID
Index
Page Page
Torque Specifications ....................... 38-1
Tools/Lubricants/Sealants ................... 38-3
Engine Specifications ........................ 38-5
General ..................................... 38-11
Engine Identification ..................... 38-11
Engine Rotation .......................... 38-12
Crankshaft ............................... 38-12
Piston and Connecting Rods .............. 38-12
Camshaft and Drive ...................... 3B-12
Cylinder Head ............................ 3B-12
Valve Train ............................... 3B-12
Intake Manifold .......................... 3B-13
Lubrication System ....................... 3B-13
Bearing Failures ............................. 3B-14
Piston Failures .............................. 3B-14
Pre-Ignition .............................. 3B-14
Detonation ............................... 38-15
Front Mount-MCM 330 (B-W) ............... 3B-16
Rear Mount/Tailstock Assembly-
MCM 330 (B-W) .......................... 3B-16
Flywheel Housing-MCM 330 (B-W) .......... 3B-16
Mounting Plates-MCM Production
Performance ............................. 3B-17
Mounting Plates for Staggered Engines-
MCM Production Performance ............ 3B-18
Flywheel Housing -MCM 370/Production
Performance ............................. 3B-19
Rear Mount/Tailstock Assembly-MCM
Production (Some Models) ................ 3B-19
Front/Rear Mounts-MIE 340/7.4 Litre
In-Line Transmission Engines ............. 3B-19
Front/Rear Mounts-MIE 340/7.4 Litre
V-Drive Engines .......................... 3B-20
Flywheel Housing-MIE 340/7.4 Litre 3B-20
Engines .................................. 3B-21
Intake Manifold ............................. 3B-21
Rocker Arm/Push Rod ....................... 3B-23
Adjustment-Engine Stopped ............. 3B-24
Adjustment-Engine Running ............. 3B-25
Hydraulic Valve Lifters ....................... 3B-26
Locating Noisy Lifters .................... 3B-27
Removal ................................. 3B-27
Disassembly ............................. 3B-27
Cleaning and Inspection .................. 3B-28
Reassembly .............................. 3B-28
Installation ............................... 3B-29
Valve Stem Oil Seal/Valve Spring ............. 38-29
Cylinder Head ............................... 3B-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-30
.1··
Cleaning and Inspection .................. 3B-30
Installation ............................... 3B-30
Cylinder Head and Valve Conditioning ........ 3B-31
Disassembly ............................. 3B-31
Cleaning ................................. 3B-31
Inspection ............................... 3B-32
Valve Guide Bore Repair .................. 3B-33
Valve Seat Repair ......................... 3B-33
Valve Repair ............................. 3B-34
Reassembly .............................. 3B-35
Oil Pan ..................................... 3B-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-35
Installation ............................... 3B-35
Oil Pump ................................... 3B-36
Removal ................................. 3B-36
Disassembly ............................. 3B-36
Cleaning and Inspection .................. 3B-37
Reassembly .............................. 3B-37
Installation ............................... 3B-37
Torsional Damper ........................... 3B-37
Crankcase Front Cover/Oil Seal .............. 3B-38
Oil Seal Replacement (without
Removing Front Cover) . . . . . . . . . . . . . . . . 3B-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39
Installation ............................... 38-39
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-41
Oil Seal (Rear Main) . . . . . . . . . . . . . . . . . . . . . . . . . 3B-42
Main Bearings............................... 3B-44
Inspection ............................... 3B-44
Checking Clearance . . . . . . . . . . . . . . . . . . . . . . 3B-44
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-46
With Crankshaft Removed ............. 3B-46
Without Crankshaft Removed . . . . . . . . . . 3B-46
Connecting Rod Bearings................... . 3B-46
Inspection and Replacement .............. 3B-47
Connecting Rod/Piston Assembly ............ 3B-48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-48
Disassembly ............................. 3B-48
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 3B-49
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-50
Installation............................... 3B-53
ENGINE -38
90-1 4499--1 887
Page
Crankshaft .................................. 3B-54
r Removal ................................. 3B-54
Cleaning and Inspection .................. 3B-54
Installation ............................... 3B-54
Crankshaft Sprocket/Gear ................... 3B-55
Timing Chain/Sprockets-Left Hand
Rotation ................................. 3B-56
Removal ................................. 3B-56
Cleaning and Inspection .................. 3B-56
Installation ............................... 3B-56
Checking Timing Chain Deflection ........ 3B-56
Timing Gears-Right-Hand Rotation .......... 3B-57
Removal ................................. 3B-57
Cleaning and Inspection .................. 3B-57
Installation ............................... 3B-57
Checking Backlash and Runout ........... 3B-58
Camshaft ................................... 3B-59
Measuring Lobe Lift ...................... 3B-59
Removal ................................. 3B-60
Inspection ............................... 3B-60
Installation ............................... 3B-60
Camshaft Degreeing ...................... 3B-61
OffsetBushing Installation ................ 3B-62
Camshaft Bearings .......................... 38-63
Removal ................................. 3B-63
Inspection ............................... 38-63
Installation ............................... 38-63
Cylinder Block .............................. 38-64
Cleaning and Inspection .................. 38-64
Repairs .................................. 3B-65
Replacmeent Part Information ............. 38-66
Oil Filter By-Pass Valve and Adaptor
Assembly ................................ 3B-67
Inspection and/or Replacement ........... 3B-68
Remote Oil Filter Adaptor Kit (90783A9)Installation
Instructions ................... 3B-69
Remote Oil Filter Kit (92043A2)
Installation Instructions ................... 38-70
NOTICE
The repair procedures in this manual can be
used for repairing Production Performance
engines. It is recommended that only mechanics
familiar with hi-performance engines attempt
the repairs.
ENGINE -38
90-1 4499--1 887
Torque Specifications
Fastener Location
454 CID (Standard) 454/482/540 CID Production Performance
Lbs. Ft. (N.m) Lbs. ln. (N.m) Lbs. Ft. (N.m) Lbs. ln. (N.m)
Alternator Brace to Alternator 192 (28) 192 (28)
Alternator Brace to Block 30 (41 ) 30 (41 )
Alternator to Mounting Bracket 35 (48) 35 (48)
Alternator Mounting Bracket 30 (41 )
25 (34)
30 (41 )
25 (34) Camshaft Sprocket
Camshaft Thrust Plate Screws
(R.H. Only)
96 (1 1)
Carburetor 132 (15) 132 (15)
Connecting Rod Cap 50 (68)
Connecting Rod Cap
(370/400/440/475)
65 (88)
Connecting Rod Cap
(460)
90 (122)
Crankshaft Damper 85 (1 15) 85 (1 15)
Crankshaft Pulley 35 (48) 35 (48)
Cylinder Head (Except 482) 80 (109) 80 (109)
Cylinder Head (482) 75 (1 02)
Distributor Hold Down 25 (34) 25 (34)
Exhaust Manifold 20 (27)
Exhaust Manifold (Bolts) 35 (48)
Exhaust Manifold (Nuts) 25 (34)
Flywheel 65 (88) 70 (95)
Flywheel Drive Plate 35 (48) 35
Flywheel Housing to Block 30 (41 ) 30 (41 )
Flywheel Housing Cover 80 (9) 80 (9)
Front Mount Bracket 30 (41 ) 30 (41 )
Fuel Pump 20 (27) 20 (27)
Intake Manifold 30 (41 ) 35 (48)
Main Bearing Cap 11 0 (1 49) 11 0 (149)
Oil Filter Bypass Valve 80 80
ENGINE -38-1
90-1 4499--1 887
454/482/540 CID Production
454 CID (Standard) Performance
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m) Lbs. Ft. (N.m) Lbs. ln. (N.m)
Oil Pan Plug 20 (27) 20 (27)
Oil Pan Screw (1/4"-20) 80 (9) 80 (9)
Oil Pan Screw (5/1 6"-18) 165 (19) 165 (19)
Oil Pump 65 (88) 65 (88)
Oil Pump Cover 80 (9) 80 (9)
Power Steering Pump Brace
30 (41 ) 30 (41 ) to Block
Power Steering Pump Bracket 30 (41 ) 30 (41 )
Rear Mount Bolts (MCM) 40 (54) 100 (1 36)
Rear Mounts (M IE) 50 (68) 50 (68)
Remote Oil (1/2"-1 3) 25 (34) 25 (34)
Filter Adaptor (5/16"-18) 20 (27) 20 (27)
Rocker Arm Cover 50 (5.5) 50
Rocker Arm Studs 50 (68) 70 (95)
Seawater Pump Brace 30 (41 ) 30 (41 )
Seawater Pump Bracket 30 (41 ) 30 (41 )
Spark Plugs 180 (20) 180 (20)
Starter Motor 50 (68) 50 (68)
Thermostat Housing 30 (41 ) 30 (41 )
Timing Chain or Gear Cover 80 (9) 80 (9)
Transmission to Housing 50 (68) 50 (68)
Water Circulating Pump 30 (41 ) 30 (41 )
Water Temp. Sender 20 (27) 20 (27)
. . .: ;:'
38-2 -ENGINE 90-1 4499--1 887
Tools/Lubricants/Sealants
MERCURY MARINE SPECIAL TOOLS
91 -24697 Piston Expanders
91 -35547 Coupler Wrench
91 -66273 Rocker Stoppers
KENT -MOORE SPECIAL TOOLS
Kent-Moore Tools, Inc.
29784 Little Mack
Roseville, Ml 48066
Phone: (313) 774-9500
J5892 Valve Spring Compressor
J8062 Valve
J8056 Valve Spring Tester
J8101 Valve Guide Cleaner
J5830-2 Valve Guide Reamer
J7049-5 Valve Guide Reamer Set
J5802-01 Rocker Arm Stud Remover
J6880 Rocker Arm Stud Installer
J571 5 Rocker Arm Stud Hole Reamer
(.003" O.S.)
J6036 Rocker Arm Stud Hole Reamer
(.013" O.S.)
J8089
Carbon Remover Brush
J24086-1 00
Piston Pin Tool
J3936-03
Piston Ring Groove Cleaner
J8037
Piston
J5239
Connecting Rod Bolt Guide Set
(3/8" Bolts)
J6098-01 Camshaft Bearing Remover and
Installer Tool
J23523-E Harmonic Balancer Removal and
Installer Tool
J22102 Crankcase Front Cover Seal Installer
J21058-20 Crankshaft Gear Installer
Mills Specialty Products
320 E. Jackson St.
Freeport, IL 61032
Phone: (815) 235-7946
CC2778 Cam-Check
6005 Crank Snout Socket
D100 8" Degree Wheel
241 6 Dial Indicator
MR Gasket Company
8700 Brookpark Rd.
Cleveland, OH 441 29
Phone: (21 6) 398-8300
85 Off-Set Bushing (Kit)
1591 Timing Tape
LUBRICANTS/SEALANTS
92-32609-1 Quicksilver Loctite
92-34227 Quicksilver Perfect
92-42649A1 Quicksilver Needle Bearing
Lubricant
92-91 601-1 Quicksilver RTV Sealer
90-14499--1 887 ENGINE -38-3
2"
16-32808
B
11 -33962
5/8" Hex ESNA
1-7/8" ____,
16-98532 c
IMPORTANT: DO NOT intermix stud/nut combinations.
A
11 -98533
5/8" Hex Crownlock
d -See Figure 2 for Coupler Wrench Modification
Figure 1. Engine Coupler/Flywheel
11/16" Hex
Crownlock
a-45 Lbs. Ft. (61 N.m)
b-35 Lbs. Ft. (42 N.m)
c-40 Lbs. Ft. (54 N.m)
Engine Coupler Wrench, 91-35547, may not work on
the later couplers. Modify wrench as shown in Figure 2,
so it will work on both earlier and later style couplings.
230-H
d-Heat and Bend as Shown (This is What Wrench Should Look
Like When it's Done)
Figure 2. Modifying Engine Coupler Wrench
a-Original 91-35547 Wrench
b -Heat and Bend as Shown
c -Grind Area Shown Slightly
3B-4 -ENGINE 90-14499--1 887
Engine Specifications
UNIT OF MEASUREMENT
in (mm)
Bore
Stroke
Cubic Inch
Displacement
Compression
Ratio
Heads
Intake
Manifold
Block Note 1
Rods
Pistons
Crankshaft
Rocker Arms
330 8/W
MCM
454 MCM
Magnum
Alpha
454
7.4 340 Magnum MCM
Litre MIE Bravo 420
4.25 (1 07.95)
4.00 (.101 .6)
400 MCM 440 MCM 460 MCM
Cyclone Cyclone Cyclone
4.25
(1 07.95)
454 (Standard) 454 (7.5L) 482 (7.9L)
(7.5L)
Production Performance ..aps:t 8.6:1 8.8:1 9.2:1
Cast Iron Cast Iron
(Oval Port) (Rectangle Ports)
Cast Iron Aluminum Hi-Rise
Cast Iron Cast Iron
(2 bolt main bearing caps) (4 bolt main bearing caps)
Special
Forged Steel Forged Steel Forged
Steel
Custom
Cast Aluminum Forged Aluminum Forged
575MCM
4.44
(1 13)
4.375
(1 11)
540
8.75:1
Aluminum
Custom
Cast Iron Forged Steel Forged
Steel
Stamped Steel Aluminum Roller
NOTE 1: Some 1988 standard blocks may have 4 bolt main bearing caps.
90-14499--1 887 ENGINE -38-5
Engine
454 CID
(Standard)
454 CID 482 CID 540 CID
Production Performance
Cylinder Bore:
4.2495 -4.2525 4.2451 -4.2525 4.440-4.442
Diameter (1 07.9373 (
1 07.8255 (
1 1 2.776108.01
35) 108.01 35) 11 2.826)
Out of Production .001 (.025) Max.
Round Service .002 (.05) Max.
Thrust
.0005 (.01 27) Max.
Produc-Side
Taper tion Relief
Side
.001 (.025) Max.
Service .001 (.025) Max. .005 (.127)
Piston:
Production .0014 -.0024 .0045 -.0065 .0055 -.0065 .0075
(.0356 -.0610) (.11 43 -.1 651 ) (.1397 -.1651 ) (.1 905)
Clearance
Service .0035 (.09) .0075 (.1 5) Max.
.0095
Max. (.2413)
Piston Ring:
Top
.0017-.0032 (.04 -.08)
Groove Produc-
Side tion 2nd
.0017 -.0032 (.04 -.08)
Clearance
c
0
.0027-.0042
Service
Hi Limit Production + .001 (.025)
(.06868-.1 0678)
UJ
UJUJ
Q)
....
Q.
.010 -.020 (.25 -.5)
Top
Produc-E
0
Gap tion
.010 -.020 (.25 -.5)
2nd
()
Service
.020-.030
Hi Limit Production + .010 (.25)
(.508-.762)
Groove Production
.005 -.0065 (.127 -.165)
Side
.001 5-.0075
ServiceClearance
Hi Limit Production + .001 (.025)
(.0381 -.1905)
-
6
.01 5-.055
.020 -.035
Production
.015 -.055 (.35
(.381-1 .397)
(.5 -.85)
Gap
.025-.065
Service
Hi Limit Production + .010 (.25)
(.635-1 .651 )
Piston Pin:
Diameter .9895 -.9898 (25.1333 -25.1 409)
.990
(25.246)
Production
Clearance
Service
.00025 -.00035 (.00635 -.00889)
.001 (.02) Max.
.001 -.001 5
(.02 -.0366)
.008-.001
(.203-.0254)
.001-.001 2
(.0254-.0305)
Fit in Rod (Note 1) .0008 -.0016 (.0203 -.0406) Interference .0006 -.001
(.015 -.02)
.001 3-.001 5
(.0330-.0381)
1.
482/540 CID Production Performance engines have floating piston pins. The pins are secured by two snap rings
inserted in grooves in each side of the piston.
38-6 -ENGINE
90-1 4499--1 887
454 CID 454 CID 482 CID 540 CID
Engine (Note 1) (Standard) Production Performance
Crankshaft:
No. 1
2.7485 -2.7494 2.748-2.749
(69.81 19 -69.8348) (69.81 95-69.8246
Diameter No. 2, 3, 4
2.7481 -2.7490 2.748-2.749
(69.8017 -69.8246) (69.81 95-69.8246) -CCIc: 2.7478 -2.7488 2.745-2.748 .... No. 5 ::::J (69.7941 -69.81 95) (69. 723-69. 799) 0""')c: Production .0002 (.0051 ) Max. .0005 (.01 27) CCI Taper.. Service .001 (.025) Max. .001 (.025)
Out of Production .0002 (.0051 ) Max. .0005 (0.1 27)
Round Service .001 (.025) Max. .001 (.025)
No. 1, 2, .001 3 -.0025 .002 -.0035 .0025-.003 Q) 3, 4 (.0330 -.0635) (.05 -.08) (.0635-.0762) uc: Production CCI .0024 -.0040 .003 -.004 .0035-.004 ....CCI No. 5
(.07 -.09) (.0889-.1 01 6) Q) (.0610 -.1016) 0 Ol No. 1 .001 -.001 5 (.03)
.0025-.0035 c: (.0635-.0889) ....CCIQ) .0025-.0035 Ill Service .001 -.0025 (.03 -.06) c: No. 2, 3, 4 (.0635-.0889) CCI.. .0035-.0045
No. 5 .0025 -.0035 (.07 -.08)
(.0889-.1143)
Crankshaft End Play .006 -.01 0 (.15 -.25)
.007 -.01 0
(.1 778 -.2540)
2.1985 -2.1995 (55.841 9-55.8673)
2.1 980-2.1 990 "0 Diameter (55 .8292-55.8546) 0a: .0005 (.01 27) Max. .005 ( .01 27) Ol Production c: Taper
Service .001 (.025) Max. .001 (.025) u-Q) CCIc: c: Production .0005 (.01 27) Max. .005 (.01 27) c: .... Out of 0 ::::J0.. Round Service .001 ( .025) Max. .001 (.025)
.0009 -.0025 (.0229 -.0635)
.0025 -.0035 .0025-.0030
Rod Bearing Production (.07 -.08) (.0635-.0762)
Clearance .0025-.0035
Service .003 (.07) Max.
(.0635-.0889)
Rod Side Clearance .01 3-.023 (.35 -.55) .010 -.020 .025
(.25 -.50) (.0635)
Crankshaft Runout .001 5 (.0381 ) Max.
.0005-.0015
(.01 27-.0381 )
90-14499--1 887 ENGINE -38-7
NOTE: 440/460 cyclone and 575 crankshafts are fully polished for added strength and added oil clearance.
Engine CID
454 CID
(Standard)
454 CID 482 CID
Production Performance
540 CID
Engine Model
MCM 330 (B-W)
7.4 Litre
454 Magnum
MIE 340
454 Magnum (Bravo)
MCM 370 400 440
(cyclone)
460
(cyclone)
MCM
575
HP 575
Camshaft and Drive:
Lobe Lift Intake
± .002 (.051 ) Exhaust
.271 (6.883) .300 (7.62) .294 (7.468) .31 2 (7.925) .323 (8.204) .363 (9.227)
.282 (7.163) .300 (7.62) .294 (7.468) .324 (8.230) .328 (8.331 ) .375 (9.53)
Duration
Intake
Exhaust
350° Note 1
352° Note 1
.224° Note 2
.224° Note 2
356° Note 1
352° Note 1
298° Note 2
306° Note 2 (..,;.. 288° Note 2
296° Note 2
292° Note 2
300° Note 2
Journal Diameter 1.9482 -1.9492
(49.484 -49.510)
Journal Out-of-Round .001 (.025) Max.
Camshaft Runout .002 (.051 ) Max.
Timing Chain Deflection
[L.H. (Standard) Rotation
Engines Only]
3/8 (10) From Taut Position [3/4 (19) Total]
Camshaft End Play
[R.H. (Opposite)
Rotation Engines Only]
.001 -.005
(.03 -.1)
Camshaft Timing Gear
Runout [R.H. (Opposite)
Rotation Engines Only]
.004 (.102)
Max.
Crankshaft Timing Gear
Runout [R.H. (Opposite
Rotation Engines Only]
.003 (.076)
Max.
Camshaft to Crankshaft
Timing Gear Backlash
[R.H. (Opposite) Rotation
Engines Only]
.004 -.006
(.1 02 -.1 52)
New Gears
.004 -.008
(.1 02 -.203)
Used Gears
Cylinder Head:
.003 (.07) in 6 (152)
Gasket Surface Flatness
.007 (.15) Overall Maximum
Flywheel
Runout .009 (.203) Max.
NOTE 1: Duration given is "advertised duration".
NOTE 2: Duration @ .050 (1.27) cam lift.
38-8 -ENGINE 90-14499--1 887
Engine CID
454 CID
(Standard}
454 CID 482 CID
Production Performance
540 CID
Engine Model
MCM 330 (B-W}
7.4 Litre
454 Magnum
MIE 340
454 Magnum
(Bravo}
MCM 370 Lf"2
d 400
(cyclone} HtH..o
440 460
(cyclone} (cyclone)
MCM
575
HP 575
Valve System:
Lifter Type Hydraulic Solid
Rocker Arm Ratio 1.70 to 1
Intake .461 (1 1 .701 ) .51 0 (1 2.9) .500 (1 2.7) .530(1 2.462) .549 (1 3.945) .61 8 (1 5.47)
Exhaust .479 (1 2.167)
1 Turn from 3/4 Turn -o ..S" 0 Lash l-(q'3S..wt\J
Valve
lift
.500 (12.7) .551 (13.995) .558 (14.173) .638 (14.97)
Valve Lash
(Intake & Exhaust) from 0 Lash Roller rocker arms -see page
Face Angle
(Intake & Exhaust) (Note 1)
Seat Angle
46°
(Intake & Exhaust)
NOTE 1: 440/460 cyclone and 575 have precise angles ground on the cylinder head and valve and valve for improved flow.
Seat Runout
(Intake & Exhaust)
Intake
Seat Width
(Note 1)
Exhaust
Stem Intake
Clearance Exhaust
Production Intake
Service Exhaust
.002 (.051 ) Max.
.031 -.062 -(.79 -1.59)
.062 -.093 (1 .59 0 2.38)
.065 -.075
(1 .66 -1.90)
.075 -.085
(1 .90 -2.16)
.060 (1 .59)
.080 (2.0)
.001 -.0027 (.0254 -.0687)
.001 2 -.0029 (.0305 -.0737)
.0037 (.0939)
.0049 (.1 244)
90-14499--1 887 ENGINE -38-9
MCM 330 (8-W)
.
.
. Production Performance
2.12 [1-1/8]
Free
(53.8)
Installed Height (47.6)
Outer -2.250
lnner-2.125
O f!t.-t
Closed @
1.88 !1-7/8] 115-125 1bs. ft.
SpringAssembly
(47.75)
(Note 2)
(With 2 Springs) Open @
305-325 1bs. ft.
1.38 [1-3/8]
(414_440 N.m)
Installed Height
(47.6)
2.210 (2-13/64]
Free Length
(56.1)
Cl
c Closed @
·;: Spring 1.875 [1-7/8]
Q.
C/) 24-62074 (47.63)
Pressure
(I) (No.
> (Note 1)
Paint Open @
a;
> Stripe) 1.375 [1-3/8]
(34.92)
Installed Height
Free Length
115 1bs. ft. (156 N.m)
340 lbs. ft. (461 N.m)
1.843 [1-27 /3] (46.8)
2.350 [2-1 1 /32] (59.69]
Closed @ Spring 1.875 [1-7/8]
145 lbs. ft. 24-69288 (47.63)
(196 N.m) (White Pressure
and Light (Note 2) Open @ Blue 1.375 (1-3/8] 'stripe) (34.92)
Installed Height
Free Length
Closed @
1.875 [1-7/8]
(47.63)
Pressure Open @ (.. 1.365 [1-3/8]
(34.92)
360 lbs. ft. (486 N.m)
1.906 [1-29/32]
(48.4)
Outer 2.38 (60.5)Inner 2.23 (56.6)
60-70 lbs. ft.
81.6
95.2 N.m)
220230
lbs. ft.
(299.2 312
N.m)
Installed Height 1.875 (47.6)
lii
a. Free Length 1.86 [1-55/64] (47.24)
E
"'
0 Aprroximate No. of Coils 4
NOTE 1: Test spring pressure with inner and outer springs assembled.
NOTE 2: Test spring pressure with inner and outer springs and damper assembled.
NOTE 3: Test spring pressure with damper removed.
38-10-ENGINE
90-14499--1 887
General
Some repairs, that are listed in this section, must be
completed with engine removed from boat. Engine
removal depends upon type of repair and boat design.
Place engine on repair stand for major repairs.
Lubricate all moving parts (during reassembly) with
engine oil. Apply Perfect Seal on threads of and under
head of cylinder head bolts and on threads of all
cylinder block external bolts, screws and studs.
FRONT
Firing Order 1-8-4-3-6-5-7-2
Left-Hand (Standard)
Rotation Engine
FRONT
Firing Order 1-2-7-5-6-3-4-8
Right-Hand (Opposite)
Rotation Engine
Engine Identification
The MerCruiser Model can be determined by looking at
the LAST TWO LETTERS of the engine code stamped
into the cylinder block. This code number is stamped
on all MerCruiser Power Packages and replacement
partial engines but not replacement cylinder block
assemblies.
If the engine serial number, and/or model decals are
missing, the engine code letters may help in determining
the engine model. Following is a list of G.M.
engines and their respective code letters.
MCM Engines (L.H. Rotation)
330 B-W -XY
454 Magnum Alpha -XY
454 Magnum Bravo -XA
-WV
370/400/420
440/460 -XF
Cyclones
7.4 Litre
MIE Engines (Either Rotation)
L.H. Rotation
340 -XY OR XYY
R.H. Rotation
340 -XZ or XZZ
a-Large Block V-8 -Front of Engine Just Above Timing Gear/ Chain Cover
G.M. Engine Code Location
90-14499--1 887 ENGINE-38-11
Engine Rotation
Engine rotation terminology at times has caused confusion.
To clarify, engine rotation is determined by
observing flywheel rotation from the rear (transmission
or stern drive end) of the engine looking forward
(water pump end).
PROPELLER ROTATION IS NOT NECESSARILY THE
SAME as engine rotation.
When ordering replacement engines, short blocks or
parts for engines, be certain to check engine rotation.
Do not rely on propeller rotation in determining engine
rotation.
a -Left Hand Rotation (CCW) -All Stern Drive Engines, MIE Inboard L.H. (Standard) Rotation b-Right Hand Rotation (CW) -MIE Inboard R.H. (Opposite) Rotation
Crankshaft
The crankshaft is supported in the block by five insert
type bearings. Crankshaft end thrust is controlled by
flanges on the number five 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 of
the pistons to provide a gradual change in thrust pressure
against the cylinder wall as the piston travels its
path. Pins have a floating fit in the piston and a press fit
in the connecting rod (to hold them in place).
Connecting rods are made of forged steel and are connected
to the crankshaft thru insert type bearings.
Camshaft and Drive
Camshaft is supported by five bearings, which are
pressed into the block, and is driven at one-half crankshaft
speed by a timing chain and sprockets or by
timing gears.
Taper on lobes coupled with spherical foot on hydraulic
valve lifters, causes the valve lifters to rotate, thus
reducing wear. A helical gear on the aft end of the
camshaft drives the distributor and oil pump, while an
eccentric cam on the front of the camshaft actuates the
fuel pump.
Cylinder Head
The cylinder heads are made of cast iron and have
individual intake and exhaust ports for each cylinder.
Stainless steel or composition head gaskets are used
to retard corrosion.
Valve Train
The valves and valve springs are of a heavy-duty design
to withstand the high engine speeds encountered.
Valve tips have been hardened to extend valve life.
Exhaust valve rotators are used on all engines except
the (production-performance 454 CID engines) to help
extend valve life.
Hydraulic valve lifters ride directly on the camshaft
lobes and transmit the thrust of the lobes to the push
rods which in turn actuate the valves thru the rocker
arm.
In addition to transmitting thrust of the cam lobes, the
hydraulic lifters also serves to remove any clearance
(lash) from the valve train to keep all parts in constant
contact.
The valve lifters also are used to lubricate the valve
train bearing surfaces.
38-12 -ENGINE 90-1 4499--1 887
Intake Manifold
The manifold is of the double level design for efficient
fuel distribution. The upper level of passages feeds
cylinders 2, 3, 5 and 8 while the lower level passages
feed cylinders 1,4, 6 and 7. All passages are of approximately
equal length to assure more even fuel-air mixture
to the cylinders.
Lubrication System
The engine lubrication system is of the force-feed type
in which oil is supplied under full pressure to the
crankshaft, connecting rods, camshaft bearings and
valve lifters, and is supplied under controlled volume to
the push rods and rocker arms. All other moving parts
are lubricated by gravity flow or splash.
A positive displacement gear-type oil pump is mounted
on the rear main bearing cap and is driven by an extension
shaft from the distributor (which is 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 assembly.
If screen should become clogged, a relief valve in the
screen will open and continue to allow oil to be drawn
into system. Once the oil reaches the pump, the pump
forces the oil thru the lubrication system. A spring
loaded relief valve in the pump limits the maximum
pump output pressure.
After leaving the pump, the pressurized oil flows thru a
full..,flow oil filter. On engines with an engine oil cooler,
the oil also flows thru the cooler before returning to the
block. A bypass valve (on all engines except productionperformance
454 CID) allows oil to bypass the filter
and oil cooler should they become restricted. A bypass
valve is not used on hi-performance 454 CID engines to
ensure that all of the oil is filtered.
Some of the oil, after leaving the oil cooler and/or filter,
is routed to the main oil gallery, on the left side of the
cylinder block, which supplies oil thru individual passages
to the No. 1,2, 3 and 4 crankshaft main bearings
and the No: 1, 2, 3 and 4 camshaft bearings. The
remainder of the oil is routed to the No. 5 crankshaft
main bearing and to an annular groove in the No. 5
camshaft bearing bore. Some of the oil is then used to
lubricate the camshaft bearing, while the remainder is
routed to both valve lifter oil galleries thru oil passages
which intersect the annular groove.
The camshaft bearings have holes which align with the
oil passages or annular grooves in the block and allow
oil to flow in between the bearings and the camshaft
journals. The oil that is forced out the front end of the
No. 1 camshaft bearing drains down onto camshaft
drive and keeps it lubricated.
The oil which reaches the crankshaft main bearings is
forced thru 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 thru grooves in the upper half of the
crankshaft main bearings and oil passages in crankshaft.
Oil which is forced out the ends of the connecting
rod bearings and crankshaft 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 lubricating 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 areating the oil in
the oil pan.
Oil which reaches the valve lifters oil galleries is forced
into each hydraulic valve lifter thru holes in the side of
the lifter. From here, the oil is forced thru the metering
valve in each of the lifters (which controls the volume of
oil flow) and then up thru the push rods to the rocker
arms. A hole in each rocker arm push rod seat allows
the oil to pass thru the rocker arm and lubricate the
valve train bearing surfaces. After lubricating valve
train, oil drains back to the oil pan thru oil returns holes
in the cylinder head and block.
The distributor shaft and gear also is lubricated by the
oil flowing thru the right valve lifter oil gallery. Fuel
pump push rod is lubricated by oil thrown off from the
camshaft eccentric.
90-1 4499--1 887
ENGINE -38-13
Bearing Failures
Overlay
Dirt Wiped Out
Imbedded
SCRATCHED
into Bearing
BY DIRT
Material
LACK OF OIL IMPROPER SEATING
Overlay Gone
from Entire Surface Radius Ride Craters or Pockets
TAPERED JOURNAL RADIUS RIDE FATIGUE FAILURE
Piston Failures
Pre-Ignition
Pre-ignition is abnormal fuel ignition, caused by combustion
chamber hot spots. Control of the start of ignition
is lost, as combustion pressure rises too early,
causing power loss and rough running. The upward
motion of 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.
Pre-Ignition Damage
Ignited by hot deposit .. . . regular ignition spark ..
38-14 -ENGINE
Pre-Ignition Causes
1. Hot spots in the combustion chamber from glowing
deposits (due in turn to the use of improper oils
and/or fuels).
2. Overheated spark plug electrodes (improper heat
range or defective plug).
3. Any other protuberance in the combustion chamber,
such as an overhanging piece of gasket, an
improperly seated valve or any other inadequately
cooled section of material which can serve as a
source.
Engine failures, which result from the foregoing conditions,
are beyond the control of Mercury Marine, therefore,
no warranty will apply to failures which occur
under these conditions.
. . flame fronts collide .
90-1 4499--1 887
. ; '..·.
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 damage to
the spark plugs, pistons, valves and, in severe cases,
results in pre-ignition.
Use of low octane gasoline is one of the most common
causes of detonation. Even with high octane gasoline,
detonation could occur if engine maintenance is neglected.
OTHER CAUSES of DETONATION
IMPORTANT: Use of improper fuels will cause engine
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 compression
ratio).
5.
Inadequate cooling of engine by deterioration of
cooling system.
Engine failures, which result from the foregoing conditions,
are beyond the control of Mercury Marine, therefore,
no warranty will apply to failures which occur
under these conditions.
Detonation Damage
Spark occurs ... . . combustion begins .. . ... continues .... .... detonation.
90-1 4499--1 887
ENGINE -38-15
Rubber Insert
cannot Be Replaced
FRONT MOUNT -MCM (8-W)
FLYWHEEL HOUSING -MCM 330 (B-W)
Press Mount Out
With Press
REAR MOUNT/TAILSTOCK ASSEMBLY MCM
330 (B-W)
38-1 6-ENGINE
:.. ·'
.,r,
90-1 4499--1 887
NOTE: View of mount is from front of engine, looking
toward transom.
MOUNTING PLATES f'
Production Performance Engines
•¥ ···_, ·: -
."
Cleaning and Inspection
1.
Wash crankshaft in solvent and dry with compressed
air.
2.
Measure main bearing journals and crankpin dimensions
with a micrometer for out-of-round, taper or
undersize (see "Specifications").
3.
Check crankshaft for runout (by supporting at front
and rear main bearings journals in "V" blocks) and
check at front and rear intermediate journals with a
dial indicator (see "Specifications").
4.
Replace or recondition crankshaft if not meeting
specifications.
Installation
1.
If a new crankshaft is being installed, proceed as
follows:
a.
Remove timing sprocket or gear from old crankshaft
and reinstall on new crankshaft.
b.
On::I-Drive Engines: Remove flywheel attaching
studs from old crankshaft, using heat if necessary.
Reinstall studs in new crankshaft with Loctite
35 applied to threads.
IMPORTANT: Be sure that all bearings and crankshaft
journals are clean.
2.
Install a new rear main bearing oil seal in cylinder
block and rear main bearing cap.
3.
Carefully lower crankshaft into place. Be careful
not to damage bearing surface.
4.
Check clearance of each main bearing, following
procedure outlined under "Main Bearing"; see
"Index". If bearing clearances are satisfactory,
apply a light coat of engine oil to journals and
bearings.
5.
Install all bearing caps and bolts. Torque all main
bearing cap bolts to specifications. When tightening
rear main bearing cap. Follow procedure outlined
under "Main Bearing"; see "Index".
6.
Check clearance for each connecting rod bearing,
following procedure under "Connecting Rod Bearings";
see "Index". If bearing clearances are satisfactory,
apply a light coat of engine oil to journals
and bearings.
90-1 4499--1 887
7. Install all rod caps and torque nuts to specifications.
8. Check crankshaft end play. Follow procedure outlined
under "Main Bearing"; see "Index".
9. Install oil pump and pan as outlined.
10.1nstall camshaft sprocket and timing chain. (Lefthand
rotation engines only.)
11. 1nstall crankcase front cover and torsional damper.
12. Remove engine from repair stand and install water
pump.
13.1nstall crankshaft pulley and belts.
14.1nstall spark plugs.
15.1nstall engine in boat, fill crankcase and install
hoses.
Crankshaft Sprocket/Gear
Removal
1. Remove torsional damper and crankcase front
cover as outlined.
2. Remove camshaft timing chain as outlined.
3. Using tool shown in chart, remove sprocket or gear.
Left Hand Rotation Engine J-1619
Right Hand Rotation Engine J-8105
14460
J-1619 Puller
90-14499--1 887
14465
J-8105 Puller
Installation
1. Using correct tool as shown, install sprocket or
gear.
2. Install camshaft timing chain as outlined.
3. Install crankcase front cover and torsional damper
as outlined.
a-Tool J-21 058-20
ENGINE -38-55
Timing Chain/Sprockets LeftHand
(Standard) Rotation
Engines
Removal
1. Remove torsional damper and crankcase front
cover as outlined.
2. Crank engine until marks on camshaft and crankshaft
sprockets are in alignment.
3. Remove camshaft sprocket to camshaft bolts.
4. Remove camshaft sprocket and timing chain together.
Sprocket is a light press fit on camshaft. If
sprocket does not come off easily, a light blow on
lower edge of sprocket (with a plastic mallet)
should dislodge the sprocket.
5. If crankshaft sprocket has to be replaced, remove as
outlined in "Crankshaft Sprocket/Gear".
a -Timing Marks Aligned
b -Locating Pin
Timing Marks Aligned
Cleaning and Inspection
1. Clean all parts in solvent and dry with compressed
air.
2. Inspect timing chain for wear or damage.
3. Inspect sprockets for wear or damage.
3B-56 -ENGINE
Installation
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 and
orient to align marks on camshaft and crankshaft
sprockets.
IMPORTANT: Do not attempt to drive sprocket on
camshaft, as welsh plug at rear of engine can be dislodged.
3. Draw camshaft sprocket onto camshaft, using the 3
mounting bolts. Torque to specifications.
4. Lubricate timing chain with engine oil. Install crankcase
front cover and torsional damper as outlined.
Checking Timing Chain Deflection
With timing chain and sprockets installed. check
timing chain deflection, as follows:
1. Rotate camshaft (in either direction) to place tension
on one side of the chain.
2. Establish a reference point on the block (on taut
side of chain) and measure from this point to the
chain.
3. Rotate camshaft in the opposite direction to slacken
the chain, then force chain out with fingers and
again measure the distance between reference
point and timing chain.
4. The deflection is the difference between these two
measurements. If the deflection exceeds specifications,
timing chain should be replaced.
a -Reference Point
Checking Timing Chain Deflection
90-14499--1 887
Timing Gears Right-Hand
Rotation
Removal
1.
Remove crankcase front cover.
2.
Crank engine over until timing mark on camshaft
gear aligns with timing mark on crankshaft timing
gear.
a -Timing Marks
b-Thrust Plate Attaching Screws
Timing Marks Aligned
3.
Remove camshaft timing gear attaching screws
through holes in timing gear.
IMPORTANT: Use extreme care when removing camshaft
(In next step) to prevent damaging camshaft bearings.
All camshaft journals are the same size.
4.
To remove camshaft and gear as an assembly, refer
to "Camshaft" (see "Index").
5.
If camshaft, timing gear or thrust plate requires
replacement, press gear off of camshaft, using an
arbor press and appropriate tools as shown. Be sure
to use a support under gear to prevent pressing on
thrust plate. If camshaft is to be replaced, remove
(and discard) woodruff key from camshaft and
remove spacer ring.
a-Support (Must Clear Thrust Plate)
Removing Camshaft Gear
6.
If crankshaft timing gear requires replacement,
remove as outlined in "Crankshaft Sprocket/Gear",
(see "Index").
Cleaning and Inspection
1.
Clean all parts in solvent and dry with compressed
air.
2.
Inspect timing gears for worn or damaged teeth.
Installation
1.
If removed, install crankshaft timing gear as outlined
in "Crankshaft Sprocket/Gear".
2.
If removed, install spacer ring, woodruff key, thrust
plate and timing gear on camshaft, as follows:
a.
Check mating surface on camshaft and timing
gear to ensure that they are clean and free of
burrs.
b.
Install spacer on camshaft with chamferred side
toward camshaft.
c.
Install new woodruff key.
90-14499--1 887
ENGINE -38-57
d.
Place thrust plate on end of camshaft with
grooved side outward.
e.
Firmly support camshaft at back of front journal
in an arbor press and press timing gear onto
camshaft with timing mark outward.
a-Woodruff Key
b -Spacer Ring
c -Thrust Plate
d -Timing Gear
Installing Camshaft Timing Gear and Related Parts
f.
Check camshaft front journal to thrust plate
clearance (end play) with feeler gauge. If clearance
is not as specified, make sure gear is
pressed on all the way. Also check thrust plate
and camshaft for excessive wear and replace as
required.
Checking End Play
38-58-ENGINE
3.
Lubricate camshaft journals with engine oil and
install cam..haft being sure to align timing marks.
4.
Install thrust plate attaching screws and torque to
specifications.
5.
Check timing gear backlash and runout as explained
under "Checking Backlash and Runout".
6.
Lubricate timing gears with engine oil.
7.
Install crankcase front cover and torsional damper,
as explained.
8.
Install hydraulic valve lifters, push rods, rocker
arms and rocker arm covers as previously explained.
Checking Backlash and Runout
1.
Remove fuel pump and fuel pump push rod.
2.
Loosen rocker arm nuts (to relieve tension on
hydraulic valve lifters).
3.
With timing gears installed, check camshaft to
crankshaft gear backlash, as follows:
a.
Mount a dial indicator on engine so that indicator
stem contacts one of the teeth on camshaft
gear. Indicator stem should be as perpendicular
to gear tooth surface as possible.
b.
Check the backlash between the camshaft gear
and crankshaftgearwhileapplying inward pressure
on camshaft gear.
c.
If backlash is not within specifications, check for
improperly machined parts or for worn camshaft
or crankshaft bearings. If bearings check out
good, replace both timing gears.
Checking Backlash
90-14499--1 887
4. With timing gear installed, check camshaft and
crankshaft timing gear runout, as follows:
a-Turn Crankshaft In This Direction
Checking Gear Runout
a.
Mount dial indicator on block so that indicator
stem is perpendicular to camshaft timing gear
and contacts gear surface just adjacent to teeth.
b.
Apply outward pressure on timing gear and zero
indicator, then turn crankshaft as shown. Check
gear runout through one complete revolution of
camshaft gear.
c.
If not within specifications, check for burrs or
foreign material between gear and camshaft
joining surfaces. If none is found, replace both
timing gears.
d.
Check crankshaft timing gear runout in same
manner. Runout should not exceed specifications.
Replace both gears, if runout is excessive.
5.
Adjust rocker arm nuts.
6.
Install fuel pump push rod and fuel pump.
Camshaft
Measuring Lobe Lift
NOTE: Procedure is similar to checking valve timing. If
improper valve operation is indicated, measure lift of
each push rod in consecutive order and record readings.
1.
Remove valve mechanism as outlined.
2.
Position indicator with ball socket adapter Tool J8520-
1 on push rod. Be sure that push rod is in lifter
socket.
3.
Rotate crankshaft damper slowly in direction of
rotation until lifter is on heel of cam lobe. At this
point, push rod will be in its lowest position.
4.
Set dial indicator on zero, then rotate balancer
slowly (or attach an auxiliary starter switch and
"bump" engine over) until push rod is in fully raised
position.
5.
Compare total lift, recorded from dial indicator,
with "Specification".
6.
Continue to rotate engine until indicator reads zero.
This will be a check on accuracy of original indicator
reading.
7.
If camshaft readings for all lobes are within specifications,
remove dial indicator assembly.
8.
Install and adjust valve mechanism as outlined.
Measuring Camshaft Lobe Lift
90-1 4499--1 887
ENGINE -38-59
Removal
1. Remove valve lifters as outlined.
2. Remove crankcase front cover as outlined.
3. Remove fuel pump and fuel pump push rod.
4. Remove camshaft as follows:
MCM and MIE L.H. Rotation Engines:
a. Refer to "Timing Chain/Sprockets, Left-Hand
(Standard) Rotation Engines" to remove chain
and sprocket.
b. Install two 5/16-18 bolts in camshaft sprocket
bolt holes and carefully remove camshaft.
MIE R.H. Rotation 454 CID Engines:
a. Refer to "Timing Gears, Right-Hand (Opposite)
Rotation Engines" to remove thrust plate attaching
screws.
b. Carefully remove camshaft and timing gear.
c. Remove timing gear as outlined.
Removing Camshaft
38-60-ENGINE
Inspection
Measure camshaft bearing journals with a micrometer
for out-of-round condition. If journals exceed .001"
(.025mm) out-of-round, camshaft should be replaced.
Also check camshaft for alignment with "V" blocks and
dial indicator which indicates exact amount camshaft
is out-of-true. If out more than .002" (.051 mm) (dial
indicator reading) camshaft should be replaced.
On engines with timing gears, inspect camshaft gear
and thrust plate for wear or damage.
14469
Checking Camshaft Alignment
Installation
1. Install camshaft as follows:
MCM and MIE L.H. Rotation
a. Install two 5/16-18 bolts in camshaft bolt holes,
then lubricate camshaft journals with engine oil
and install camshaft, being careful not to damage
bearings. Remove the two 5/16-18 bolts.
b. Install timing chain and sprocket as outlined in
"Timing Chain/Sprockets, Left-Hand (Standard)
Rotation Engines".
MIE R.H. Rotation
a. If removed, press timing gear onto camshaft as
outlined in "Timing Gears, Right-Hand (Opposite)
Rotation Engines".
b. Lubricate camshaft journals with engine oil and
install camshaft and timing gear, as outlined,
being careful not to damage bearings.
2. Lubricate camshaft drive system with engine oil.
3. Install fuel pump push rod and fuel pump.
4. Install crankcase front cover and valve lifters as
outlined.
90-14499--1 887
Camshaft Degreeing
(440/460 Cyclone)
There are various methods of degreeing camshafts.
r-.....
The method described in this manual is most widely
used and recommended by Mercury Marine.
1.
Install stock crankshaft balancer and timing tab or
use a degree wheel and fabricated pointer.
201848
Degree Wheel
2. Find Top Dead Center (TDC) of piston travel, two
methods used;
a. Use dial indicator on number one piston.
b.
Mount a fabricated plate on number one cylinder
deck.
a-Plate
.
b -Balancer
c-Timing Tab
Rotate engine clockwise until piston hits plate. Mark on
balancer/degree wheel where "0" on timing tab or
pointer stopped. Rotate engine counterclockwise until
piston hits plate. Mark on balancer/wheel again. Mark
halfway between the two marks on the balanced wheel
is TDC.
3.
Install timing tape on balancer with TDC aligned
with "0" of timing tab or adjust degree wheel to
align "0" with pointer.
NOTE: Turn crankshaft the same direction as engine
rotation.
4.
Locate maximum lift on number one intake lobe.
Use solid lifter or MSP tool with dial indicator. Zero
Dial Indicator.
20184A
MSP Cam-Check (Dial Indicator Installed)
5.
Rotate crankshaft to .050 BEFORE maximum lift.
Record the degrees at the timing tab/pointer.
MSP Tool (Installed)
90-1 4499--1 887
ENGINE -38-61
6. Rotate crankshaft to .050 AFTER maximum lift.
Subtract this reading from 180° and record.
7. ADD the before and after degrees from Steps 5 and
6.
8. Divide the degrees from Step 7 by two. Answer
should come out to 104° -106°.
Formula
(Degrees @ .050 before max. lift) + (180° -Degrees @
050 after max. 2
NOTE: If degrees are less than 104° cam is advanced. If
degrees are more than 106° cam is retarded. To get
correct degrees move cam sprocket in relation to camshaft,
counterclockwise to advance cam and clockwise
to retard. Use offset bushings in locating pin as
needed.
Offset Bushing Installation
1. With cam sprocket removed, drill all three mounting
and locating pin holes out to 13/32 inch.
a-Drilled Sprocket
b-Bushings
c -Standard Sprocket
38-62 -ENGINE
20183
2. Install needed bushing in locating pin hole.
3. Assemble sprocket and chain on cam.
Bushing (Installed)
4. Recheck cam for 104° -106° reading.
5. Torque mounting bolts to specifications.
6. Center punch three spots between bushing and
sprocket.
a -Center Punch Here
90-14499--1 887
Camshaft Bearings
Removal
Camshaft bearings can be replaced while engine is
disassembled for overhaul or without complete disassembly.
To replace bearings without complete disassembly,
remove camshaft and crankshaft, leaving cylinder
heads attached and pistons in place. Before
removing crankshaft, tape threads of connecting rod
bolts to prevent damage to crankshaft. Fasten connecting
rod against sides of engine so that they will not
interfere while replacing camshaft bearings.
1.
With camshaft and crankshaft removed, drive camshaft
rear plug from cylinder block.
NOTE: This procedure is based on removal of bearings
center of engine first, thus requiring a minimum
amount of turns to remove all bearings.
2.
Using tool set J-6098-01 (with nut and thrust washer
installed 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.
4.
Using 2 wrenches, hold puller screw while turning
nut. When bearing has been pulled from bore,
remove tool and bearing from puller screw.
5.
Remove remaining bearings (except front and rear)
in same manner. It will be necessary to position
pilot in rear camshaft bearing to remove rear intermediate
bearing.
Replacing Camshaft Bearings
6.
Assemble remover tool on drier handle and remove
front and rear camshaft bearings by driving toward
center of cylinder block.
Replacing Front and Rear Camshaft Bearings
Inspection
Clean camshaft bearing bores in cylinder block with
solvent and blow out with compr..ssed air. Be sure
grooves and drilled oil passages are clean.
Installation
Front and rear bearings should be installed first to act
as a guide to center pilot when installing center and
intermediate bearings.
Lubricate outer surface of new camshaft bearings with
engine oil to ease installation.
IMPORTANT: All camshaft bearings are not the same.
Be sure to install bearing in proper location (indicated
by bearing manufacturer) and to position bearings as
follows: (Directional references are in reference to
engine in its normal operating position.) Front, Intermediate
and Center camshaft bearings must be installed
so that oil hole in each aligns with oil hole in
block. Rear bearing bore is grooved and bearing oil
hole must be positioned at or near the 6 o'clock position.
1.
Installing Intermediate and Center Bearings:
a.
Install nut and thrust washer all-the-way onto
puller screw, then position pilot in front camshaft
bearing bore and insert screw thru pilot.
90-14499--1 887
ENGINE -38-63
b.
Index center camshaft bearing, then position
appropriate size remover and installer tool in
bearing and thread puller screw into tool. Be
sure at least 1/2" (13mm) of threads are engaged.
c.
Using 2 wrenches, hold puller screw and turn
nut until bearing has been pulled into position.
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 camshaft bearing
bore to install rear intermediate bearing.
2.
Installing Front and Rear Bearings:
a.
Install appropriate size remover and installer
tool on drive handle.
b.
Index front bearing (as explained in "Important"),
and drive it into position with tool. Check
position of oil hole(s) in bearing to ensure bearing
is positioned correctly.
c.
Install rear bearing in same manner, being sure
to index bearing correctly.
3.
Install a new camshaft rear plug.
IMPORTANT: Plug must be installed flush to 1/32"
(.8mm) deep and must be parallel with rear surface of
cylinder block.
4.
Install crankshaft and camshaft as outlined.
Cylinder Block
Cleaning and Inspection
1.
Remove all engine components as previously outlined.
2.
Wash cylinder block thoroughly in cleaning solvent
and clean all gasket surfaces.
3.
Remove oil gallery plugs and clean all oil passages.
NOTE: These plugs may be removed with a sharp
punch, or they may be drilled and pried out.
4.
Clean and inspect water passages in cylinder block.
5.
Inspect cylinder block for cracks in cylinder walls,
water jacket valve lifter bores and main bearing
webs.
38-64 -ENGINE
6.
Measure cylinder walls for taper, out-of-round or
excessive ridge at top of ring travel. This should be
done with a dial indicator or inside micrometer.
Carefully work gauge up and down cylinder to
determine taper and turn it to different points
around cylinder wall to determine out-of-round '-.._.,/
condition. If cylinders exceed specifications, boring
and/or honing will be necessary.
-..;enter Line or t:ngme
"A" = At right angle to centerline of engine
"B" = Parallel to centerline of engine
"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.
Cylinder Measurement
Measuring Cylinder Bore
Measuring Cylinder Bore
90-1 4499--1 887
7.
Check cylinder head gasket surfaces for warpage
with a machinists straight edge and a feeler gauge,
as shown. Take measurements diagonally across
surfaces (both ways) and straight down center. If
surfaces are out-of-flat more than .003" (.07mm) in
a 6" area or .007" (.2mm) overall, block must be
resurfaced by an automotive machine shop.
a-Machinists Straight Edge
b -Feeler Gauge
c -Take Measurements Diagonally Across Surface and Straight
Down Center
Checking Cylinder Head Gasket Surfaces for Warpage
Repairs
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" (.127mm) taper or
wear, they can be conditioned with a hone and fitted
with high limit standard size piston. A cylinder bore
of less than .005" wear or taper may not clean up
entirely when fitted to a high limit piston. To entirely
clean up the bore, it will be necessary to rebore for
an oversize piston. If more than .005" taper or wear,
bore and hone to smallest oversize that will permit
complete resurfacing of all cylinders.
4.
When pistons are being fitted and honing is not
necessary, cylinder bores may be cleaned with a
hot water and detergent wash. After cleaning, swab
cylinder bores several times with light engine oil
and a clean cloth, then wipe with a clean dry cloth.
CYLINDER BORING
1.
Before using any type boring bar, file off top of
cylinder block to remove dirt or burrs. This is very
important to prevent boring bar tilt, with result that
rebored cylinder wall is not at right angles to crankshaft.
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 diameter
as piston and hone to give specified clearance.
NOTE: Hone cylinders as outlined under "Cylinder
Honing" and "Piston Selection", following.
3.
Carefully observe instructions furnished by manufacturer
of equipment being used.
CYLINDER HONING:
1.
Follow hone manufacturer's recommendations for
use of hone and cleaning and lubrication during
honing.
2.
Occasionally, during the honing operation, thoroughly
clean cylinder bore and check piston for
correct fit in cylinder.
3.
When finish-honing a cylinder bore to fit a piston,
move hone up-and-down at a sufficient speed to
obtain very fine uniform surface finish marks in a
cross-hatch pattern of approximately 30° 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 cylinder 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 extremely
essential that a good cleaning operation be performed.
If any abrasive material remains in cylinder
bores, it will rapidly wear new rings and cylinder
bores in addition to bearings lubricated by the contaminated
oil. Swab bores several times with light
engine oil on a clean cloth, then wipe with a clean
dry cloth. Cylinder should not be cleaned with
kerosene or gasoline. Clean remainder of cylinder
block to remove excess material spread during honing
operation.
90-1 4499--1 887
ENGINE -38-65
PISTON SELECTION:
1.
Check USED piston to cylinder bore clearance as
follows:
a.
Measure "cylinder bore diameter" with a telescope
gauge 2-1/2" (64mm) from top of cylinder
bore.
b.
Measure "piston diameter" at skirt across center
line of piston pin.
c.
Subtract piston diameter from cylinder bore
diameter to determine "piston-to-bore clearance".
d.
Determine if "piston-to-bore clearance" is in
acceptable range shown in "Specifications".
2.
If used piston is not satisfactory, determine if a new
piston can be selected to fit cylinder bore within
acceptable range.
3.
If cylinder bore must be reconditioned, measure
new piston diameter (across centerline of piston
pin). then hone cylinder bore to correct clearance
(preferable range).
4.
Mark piston to identify cylinder for which it was
fitted.
Measuring Cylinder Bore
Measuring Piston
Replacement Part Information
If replacement of cylinder block is necessary, the following
must be performed:
1.
Retain double-ended main bearing cap attaching
screws (used to support oil splash plate) for use
with new engine. New engines are shipped with
regular (single-ended) bolts only.
2.
Retain oil filter by-pass valve and adaptor assembly
and related parts for use with new engines.
3.
If engine being replaced has a remote oil filter,
check the cylinder block being replaced to determine
method used to attach cylinder block adaptor
to cylinder block. Refer to "Oil Filter By-Pass Valve
and Adaptor Assembly". If it uses the older style
adaptor that is secured to the block with one 1/2-13
bolt, a Remote Oil Filter Adaptor Kit (90783A9) is
required to adapt the remote oil filter to new block.
All new blocks are machined to accept new style oil
hoses to cylinder block adaptor which is secured to
block with two 5/16-18 screws.
38-66 -ENGINE
90-14499--1 887
Oil Filter By-Pass Valve and
Adaptor Assembly
14527
Oil Filter By-Pass Valve and Adaptor Assembly for
Engines With Block Mounted Oil Filter
90-14499--1 887
I o I
14528
a-One 1/2"-13 Adaptor Attaching Bolt
Engines With Remote Oil Filter Adaptor (1/2"-13 Bolt)
ENGINE -38-67
a-Two 5/16"-18 Adaptor Attaching Bolts
Engines With Remote Oil Filter Adaptor
(5/16"-18 Bolts)
14529
Inspection and/or Replacement
IMPORTANT: Production-performance engines do
not use an oil filter by-pass valve. On these engines,
by-pass valve is removed from adaptor and oil by-pass
hole is welded shut. Do not install an adaptor with a
by-pass valve incorporated as inadequate oil filteration
will result.
Oil by-pass valve and adaptor assembly should be
inspected whenever engine is disassembled for major
repair or whenever inadequate oil filteration is suspected.
3B-68 -ENGINE
Refer to "Engine Parts List" when ordering parts for oil
filter by-pass valve, adaptor assembly or remote oil
filter parts.
1. Remove oil filter (on engines with block mounted
filter) or cylinder block adaptor (on engines with
remote oil filter) and remove by-pass valve and
adaptor assembly.
2. 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 questionable, bypass
valve and adaptor assembly should be replaced.
a-Fiber Valve (Be Sure Valve Fits Tightly Against Its Seat)
Typical By-Pass Valve and Adaptor Assembly
14530
4. Wipe out valve chamber in cylinder block to remove
any foreign material.
5. Install by-pass valve and adaptor assembly and oil
filter or cylinder block adaptor and secure as
shown. Be sure to torque bolts or screws to specifications.
90-14499--1 887
Remote Oil Filter Kit
(90783A9)
MerCruiser MCM 400/440/460,
Stern Drive Engines
INSTALL KIT AS SHOWN:
•
Before installing pipe plug (d), goo elbow (e) and
45° male connector (k), coat pipe threads with
Quicksilver Perfect Seal. Tighten securely.
•
Torque screws (f & g) to 20-25 lbs. ft. (27-34 N.m).
•
When installing hose (j), coat pipe thread end with
Perfect Seal. Do not apply any kind of sealant to
swivel end. Tighten securely.
•
Remove and retain original hose (m) from oil
cooler. Remove and discard original goo male
elbow and replace with new goo elbow (I). Coat pipe
thread end of original hose with Perfect Seal and
install into oil adaptor assembly. Install other end of
hose without sealant into new goo elbow.
NOTE: EXTRA PARTS. When installing kit on MIE340,
one goo elbow, the straight male connector and new
30" (762mm) hose will not be needed.
Remote Oil Filter System (MIE, MCM)
a-Engine Cylinder Block
b -"0" Ring (25-3502g)
c -Oil Adaptor Assembly (g0783A8)
d -Pipe Plug (22-37372)
e -goo Elbow (22-48246)
f-5/16" -18 x4" (102mm) Screw (10-g1g66)
g-5/16"-18 x3-1/4" (83mm) Screw (10-g1g67)
h-Gasket (27-g18g2)
i -Adaptor Cover (g1830)
j-24" (610mm) Hose (32-48242-4g)
k-45° Male Connector (22-71g23)
I-goo Male Connector (22-63825)
m -Hose, Original (Oil Cooler to Adaptor)
n-Oil Filter Adaptor (Original)
o -Oil Filter (Original)
p-Hose, Original (Oil Cooler to Oil Filter Adaptor)
q-Engine Oil Cooler
go-1 44gg __1 887
Remote Oil Filter Kit
(92043A2) Installation
Instructions
IMPORTANT: Retain existing parts unless stated otherwise.
MERCRUISER STERN DRIVES 454 CID ENGINES
WITH CENTER EXHAUST ELBOWS.
IMPORTANT: If installing kit on engine equipped with
2 studs (16-34713) must be ordered.
MODIFY PORT EXHAUST ELBOW
ACAUTION
Water must be drained from exhaust manifold to prevent
water from entering combustion chamber when
hose is removed.
1.
If equipped with standard cooling system, remove
hose clamp, hose and straight fitting from front of
exhaust elbow. Discard fitting only. If equipped
with Closed Cooling System, proceed with Step 2.
2.
Coat threads of 45° fitting (from kit) with Quicksilver
Perfect Seal.
3.
Insert fitting in elbow opening and tighten securely.
Position fitting to point toward engine. Replace
hose and tighten hose clamp.
4.
Remove front 2 exhaust elbow attaching nuts,
washers and studs. Discard studs.
MODIFY OIL FILTER OPENING IN
CYLINDER BLOCK
1.
Remove and discard existing filter, 2 screws and
filter valve.
INSTALL REMOTE OIL FILTER
ASSEMBLY
1.
Remove oil filter adaptor cover and mount adaptor
body with 2 screws provided. Be sure cover seal and
adaptor "0" ring are in place. Torque to 20-251bs. ft.
(27-34 N.m).
2.
Route hoses up and between exhaust manifold and
engine.
A CAUTION
Hoses must not contact hot spots on exhaust manifold.
3.
Install oil filter bracket on front·of exhaust elbow.
Where elbow is fastened to manifold or 6" (152mm)
riser, use 2 screws (from kit) and original washers.
Discard original nuts. Torque to 20-251bs. ft. (27-34
N.m).
NOTE: If installing kit on engine equipped with 3"
(76mm) risers and replacement studs, use original
washers and nuts. Discard 2 screws from kit.
4.
Run engine until warm. Stop engine and wait 5
minutes. Check crankcase oil level and add oil if
necessary.
38-70 -ENGINE
90-1 4499--1 887
ELECTRICAL SYSTEM
STARTING SYSTEM
Index
Page
Identification ................................. 4A-1
Replacement Parts Warning ................... 4A-1
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Battery Cable Recommendation ............ 4A-1
Maintenance .............................. 4A-1
Testing ................................... 4A-2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
Torque Specifications ........................ 4A-3
Lubricants-Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
Starting System Components ................. 4A-4
Diagnosis .................................... 4A-5
Starter Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Periodic Inspection ........................... 4A-6
Repair ....................................... 4A-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Replacement of Contacts . . . . . . . . . . . . . . . 4A-6
Installation ............................. 4A-6
Starter Motor Disassembly . . . . . . . . . . . . . . . . . 4A-7
Cleaning and Inspection ................... 4A-7
Armature Tests ............................ 4A-8
Test for Shorts ......................... 4A-8
Test for Ground . ... ... .... .... .. .. ..... · 4A-8
Field Coil Tests ........................... 4A-8
Test for Open Circuit ................... 4A-9
Test for Ground ........................ 4A-9
Loose Electrical Connections . . . . . . . . . . . . . . 4A-9
Turning the Commutator ................... 4A-9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
Clearances ............................... 4A-1 0
Pinion Clearance ...................... 4A-10
Commutator End Frame Gap ........... 4A-11
Installation ............................... 4A-11
Standard Starter Type Solenoid .............. 4A-11
Testing/Replacement ..................... 4A-11
ELECTRICAL SYSTEM -4A 90-14499--1 887
Identification
The starter identification number is located as shown.
("'"\\.-I
'>'\.,;,: , -..);;':
AWARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
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.
Battery
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
Maintenance
A WARNING
Hydrogen gases that escape from the battery during
charging are explosive. Be sure that battery area is well
ventilated and that bilge blower is in operation when
charging. Do not smoke or allow sources of spark or
open flame in area when charging battery.
A WARNING
Battery electrolyte is a corrosive acid and should be
handled with extreme care. If electrolyte is spilled or
splashed on any part of the body, immediately flush the
exposed area with liberal amounts of water and obtain
medical aid as soon as possible. Safety glasses and
rubber gloves are recommended when handling batteries.
A CAUTION
To prevent damage to the electrical system be sure to
adhere to the following:
a.
When installing battery, be sure to connect the (-)
negative (grounded) battery cable to the (-) negative
battery terminal and (+) positive battery cable
to (+) positive battery terminal.
b.
Never disconnect the battery cables while the
engine is running.
c.
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 negative).
d.
When applying a booster charge to battery, disconnect
both cables from battery (to prevent damage to
voltage regulator).
e.
Check battery condition periodically.
f.
Make sure that battery leads are kept clean and
tight.
Cable Length Cable Gauge
Up to 3-1/2 Ft. (1 .1m)
3-1/2 -6 Ft. (1.1-1 .8m)
6-7-1/2 Ft. (1 .8-2.3m)
7-1/2 -9-1/2 Ft. (2.3-2.9m)
9-1/2 -12 Ft. (2.9-3.7m)
12 -15 Ft. (3.7-4.6m)
15 -19 Ft. (4.6-5.8m)
4 (19mm2)
2 (32mm2)
1 (40mm2)
0 (50mm2)
00 (62mm2)
000 (81 mm2)
0000 (103mm2)
Both positive (+) and negative (-) cables
90-14499--1 887
ELECTRICAL SYSTEM -4A-1
Testing
Place battery under heavy load (as during engine
cranking or with a variable resistor tester) and test cell
voltage while under load.
Certain conditions must be met before testing.
a.
Battery must be between 60° and 1 ooo .
b.
Electrolyte level must be correct in all cells.
Battery must be at least half charged.
d.
No obvious defects.
1.
Check voltage per manufacturers specifications.
2.
If readings are low, recharge and retest.
3.
If readings remain low, battery should be replaced.
ACAUTION
Test battery in well ventilated area as gases given off by
battery are hazardous.
Storage
a.
Remove battery and clean exterior.
b.
Check fluid level and fill if low.
c. Cover terminals and bolts with light coat of grease.
d.
Set battery on wood or in carton, store in cool, dry
place.
e.
Check every 20 days for fluid level and slow charge.
IMPORTANT: A discharged battery can be damaged
by freezing.
...,.,t3too'.. i'!I)Uibnoo \;'UU: ....lit •ne ab.att. '(lethHi .tsdt •
'1· ,, },
·\'",
\.._,/'
Specifications
DELCO
IDENTIFICATION
ENGINE
NUMBER
ROTATION VOLTS
1998314 L.H. 10.6
1998315 R.H. 10.6
1998316 L.H. 10.6
1998317 L.H. 10.6
1998318 L.H. 10.6
1998404 L.H. 10.6
1998460 L.H. 10.6
1998405 R.H. 10.6
1998513 L.H. 10.6
1998568 L.H. 10.6
1998566 L.H. 10.6
NO LOAD TEST
MIN. MAX.
AMPS AMPS
70 120
70 120
70 120
70 120
60 100
60 100
60 100
60 100
60 100
60 100
70 120
BRUSH
MIN. MAX. SPRING TENSION
RPM RPM OZ. (GRAMS)
5400 10,800
56-105
(1 588-2976)
5400 10,800
56-105
( 1 588-2976)
5400 10,800
56-105
( 1 588-2976)
5400 10,800
56-105
( 1 588-2976)
5300 10,600
56-105
( 1 588-2976)
5300 10,600
56-105
( 1 588-2976)
5300 10,600
56-105
( 1 588-2976)
5300 10,600
56-105
(1 588-2976)
5300 10,600
56-105
(1 588-2976)
5300 10,600
56-105
(1 588-2976)
5400 10,800 56-105
( 1 588-2976)
PINION CLEARANCE .010-.140 (.25-3.5mm)
COMMUTATOR END FRAME GAP .025 MAX. (.6mm MAX.)
L.H. =LEFT HAND ENGINE ROTATION
R.H. =RIGHT HAND ENGINE ROTATION
TORQUE SPECIFICATIONS
LBS. FT. (N.m)
50 (68)
LBS. IN. (N.m)
FASTENER LOCATION
Starter Motor to Block
LUBRICANTS -SEALANTS
92-2571 1 Liquid Neoprene
SAE 10W Oil
SAE 20W Oil
90-1 4499--1 887 ELECTRICAL SYSTEM -4A-3
Starting System Components
a-Ignition Switch
b -Neutral Start Switch
c -Starter Solenoid
d-Circuit Breaker
e-Engine Ground Stud
f -Solenoid Switch
g -Wire Junction
/--------....___ I I.)'c..· _l
h -20 Amp Fuse
i -Yellow-Red
j-Red-Purple
k-Black
1-Red
m -Yellow-Red 7
n -Red-Purple 6
4A-4 -ELECTRICAL SYSTEM
·--·--·i j..;
90-14499--1 887
Diagnosis
Starter Motor Assembly
This is a general description of the positive current
flow, from the battery and thru the system until the
starter motor cranks.
A
Battery to the solenoid switch (on starter) (RED
battery cable)
B
Solenoid switch to circuit breaker (RED)
C
Circuit breaker to wire junction (RED-PUR)
D
Wire junction to wiring harness plug (RED-PUR)
Terminal #6
E
Wiring harness plug to 20 AMP fuse (RED-PUR)
F
20 AMP fuse to ignition switch Terminal "I" (REDPUR)
At this point ignition switch is turned to
"Start"
G
Ignition switch Terminal "I" to Terminal "C"
H
Ignition switch Terminal "C" to neutral start switch
(YEL-RED) neutral start switch must be at neutral
position
Neutral start switch to wiring harness plug terminal
number "7" (YEL-RED)
J
Wiring harness plug to starter solenoid (small terminal)
(YEL-RED). Also ensure that black (small
terminal) wire is grounded.
K
Starter Solenoid is now "closed" completing circuit
between large terminal (RED-PUR) and other large
terminal (YEL-RED) causing starter motor to crank.
21
@-1
II
b-13
L _____ j
25-1
..--12
1 HOUSING, drive end
2 BUSHING, drive end housing
3 COLLAR, thrust
4 RING, retaining -pinion stop collar
5 COLLAR, pinion stop
6 DRIVE ASSEMBLY, clutch
7 PLATE, bearing
8 BUSHING, bearing plate
9 WASHER, bearing plate
10 SCREW, bearing plate
11 ARMATURE
12 SHOE, pole -field coil
13 SCREW, pole shoe to field coil
14 GROMMET, field coil -field frame
15 FIELD COIL ASSEMBLY
16 WASHER, leather -commutator end frame
17 FRAME, commutator end -lower
18 BOLT, thru
19 HOLDER, insulated -field frame brush
20 HOLDER, field frame brush ground
21 BRUSH, field frame
22 SCREW, brush lead
23 SUPPORT PACKAGE, ground and insulated holders
24 SPRING, field frame brush
25 PIN, dowel -field frame
26 LEVER, shift
27 STUD, shift lever
28 WASHER, shift lever stud
29 NUT, shift lever stud
30 PLUNGER, shift lever
31 PIN, plunger to shift lever
32 SPRING, plunger return
33 SCREW, solenoid switch
34 SOLENOID SWITCH ASSEMBLY
<' ,,
90-14499--1 887
ELECTRICAL SYSTEM -4A-5
Periodic Inspection
Cranking motor and solenoid are completely enclosed
in the drive housing to prevent entrance of moisture
and dirt. However, periodic inspection is required:
A
Inspect terminals for corrosion and loose connec
tions.
8 Inspect wiring for frayed and worn insulation.
C Check mounting bolts for tightness.
Repair
Removal
AWARNING Disconnect battery cables at battery before removing
starter.
1.
Disconnect battery cables from battery.
2.
Disconnect wires from solenoid terminals.
3.
Remove starter mounting bolts.
4.
Pull starter assembly away from flywheel and remove
from engine.
Solenoid Switch
REMOVAL
1.
Remove starter motor as outlined.
2.
Remove screw from field coil connector and solenoid
attaching screws.
3.
Twist solenoid to disengage tab, and remove.
a -Field Coil Screw
b-Attaching Screws
4A-6-ELECTRICAL SYSTEM
REPLACEMENT of CONTACTS
1.
With solenoid removed from motor, remove nuts
and washers from switch ("S") terminal and starter
motor connector strap terminal.
2.
Remove solenoid end cover retaining screws and
washers and remove end cover from solenoid body.
3.
Remove nut and washer from battery terminal on
end cover and remove battery terminal.
IMPORT ANT: Do not cut starter motor connector strap
terminal wire to remove terminal, or wire will be too
short.
a -Solenoid Body
b-To Hold in Coil
c-Switch Terminal d -Motor Connector Strap Terminal
e-To Pull in Coil
f -Contact Ring and Push Rod Assembly
g -Battery Terminal
h -Contact Finger
i-End Cover
01 449A
4. Remove motor connector strap terminal and solder
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 terminals
and install end cover retaining screws. Also install
washers and nuts on solenoid switch and starting
motor terminals.
INSTALLATION 1. Install solenoid onto plunger.
2. Twist solenoid to engage lock tab.
3. Install screws and tighten securely.
4. Install field coil connector screw.
90-14499--1 887
Starter Motor Disassembly
1. Remove screw from field coil connector.
a -Connector Screw
2. Remove end frame thru bolts, end frame, washer
and field frame.
a-Thru Bolts
b-End Frame
c-Washer
d-Field Frame
90-14499--1 887
17872
3. Remove screws, center bearing plate and armature.
a-Screws
b-Bearing Plate
c-Armature
4. Slide thrust collar off armature shaft.
5. Drive retainer ring toward armature.
17873
6. Remove snap ring, retainer and clutch assembly.
Cleaning and Inspection
With starting motor completely disassembled, except
for removal of field coils, component parts should be
cleaned and inspected. Field coils should be removed
only where defects are indicated by tests. Defective
parts should be replaced or repaired.
1. Clean all starting motor parts but do not use dissolving
solvents for cleaning over-running clutch, armature
and field coils. Such a solvent would dissolve
grease packed in clutch mechanism and damage
armature and field coil insulation.
2. 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. Replace
if necessary.
3. Check that brush holders are not damaged or bent
and will hold brushes against commutator.
4. Check brushes. Replace if pitted or worn to onehalf
their original length [5/16" (8mm) or less].
ELECTRICAL SYSTEM -4A-7
5.
Check fit of armature shaft in bushing of drive housing.
Shaft should fit snugle. Replace bushing, if
worn. Apply SAE 20 oil to bushing before reassembly.
Avoid excessive lubrication.
6.
Check fit of bushing in commutator end frame. If
bushing is damaged or worn excessively, replace
end frame assembly. Apply SAE 20 oil to bushing
before reassembly. Avoid excessive lubrication.
7.
Inspect armature commutator. If rough or out-ofround,
turn down and undercut. Inspect points
(where armature conductors join commutator bars)
for good, firm connection. Burned commutator bar
usually is evidence of poor connection.
Armature Tests
TEST for SHORTS
Check armature for shorts by placing on growler and
holding hack saw blade over armature core while rotating
armature. lf saw blade vibrates, armature is shorted.
After cleaning between commutator bars, recheck. If
saw blade still vibrates, replace armature.
TEST for GROUND
1.
With continuity meter, place one lead on armature
core or shaft and other lead on commutator.
2. If meter hand moves armature is grounded and
must be replaced.
Field Coil Tests
..
TEST for OPEN CIRCUIT
1.
With continuity meter, place one lead on each end
of field coils (insulated brush and field connector
bar).
2.
If meter does not move, field coils are open and
must be replaced.
4A-8 -ELECTRICAL SYSTEM
90-14499--1 887
TEST for GROUND
IMPORTANT: Be sure that positive brushes and leads
do not contact field frame assembly during test, or
false reading will result.
1.
With continuity meter, place one lead on field connector
bar and other lead on grounded brush.
2.
If meter moves, field coils are grounded and must
be replaced.
!"""
Loose Electrical Connections
If open soldered connection of armature to commutator
leads is found during inspection, resolder with rosin
flux.
IMPORTANT: NEVER USE ACID FLUX ON ELECTRICAL
CONNECTIONS.
Turning the Commutator
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.
90-1 4499--1 887
Reassembly
After all parts are thoroughly tested and inspected and
worn or damaged parts replaced, reassemble starter as
follows:
1.
Assemble brushes and related parts to field frame
as 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 armature
shaft as follows:
a.
Lubricate drive end of armature shaft with SAE
10 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).
d.
Drive snap ring onto shaft slide down into goove.
e.
Assemble thrust collar on shaft with shoulder
next to snap ring.
f.
Place thrust collar nd retainer next to snap ring
and using 2 pliers squeeze both until snap ring is
forced into retainer.
a-Snap Ring
b-Groove
3.
Place 4 or 5 drops of light engine oil in drive housing
bushing. Slide armature and cluth assembly into
place while engaging shift lever with clutch.
4.
Position field frame over armature and apply Liquid
Neoprene between frame against drive housing,
observing caution to prevent damage to brushes.
ELECTRICAL SYSTEM -4A-9
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.
9.
Secure starter motor connector strap terminal with
screw and washer.
Clearances
PINION CLEARANCE
Pinion clearance must be checked as follows after
reassembly of motor to insure proper adjustment.
1.
Disconnect motor field coil connector from solenoid
motor terminal and insulate it carefully.
4A-10-ELECTRICAL SYSTEM
2.
Connect 12-volt battery from solenoid switch(s)
terminal to solenoid frame.
3.
Momentarily touch a jumper lead from solenoid
motor terminal to starter motor frame. This shifts
pinion into cranking position where it will remain
until battery is disconnected.
4.
Push pinion back toward commutator end to eliminate
slack.
01447
a-Pinion
b-Retainer
5.
Measure distance between pinion and pinion retainer.
6.
If clearance is not within specified limits, it may
indicate excessive wear of solenoid linkage shift
lever yoke buttons or improper assembly of shift
lever mechanism. Check for proper assembly, and
recheck gap. If still excessive, replace worn or
defective parts, since no provision is made for
adjusting pinion clearance.
90-14499--1 887
COMMUTATOR END FRAME GAP
To keep the ignition-proof and safety requirement. the
gap between the commutator end frame and field coil
housing must be checked. See specifications. If the
gap exceeds measurement when checked with a feeler
gauge, the end frame should be checked for proper
seating on the field coil housing. If properly seated and
still found to have excessive gap, the end frame must
be replaced.
Installation
1. Place starter motor and solenoid assembly in position
and install mounting bolts.
2. Fasten wires as outlined in wiring diagram.
3. Coat solenoid terminal connections with Liquid
Neoprene.
4. Place rubber boot over positive battery cable connection.
a -Positive Battery Cable Connection
b -Rubber Boot
90-14499--1 887
Standard Starter Type
Solenoid
Testing/Replacement
1. Using continuity meter, connect test leads as
shown, and connect 12-volt battery with jumper
leads as shown.
12-V
2. If no meter movement is present, replace solenoid.
ELECTRICAL SYSTEM -4A-1 1
ELECTRICAL SYSTEM
0
IGNITION SYSTEM
Index
Page
Identification ................................. 48-1
Replacement Parts Warning ...................48-1
MALLORY DISTRIBUTOR SYSTEM
Torque Specifications 48-1........................
Tools/Lubricants/Sealants 48-1....................
Specifications ................................48-2
Coil 48-2
......................................
Distributor ................................ 48-2
Spark Plugs ............................... 48-2
Firing Order 48-3
...............................
Distributor Advance Curve 48-3
.................
Total Spark Advance For Production
Performance Engines ................... 48-4
Repair ....................................... 48-4
Precautions ............................... 48-4
Distributor Cap and Rotor .................. 48-4
Contact Points 48-5
............................
Replacement ........................... 48-5
Condenser ................................ 48-7
Coil 48-7
......................................
Ignition Resistance Wire 48-7
...................
Spark Plugs ...............................48-7
High Tension Leads 48-8
.......................
............................
Distributor Repair 48-8
Removal 48-8
..................................
Disassembly 48-8
..............................
Reassembly ............................... 48-9
Distributor Installation ....................... 48-10
Engine Not Disturbed ..................... 48-10
Engine Disturbed .........................48-10
Ignition Timing ..............................48-10
THUNDERBOLT IV SYSTEM
Torque Specifications 48-1 1
.......................
Tools/Lubricants/Sealants 48-1 1 ...................
Specifications ...............................48-1 1
Coil 48-1 1 .....................................
Timing ...................................48-1 1
Spark Plugs .............................. 48-1 1
Firing Order 48-12 ..............................
Distributor Advance Curve 48-12
................
Repair ......................................48-1 3
Precautions .............................. 48-13
Distributor Cap ........................... 48-1 3
Rotor and Sensor Wheel 48-14
..................
Sensor ...................................48-15
Spark Plugs ..............................48-15
High Tension Leads ...................... 48-16
Distributor Repair ........................... 48-1 6
Removal ..............................•.. 48-16
Disassembly ............................. 48-16
Reassembly .............................. 48-16
Distributor Installation .......................48-1 7
Engine Not Disturbed .....................48-1 7
Engine Disturbed ......................... 48-17
Ignition Timing ..............................48-17
Testing HEI System .........................48-1 8
ELECTRICAL SYSTEM -48 90-14499--1 887
Mallory Distributor
Mercury Marine Thunderbolt IV (HEI) Distributor
90-14499--1 887
Replacement Parts Warning A WARNING Electrical, Ignition and fuel system components on
your MerCrulser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
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.
Mallory Distributor System
Torque Specifications
Fastener Location Lbs. Ft. (N.m)
Distributor Clamp 3/8-16 20 (27)
Spark Plugs (14mm) 15 (20)
18382 Tools/Lubricants/Sealants
TOOLS
91-59339 Dwell Meter
91-76032 Magneto Analyzer
91 -52024A1 Remote Starter Switch
91-99379 Timing Light
91-99750 Volt/Ohm Meter
TOOLS OBTAINED LOCALLY
Spring Tension Gauge
SEALANTS
92-2571 1 Quicksilver Liquid
Neoprene
LUBRICANT OBTAINED LOCALLY
Distributor Cam Lubricant
18381
ELECTRICAL SYSTEM -48-1
Specifications
Coil
Coil Part No.
Max. Operating Amps •
UNIT OF MEASUREMENT
ln. (mm)
26433
.9
32193
1.1
Primary Resistance • .9 -1 .2 ohms 1.1 -1.5 ohms
Secondary Resistance • 7,500 -10,500 ohms 9,500 -15,000 ohms
Secondary Continuity • 53-63 60-70
Resistor Wire • 1.8-2 ohms
NOTE: *Use Magneto Analyzer
Distributor
MODEL MCM 370/400/400 CYCLONE MCM 440/460 CYCLONE MIE 5.7L SKI
Condenser*
.26 -.30 MFD.
Point Dwell 26° -31° 28° -31°
Point Gap .016 -.019 (.4 -.45)
Timing 10° BTDC 15° BTDC 10° BTDC
Point Spring
25 -30 oz. (709-850g)
Tension
NOTE: *Use Magneto Analyzer
Spark Plugs
MODEL MCM 370/400 400/440 CYCLONE MIE 5.7L SKI MCM 460 CYCLONE
Plug Gap .035" (.9mm) .032" (.8mm) .035 (.9mm) .032" (.8mm)
Plug Type AC -MR43T /Champion RV8C AC-
Autolite -144/NGK-BR6FS MR41T
48-2 -ELECTRICAL SYSTEM 90-14499--1 887
r--
Firing Order
L.H. ROTATION
FRONT
FIRING ORDER
1-8-4-3-6-5-7-2
L.H. (Standard) Rotation
Distributor Advance Curve
IMPORTANT: Distributor advance curve charts do not
Include the initial engine timing. Initial engine timing
must be added to chart for total advance curve.
-......_,1 MIE 5.7L SKI
30°
..CJzz 25°ce->!Cl-c(....c(a:-20°ce !:: Q.Zcn -..(I)ce :::l.... .. 15°..:I
10°
R.H. ROTATION
FRONT
FIRING ORDER
1-2-7-5-6-3-4-8
R.H. (Opposite) Rotation
Example: A 5.7L Ski on the following chart reads 20°
spark advance at 2900 RPM. Add 8° BTDC initial timing
fora 5.7L and total spark advance would be 28° at 2400
RPM.
500 1000 1500 2000 2500 3000 3500 4000 4500 5000
ENGINE R.P.M.
90-14499--1 887 ELECTRICAL SYSTEM -48-3
Total Spark Advance for Production
Performance Engines
IMPORT ANT: This chart shows total spark advance
including the initial timing of the engine.
Model
370/400
400 Cyclone
440 Cyclone
460 Cyclone
Repair
Precautions A WARNING
Max. Spark Advance Engine R.P.M.
34° 3500
36° 3500
36° 3500
36° 3500
When Performing the following procedure, be sure to
observe the following.
Be sure that engine compartment is well ventilated and
that no gasoline vapors are present, to avoid the possibility
of fire.
Be sure to keep hands, feet, and clothing clear of
engine moving parts.
Do not touch or disconnect any ignition system parts
while engine is running.
Do not reverse battery cable connections. System is
negative (-) ground.
Do not disconnect battery cables while engine is
running.
Distributor Cap and Rotor
1. Loosen distributor cap clamp 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 corrosion.
Check center contact for deterioration.
IMPORTANT: Distributor caps (for marine use) should
have brass contacts, aluminum contacts should not be
used.
5. Check cap for cracks or carbon tracks using Magneto
Analyzer.
6. Lift rotor up, off of distributor shaft.
7. Check for burned or corroded center contact.
48-4 -ELECTRICAL SYSTEM
8. Check rotor for cracks and carbon tracks using
Magneto Analyzer.
9. Install rotor on shaft. Make sure to line up rotor with
keyway on distributor shaft. Be sure rotor is completely
seated on distributor shaft.
10. Place cap on distributor. Make sure notch on cap
lines up with notch in distributor and cap is firmly
seated.
11. Tighten clamp retaining screws.
12. 1nstall spark plug wires (if removed) as shown.
Left Hand Rotation
18384
a -Alignment Notch
Right Hand Rotation
18384
a-Alignment Notch
90-14499--1 887
Contact Points
1.
Examine contact points for dirt, wear, pitting and
misalignment. Dirty points should be cleaned. Normal
point condition is an overall grey color on contact
surface.
2.
Check for point resistance. A voltage drop of less
than .125 volts across points should exist. Make this
check with a sensitive volt meter or point resistance
meter.
Abnormal Point Wear
1.
Points, which have been operated for a period of
time, have a rough surface, but this may not mean
that points are worn out.
2.
If points burn or pit, however, they soon become
unsatisfactory for further operation. Not only must
they be replaced, but ignition system and engine
must be checked to determine cause and elimination
of trouble. Unless condition is corrected, new
points will provide no better service than old points.
Cleaning of Points
1.
Dirty contact points should be dressed with a few
strokes of a clean, fine-cut contact file. File should
not be used on other metals and should not be
allowed to become greasy or dirty.
f"""'
IMPORTANT: Never use emery cloth to clean contact
points.
2.
Contact surfaces, after considerable use, may not
appear bright and smooth, but this is not necessarily
an indication that they are not functioning satisfactorily.
Do not attempt to remove all roughness
nor dress point surfaces down smooth. Merely
remove scale or dirt.
3.
Badly burned or pitted contact points should be
replaced and cause of trouble determined and
corrected.
Burning of Points
1.
Contact point burning results from high voltage,
presence of oil or other foreign material, defective
condenser or improper point adjustment.
2.
High voltage causes excessively high current flow
thru contact points which burns them rapidly. High
voltage can result from improperly adjusted or
inoperative voltage regulator.
3.
Oil or crankcase vapors, which work up into distributor
and deposit on point surfaces, cause them to
burn rapidly.
'-"' 4.
If contact point opening is too small (cam angle too
large), points will be closed too long. Average current
flow thru points will be too high, so points will
burn rapidly and arcing will occur between points.
90-1 4499--1 887
Pitting of Points
1.
Contact point pitting results from an out-of-balance
condition in ignition system which causes transfer
of material from one point to other so that a tip
builds up on one point while a pit forms in other.
2.
If points are pitted, condenser should be checked
for proper capacity.
Replacement
1.
Remove primary lead from primary terminal on distributor.
Remove primary terminal screw and nut
from distributor. (Use care not to lose the 2 insulator
bushings in distributor housing). Remove condenser
lead and point lead from primary terminal
screw.
2.
Remove contact set attaching screw and lift contact
point set from breaker plate.
3.
Clean oil and dirt from breaker plate.
IMPORTANT: Carefully wipe protective film from point
set prior to installation.
4.
Place a small amount of Distributor Cam Lubricant
on distributor cam.
5.
Place a new contact point assembly in position on
breaker plate and install attaching screw.
6.
Place primary terminal screw through condenser
lead and point lead. Install primary screw through 2
insulator bushings in distributor housing. Install
primary terminal lock nut, primary lead, and primary
lead retaining nut to primary terminal screw.
7.
Check points for proper alignment. If points do not
align properly, replace with another set of points.
Lateral
Proper
Misalignment Lateral Al ignment
ELECTRICAL SYSTEM -48-5
8. Check point spring tension.
Contact point spring tension must fall within specified
limits. Weak tension will cause chatter which results in
arcing and burning of points and an ignition miss at
high speed, while excessive tension will cause undue
wear of contact points, cam and rubbing block. Contact
point tension should be checked with a spring
gauge. Scale should be hooked to breaker lever and
pull exerted at 90° to breaker lever. Reading should be
taken just as points separate. Tension can be adjusted
by bending breaker lever spring. If tension is excessive,
it can be decreased by pinching spring carefully. To
increase tension remove lever from distributor so that
spring can be bent away from lever. Avoid excessive
spring distortion.
18373
a -Movable Contact
b-Spring Tension Gauge
48-6 -ELECTRICAL SYSTEM
Point Adjustment with Feeler Gauge
IMPORTANT: Point gap (dwell) can be adjusted by 2
methods. It is preferred that points be adjusted with a
feeler gauge, then checked with a dwell meter. Points,
however, also can be adjusted, as well as checked, with
a dwell meter: After points have been set, dwell should
be checked with engine running.
1. Rotate distributor until rubbing block rests on peak
of cam lobe, which will provide maximum breaker
point opening.
2. Insert correct feeler gauge between breaker points.
3. Loosen lockscrew and adjust points to specifications.
a-Adjustment Screw
b -Locking Screw
Point Adjustment
Dwell Adjustment
1. Remove distributor cap and rotor.
18370
2. Connect positive (+) dwell meter lead to negative
(-) side of coil. Connect negative (-) meter lead to
ground.
3. Loosen point lock screw slightly.
4. While cranking engine with starter, adjust dwell
with a screwdriver to obtain reading on dwell meter,
as specified in "Specifications", and tighten lockscrew.
(Dwell reading will be unsteady using this
method).
90-14499--1 887
IMPORTANT: Cam angle increased as point opening is
decreased and vice versa.
() .. 0
\
,I..
V 0
a-Cam d-Points Open
b-Direction of Rotation e-Points Close
c -Breaker Points f -Cam Angle or Dwell
5.
Install rotor and distributor cap and recheck dwell
with engine running.
IMPORTANT: Dwell should be checked between idle
and 1750 RPM. Any dwell reading variations of more
than 3° between idle and 1750 RPM would indicate
wear in the distributor.
Cam angle readings, taken at speeds above 1750
engine RPM, may prove unreliable on some dwell
meters.
Condenser
1.
Use Magneto Analyzer for test.
2.
Test condenser for the following:
a.
Condenser capacity test.
b.
Condenser leakage and short test.
c.
Coil continuity test.
d.
Primary resistance test.
e.
Secondary resistance test.
,
3.
Replace coil if test results are not within specfications.
Coil
1.
Use Magneto Analyzer for test.
2.
Check coil for the following:
a.
Coil power test.
b.
Coil surface insulation test.
c.
Coil continuity test.
d.
Primary resistance test.
e.
Secondary resistance test.
3.
Replace coil if test results are not within specifications.
90-14499--1 887
Ignition Resistance Wire
Engine with Electric Choke
1.
Disconnect wire from positive (+) side of coil.
2.
Unplug quick disconnect (with 2 wires) from electric
choke heater element.
3.
Connect ohmmeter leads to ends of disconnected
wires. Replace resistor wire if reading is not within
specifications.
4.
Reconnect wires to coil and choke.
5.
For instructions on replacing resistor wire refer to
"Section 3, Part E".
Engine without Electric Choke
1.
Disconnect wire from positive (+) side of coil.
2.
Unplug instrumentation harness from engine
harness.
3.
Connect one ohmmeter lead to wire removed from
coil. Connect other ohmmeter lead to No.5 pin hole
in engine harness. Replace resistor wire if reading is
not within specifications.
Engine Harness Connector
4.
Reconnect wire to coil. Plug instrumentation harness
onto engine harness and tighten retaining
clamp securely.
5.
For instructions on replacing resistor wire refer to
"Section 3, Part E".
Spark Plugs
1.
Inspect each plug individually for badly worn electrodes,
glazed, broken or blistered porcelain and
replace where necessary.
2.
Inspect each spark plug for make and heat range.
All plugs must be the same make and number or
heat range. Refer to "Specifications" for spark plug
numbers.
ELECTRICAL SYSTEM -48-7
IMPORTANT: Never bend the center electrode to
adjust gap. Always adjust by bending ground or side
electrode.
3.
Adjust spark plug gaps with a round feeler gauge.
Refer to "Specifications" for proper spark plug gap.
a-Porcelain Insulator
b-Insulator Cracks Often Occur at this Point
c-Shell
d -Proper Gap
e-Side Electrode (File Flat When Adjusting Gap-DO NOT Bend)
4.
Clean spark plug seating area. Do not use gaskets
on taper seat plugs. Install spark plugs and torque
to specifications. Where used, gasket must be fully
compressed to complete heat transfer and provide
a gas-tight seal in cylinder. For this reason, as well
as necessity of maintaining correct plug gap, correct
torque is very important during installation.
IMPORTANT: Tapered seat spark plugs are not interchangeable
with nontapered (with gasket} spark plugs.
High Tension Leads
1.
Inspect high tension leads for damage.
2.
Check high tension leads for continuity.
3.
Replace any leads that are cracked, cut, or have
damaged spark pi ug boots.
4.
Replace any leads that do not show continuity from
end to end.
5.
Reinstall high tension leads in proper order.
IMPORTANT: Proper positioning in high tension lead
supports is important to prevent cross firing.
4B-8 -ELECTRICAL SYSTEM
Distributor Repair
Removal
1.
Remove distributor cap (2 screws) and gasket. Do
not remove plug wires from cap unless necessary. (\,
2.
Disconnect coil primary lead from distributor.
3.
Crank or turn engine slowly. Align timing marks
when rotor is pointing to No. 1 terminal of distributor
cap. If same distributor is to be reinstalled in
engine, mark position of distributor housing in relation
to engine so that distributor may be installed in
same position.
4.
Remove distributor retaining clamp.
5.
Remove distributor.
IMPORTANT: To simplify distributor installation, do
not turn crankshaft with distributor removed from
engine.
Disassembly
IMPORTANT: It is not necessary to disassemble distributor
any further than required to complete repairs.
1.
Lift rotor off of distributor shaft.
2.
Remove condenser and breaker points and test as
previously outlined.
3.
Mark breaker plate location and remove 2 retaining
screws. Remove breaker plate.
"---"'
a -Rotor Alignment Notch
b-Primary Terminal
c -Breaker Point Attaching Screw
d-Breaker Point Adjustment Screw
e -Breaker Plate
90-14499--1 887
4.
Remove pin from driven gear and shaft and remove
gear from shaft.
5.
Remove washer(s) from shaft. (If there are 2
washers, the steel washer goes towards housing
and the brass washer towards gear.)
IMPORTANT: Housing bushings are not serviced
separately. (Refer to parts manual).
6.
Check for side play between shaft and housing
bushings. Maximum side play is .002" (.05mm).
7.
Remove and check shaft for being bent by placing
in V-blocks and checking run out with a dial indicator.
Maximum run out allowed is .002" (.05mm)
(retain washer between advance mechanism and
distributor housing).
8.
Check cam lobes for wear and cam should fit tight
on shaft. Advance plate should fit tight on shaft.
IMPORTANT: Shaft, advance mechanism and cam are
serviced as an assembly and should not be disassembled.
(Refer to parts manual).
9.
Check advance mechanism for free movement.
Mechanism should return freely when released.
Reassembly
1.
Install washer on shaft assembly and lubricate shaft
with engine oil. Install shaft in housing.
2.
Install washer(s) on shaft between housing and
gear (if there are 2 washers, steel goes toward housing
and brass goes toward gear).
3.
If installing original driven gear slide onto shaft and
install roll pin.
IMPORTANT: Hole in gear is offset, gear will fit on
shaft and line up with hole only one way.
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.
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90-1 4499--1 887
4.
If installing a new driven gear the gear will not come
drilled all the way through. Install gear on shaft.
Turn gear to line up the hole with the hole in shaft.
Using hole in gear and hole in shaft as a guide, drill
through other side of gear with a 3/16" carbide
tipped drill, install roll pin.
IMPORTANT: If new gear has only a dimple, you will
have to drill through one side of the gear before you
slide gear onto shaft. In most cases it is recommended
to have a machine shop complete the drilling operation
for new gear installation.
a -Dri II Press
b-3/16" Carbide Tip Drill
c-V-Biock
d-New Gear
5.
Install breaker plate using alignment mark to properly
locate.
6.
Install points, condensor, and primary terminal
screw.
7.
Install distributor as outlined in "Distributor Installation".
ELECTRICAL SYSTEM -48-9
Distributor Installation
Engine Not Disturbed
1.
Install new gasket on distributor housing.
2.
Turn rotor approximately 1/8-turn in a counterclockwise
direction past mark previously scratched
on distributor housing.
3.
Work distributor down into position in engine block
with distributor positioned as noted during removal.
IMPORTANT: It may be necessary to move rotor
slightly to start gear into mesh with camshaft gear, but
rotor should line up with the mark when distributor is
down in place. Distributor shaft must enter oil pump
shaft for complete installation.
4.
Replace and tighten distributor hold-down bolt and
clamp. Connect primary lead to coil. Also install
spark plug and coil secondary wires, if removed.
IMPORTANT: Wires must be installed in supports, to
prevent cross-firing. Refer to "Specifications", for firing
order.
5.
Set point gap and dwell.
6.
Install rotor and cap.
7.
Time ignition as outlined under "Ignition Timing".
Engine Disturbed
1.
Locate No. 1 piston in firing position by either of 2
methods.
a.
Remove No. 1 spark plug and, with finger on
plug hole, crank engine until compression is felt
in No. 1 cylinder. Continue cranking until pointer
lines up with timing mark on crankshaft pulley
or. ..
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.
2.
Position distributor to opening in block in normal
installed attitude.
3.
Position rotor to point toward No.1 cylinder on cap
(with distributor housing held in installed attitude),
then turn rotor counterclockwise approximately
1 /8-turn more and push distributor down to engage
camshaft. It may be necessary to rotate rotor
slightly until camshaft engagement is felt.
4.
While pressing down firmly on distributor housing,
engage starter a few times to make sure oil pump
shaft is engaged. Install hold-down clamp and bolt
and snug up bolt.
5.
Turn distributor body slightly until points just open
and tighten distributor clamp bolt.
6.
Place distributor cap in position and check that
rotor lines up with terminal for No. 1 spark plug.
48-10 -ELECTRICAL SYSTEM
7.
Install cap, distributor primary lead to coil. Check
all high tension wire connections and connect
spark plug wires, if they have been removed. Wires
must be installed in their proper location in supports
to prevent cross-firing. Refer to "Specifica
tions" for firing order.
"-../'
8.
Set point gap and dwell.
9.
Time ignition as outlined under "Ignition Timing".
Ignition Timing
IMPORTANT: Dwell must be set to specification before
adjusting timing.
1.
Connect timing light to No. 1 spark plug. Connect
power supply leads on light to battery (12 volts).
Refer to "Specification" 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 harmonic balancer.
IMPORTANT: GM engine timing marks (on tab) are in
2° increments. MCM and MIE L.H. engines will have
the "A" (Advance) mark to the left of "0". MIE R.H.
engines will have the "A" mark to the right of "0". Timing must be set on the "A" side of "0" (Top Dead
Center).
a-Degree Marks
b-Timing Marks
Timing Tab on "GM" V-8 Engine
5.
Adjust timing by loosening distributor clamp and
rotating distributor body as required until timing
-...
i."tt)
mark on balancer or pulley lines up with mark on tab ;..--specified
in "Specifications". Tighten clamp and
recheck location of timing mark.
6.
Stop engine and remove timing light.
90-1 4499--1 887
Thunderbolt IV (HEI) System
Torque Specifications
Fastener Location Lbs. Ft. (N.m)
Distributor Clamp 3/8 -16 20 (27)
Spark Plugs (14mm) 15 (20)
Tools/Lubricants/Sealants
TOOLS
91 -52024A1 Remote Starter Switch
91 -63998 Spark Gap Tester
91 -99379 Timing Light
91 -63209 Torch Lamp
91 -99750 Volt/Ohmmeter
LUBRICANTS/SEALANTS
92-90018 2-4-C Lubricant
92-41 669 Insulating Compound
92-25711 Liquid Neoprene
92-32609 Quicksilver Loctite "A"
0 Specifications
UNIT OF MEASUREMENT
ln. (mm)
COIL
NOTE: * Use mGf{neto analyzer
TIMING
Coli Part Number 392-7803
Primary Resistance* .60 -.80 Ohms
Secondary Resistance* 9,400 -11 ,700 Ohms
MCM 200, 230, 260, 300
MIE 230, 260, 340
Model
330 BW, 350
5.0 Litre, 5.7 Litre, MCM 370/420/575
5.0 Litre, 5.0 Litre LX
5.7 Litre, 350/454 Magnum
7.4 Litre
Timing 8° BTDC 10° BTDC
MCM 320
EFI
12° BTDC
SPARK PLUGS
Model
MCM Models, MIE Models, Production Performance Models
Litre Models, Magnums
MCM 300,
320 EFI
Spark Plug
Gap .035 (.9) .032 (.8mm)
Spark Plug
Type
AC-MR44T
RV8C
AC-MR43T/Champion-RV8C (Note 1) AC-MR44T
RV8C
AC-MR43T
RV8C
NOTE 1: 460/575 spark plugs use: AC-MR41T or equal.
90-14499--1 887 ELECTRICAL SYSTEM-48-11
FIRING ORDER
L.H. ROTATION
R.H. ROTATION
FRONT FRONT
FIRING ORDER FIRING ORDER
1-8-4-3-6-5-7-2 1-2-7-5-6-3-4-8
ALL MCM/MIE L.H. (Standard} Rotation Models MIE R.H. (Opposite} Rotation
EXAMPLE: On the advance curve chart a 260 shows
Distributor Advance Curve
19° spark advance at 2900 R.P.M. Add 8° BTDC initial
timing for a 260 and total spark advance at 2400 R.P.M.
IMPORTANT: Distributor advance curve charts do not
is 25°.
include the initial engine timing. Basic initial timing
must be added to chart for total advance curve.
IMPORTANT: On the HEI ignition the spark advance is
controlled by the amplifier.
500 1000 1500 2000 2500 3000 3500 4000 4500 5000
ENGINE RPM
MCM 200/230/260/300/330 BW/350 MAGNUM/
370TR/454 MAGNUM/230TR/260TR MIE 230/260/340
5.0 Litre, 5.0 Litre LX, 5.7 Litre, 7.4 Litre, 320 EFI
30°
wOC) 25°Z zC(_>:IE0-C( l-:lil:: .. a:.. 20°C(l-.... -(f)....(f)CI:::Jt-z 15°0-I-::IE
10°
MIN.
693-H
48-12 -ELECTRICAL SYSTEM 90-14499--1 887
Repair
Precautions A WARNING
When performing the following procedure, be sure to
observe the following.
Be sure that engine compartment is well ventilated and
that no gasoline vapors are present, to avoid the possibility
of fire.
Be sure to keep hands, feet, and clothing clear of
engine moving parts.
Do not touch or disconnect any ignition system parts
while engine is running.
Do not reverse battery cable connections. System is
negative (-) ground.
Do not disconnect battery cables while engine is
running.
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 corrosion.
Check center contact for deterioration.
5. Check cap for cracks or carbon tracks using Magneto
Analyzer.
IMPORTANT: If high tension leads are removed from
cap refer to Figures following for installation.
L.H. Rotation Wiring
18387
a -Alignment Notch
90-14499--1 887
R.H. Rotation Wiring
a -Alignment Notch
Non Vented Cap
18378
Vented Cap
a-Vent
ELECTRICAL SYSTEM -48-13
Rotor and Sensor Wheel
1.
Remove distributor rotor/sensor wheel assembly
from distributor shaft. Rotor and sensor wheel are
Loctited onto shaft. Use two 3/8" (10mm) wide flat
blade screwdrivers approximately 8" (203mm) to
10" (254mm) long. Thescrewdriversarepositioned
opposite each other with the blade tips on the
underside of the rotor and sensor wheel assembly.
Make sure blade tips are toward distributor shaft
until they come in contact with shaft. A downward
push on both screwdriver handles at the same time
will pry rotor and sensor wheel assembly off. The
use of Torch Lamp will also aid in the removal of the
rotor/sensor wheel assembly.
2.
With the rotor and sensor wheel assembly removed,
inspect the locating key inside the rotor.
3.
The locating key will appear as a clean edged, 1/8"
(3mm) wide, sloped ramp at the bottom of the
splined hole.
a-Locating Key c -Sensor Wheel
b-Phillips Screws d-Locating Pin
IMPORTANT: If there is any doubt if sensor wheel is
located properly, lay sensor wheel on top of Figure
with sensor fingers facing up (toward you). Line up 3
screw holes and locating pin hole on sensor wheel with
Figure. If wheel is indexed properly all the fingers on
wheel will line up with the one in the Figure.
4.
If there are pieces of material shaved off of key or if
it appears to have been damaged by being forced
down while misaligned with slot in distributor shaft,
the rotor must be replaced.
5.
Check rotor for burned or corroded center contact.
6.
Check rotor for cracks and carbon tracks using
magneto analyzer and instructions supplied with
analyzer.
48-14 -ELECTRICAL SYSTEM
7.
If rotor is damaged, replace rotor by removing 3
phillips screws and separating sensor wheel from
rotor. Reinstall sensor wheel to new rotor making
sure locating pin on rotor is installed in locating
hole in sensor wheel. Tighten 3 phillips screws .. securely.
."--""
8.
Bend carbon brush tang upward slightly until a
distance of 1/4" (6.5mm) is obtained between rotor
and tang.
a-1/4" (6.5mm)
9.
Put 2 drops of Loctite 271 or Loctite Type "A" into
the rotor so it lands on the locating key.
10. Put 2 drops of Loctite in keyway on upper portion of
distributor shaft.
11. 1mmediately install rotor assembly onto distributor
"-.../
shaft. Make sure rotor locating key is aligned with
keyway in distributor shaft before pressing rotor all
the way down on shaft until it stops with the palm of
your hand. Let Loctite cure overnight with distributor
in inverted position.
IMPORTANT: The rotor should fit very tight. It may be
necessary to heat rotor with Torch Lamp to properly
install. It is important not to let any Loctite run down
distributor shaft. Loctite could get into top distributor
housing bushing.
12. Reinstall distributor cap on distributor.
13. 1nstall spark plug wires (if removed) as shown previously.
Apply a small quantity of Insulating Compound
to the inside of each spark plug wire boot
before installing the boot on distributor cap. Wipe
off excess. This Insulating Compound will help
"waterproof" this area of the ignition system.
IMPORTANT: Make sure boot does not "hydraulic"
back off of distributor cap terminal. If it does, use
needle nose pliers and bend metal spark plug wire
terminal (inside of boot) slightly so it grips the distributor
cap terminal tighter.
IMPORTANT: Black boot is distributor end of spark
plug wire. Gray (or Red) boot is spark plug end of wire.
90-14499--1 887
Sensor
1. Remove rotor and sensor wheel.
2. Remove 2 screws that hold sensor into distributor
housing.
3. Remove sensor from housing.
a -Mounting Screws
b -Sensor Assembly
4. Use a magnifying glass and light to inspect the two
metal "jumper leads" for cracks. If a crack is found
in either metal "jumper lead", install a new sensor.
15520
90-14499--1 887
A CAUTION Do not use any type of silicone sealer on the inside 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 ignition components.
5. Install sensor into housing and install 2 retaining
screws.
6. Install sensor wheel, rotor, and distributor cap.
Spark Plugs
1. Inspect each plug individually for badly worn electrodes.
glazed, broken or blistered porcelain and
replace where necessary.
2. Inspect each spark plug for make and heat range.
All plugs must be the same make and number or
heat range. Refer to "Specifications" for spark plug
numbers.
IMPORTANT: Never bend the center electrode to
adjust gap. Always adjust by bending ground or side
electrode.
3. Adjust spark plug gaps with a round feeler gauge.
Refer to "Specification" for proper spark plug gap.
a -Porcelain Insulator
b-Insulator Cracks Often Occur at this Point
c-Shell
d -Proper Gap
e-Side Electrode (Bend to Adjust Gap)
f-Center Electrode (File Flat When Adjusting Gap -Do Not Bend)
4. Clean spark plug seating area. Do not use gaskets
on taper seat plugs. Install spark plugs and torque
to specifications. Where used, gasket must be fully
compressed to complete heat transfer and provide
a gas-tight seal in cylinder. For this reason, as well
as necessity of maintaining correct plug gap, correct
torque is very important during installation.
IMPORTANT: Tapered seat spark plugs are not interchangeable
with non tapered (with gasket) spark plugs.
ELECTRICAL SYSTEM -4B-15
High Tension Leads
1. Inspect high tension leads for damage.
2. Check high tension leads for continuity.
3. Replace any leads that are cracked, cut, or have
damaged spark plug boots.
4. Replace any leads that do not show continuity from
end to end.
5. Reinstall high tension leads in proper order.
IMPORTANT: Proper positioning in high tension lead
supports is important to prevent cross-firing.
IMPORTANT: Black boot is distributor end of spark
plug wire. Gray (or Red) boot is spark plug end of wire.
Distributor Repair
Removal
1. Remove distributor cap. Do not remove high tension
leads unless necessary.
2. Crank engine over until timing marks line up and
rotor is pointing towards No. 1 cylinder on distributor
cap.
3. Mark distributor housing in reference to engine
block.
4. Remove bolt and hold down clamp and remove
distributor.
IMPORTANT: To simplify distributor installation, do
not turn crankshaft with distributor removed from
engine.
Disassembly
1. Remove rotor, sensor wheel, and sensor 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"
(.05mm).
4. Remove shaft from housing and check shaft for
being bent with a dial indicator and V-blocks. Maximum
runout is .002" (0.5mm).
48-16 -ELECTRICAL SYSTEM
Reassembly
1. Lubricate shaft with engine oil. Install "E" clip (if
removed) on shaft. Install shaft in housing.
2. Install washer on shaft. Install original gear slide
onto shaft and install roll pin. -...__/
IMPORTANT: Hole may be offset and gear will only fit
in one direction.
3. If installing a new gear, the gear will come drilled on
one side. Slide gear onto shaft, line hole in gear with
hole in shaft. Using these holes as guides, drill
through other side of gear with a 3/16" carbide
tipped drill.
a-Drill Press
b-3/16" Carbide Tip Drill
c-V-Biock
d-New Gear
4. Install sensor, sensor wheel, and rotor as previously
outlined.
5. Install distributor as outlined in "Distributor Installation".
90-14499--1 887
Distributor Installation
r Engine Not Disturbed
.. 1. Install new gasket on distributor housing.
2.
Turn rotor approximately 1/8-turn in a counterclockwise
direction past mark previously scratched
on distributor housing.
3.
Work distributor down into position in engine block
with distributor positioned as noted during removal.
IMPORTANT: It may be necessary to move rotor
slightly to start gear into mesh with camshaft gear, but
rotor should line up with the mark when distributor is
down in place. Distributor shaft must enter oil pump
shaft for complete installation.
4.
Replace and tighten distributor hold-down bolt and
clamp. Connect leads. Also install spark plug and
coil secondary wires, if removed.
IMPORTANT: Wires must be installed in supports, to
prevent cross-firing. Refer to "Specifications", for firing
order.
5.
Install cap.
6.
Time ignition as outlined under "Ignition Timing".
(' Engine Disturbed
1.
Locate No. 1 piston in firing position by either of 2
methods described below.
a.
Remove No. 1 spark plug and, with finger on
plug hole, crank engine until compression is felt
in No. 1 cylinder. Continue cranking until pointer
lines up with timing mark on crankshaft
pulley or ...
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.
2.
Position distributor to opening in block in normal
installed attitude.
Position rotortopointtoward No. 1 cylinderoncap
(with distributor housing held in installed attitude),
then turn rotor counterclockwise approximately
1/8-turn more and push distributor down to engage
camshaft. It may be necessary to rotate slightly
until camshaft engagement is felt.
While pressing down firmly on distributor housing,
engage starter a few times to make sure oil pump
shaft is engaged. Install hold-down clamp and bolt
and snug up bolt.
Place distributor cap in position and check that
rotor lines up with terminal for No. 1 spark plug.
6.
Install cap and distributor leads. Check all high
tension wire connections and connect spark plug
wires, if they have been removed. Wires must be
installed in their proper location in supports to prevent
cross-firing. Refer to "Specifications" for firing
order.
7.
Time ignition as outlined under "Ignition Timing".
Ignition Timing
1.
Connect timing light to No. 1 spark plug. Connect
power supply leads on light to battery (12 volts).
Refer to "Specifications" 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 harmonic balancer.
a-Degree Marks
b-Timing Mark
5.
Adjust timing by loosening distributor clamp and
rotating distributor body as required until timing
mark on balancer or pulley lines up the mark on
tab specfied in "Specifications". Tighten clamp and
recheck location of timing mark.
6.
Stop engine and remove timing light.
IMPORTANT: GM engine timing marks (on tab) are in
2° increments. MCM and MIE L.H. engines will have
"A" (Advance) mark to left of "0". MIE R.H. engines will
have the "A" mark on the right of "0". Timing must be
set on the "A" side of "0" (Top Dead Center).
90-1 4499--1 887
ELECTRICAL SYSTEM -48-17
Testing HEI System
A WARNING
Be sure that engine compartment is well ventilated and
that there are no gasoline vapors present during the
following test -to prevent a potential fire hazard.
Check all Terminal Connections
at Distributor, Ignition Amplitier
& Ignition Coil
Battery OK?
Dist. Clamping Screw Tight?
Replace
Ignition
Amplifier
Volts
Disconnect WHT I RED Lead From
Dist. Term. Then
Check for 12-Volt
on This Lead
Volts
Replace
Ignition
Sensor in
Distributor
0
Volts
Spark
With Key in Run Position, Check
for 12-Volt at Positive (+)
Terminal on Ignition Coil
Check for 12-Volts at WHT /RED
Terminal on Distributor
Volts
Remove Hi-Tension Lead
from Dist. to Coil.
Insert a Spark Gap from
Coil Tower to Ground. Remove
WHT/GRN Lead from Dist.
Terminal -Ignition Key in
Run Position. Strike the
Terminal on the WHT/GRN Lead
Against Ground
0
Volts
Spark
@
Coil
Check Engine
& Instrument
Wiring Harness,
Battery Cables,
Key Switch
Replace
Ignition
Sensor in
Distributor
No Spark Coil
Substitute a New Ignition
Coil. Repeat Above Test
No Spark @ Coil
Spark@Coil
Install New
Ignition
Coil
Replace Ignition Amplifier
48-18-ELECTRICAL SYSTEM 90-14499--1 887
ELECTRICAL SYSTEM
CHARGING SYSTEM
Table of Contents
Page
MANDO ALTERNATOR ...................... 4C-1
Specifications ................................ 4C-1
Torque Specifications ................•....... 4C-1
Special Tools ...............•....•...•••.•... 4C-1
Identification......................•..••...... 4C-2
Replacement Parts Warning ..•.........•••....4C-2
System Components ......................... 4C-2
Precautions ...........................••..... 4C-2
Diagnosis ......................••............ 4C-3
Diagnosis of Engine ..............•........ 4C-3
Alternator System Circuitry Test ......••....4C-4
Output Circuit ............................. 4C-4
Excitation Circuit .......................... 4C-4
Sensing Circuit. ........................... 4C-5
Current Output .....•..............•.......4C-5
Voltage Output ..•.•....................... 4C-6
Repair ..............••....................... 4C-7
Removal .........•••...................... 4C-7
Disassembly ........................•..... 4C-8
Inspection and Cleaning ............•..... 4C-10
Component Testing ........................ .4C-10
Rotor..................•................. 4C-10
Stator ...........................•.•..... 4C-11
Negative Rectifier Diodes .................4C-12
Positive Rectifier Diodes and Diode Trio ...4C-12
Condenser ............................... 4C-13
Reassembly ............•....................4C-13
Installation .................................. 4C-15
Drive Belt Replacement and Adjustment ......4C-15
MOTOROLA ALTERNATOR ................. 4C-16
Specifications ............................... 4C-16
Torque Specifications ....................... 4C-16
Special Tools ..........•.................... 4C-16
Identification ................................ 4C-17
Replacement Parts Warning .................. 4C-17
System Components ........................ 4C-17
Precautions..............•..................4C-17
Diagnosis ..............••................... 4C-18
Diagnosis on Engine ......................... 4C-18
Alternator System Circuitry Test. ..........4C-19
Output Circuit. ........................... 4C-19
Excitation Circuit. ........................ 4C-19
Sensing Circuit. .......................... 4C-20
Current Output .........•........•..••.... 4C-20
Voltage Output ........................... 4C-21
Repair .............•.•...................... 4C-22
Removal .......•..............•.......... 4C-22
Disassembly ..................•.......... 4C-23
Page
Inspection and Cleaning .................. 4C-25
Component Testing ................•........ 4C-25
Rotor....................•.•.•..•••...... 4C-25
Stator .....................•............. 4C-26
Negative Rectifier Diodes ................. 4C-26
Positive Rectifier Diodes and Diode Trio ...4C-27
Condenser ............................... 4C-28
Reassembly ................................. 4C-28
Installation .................................. 4C-31
Drive Belt Replacement and Adjustment ...... 4C-31
PRESTOLINE ALTERNATOR .. 4C-32
Specifications ............................... 4C-32
Special Tools ............................... 4C-32
Torque Specifications ....................... 4C-32
Sealants .................................... 4C-32
Description ................................. 4C-33
Diagnosis on Engine ......................... 4C-33
System Components ........................ 4C-34
Exploded View .............................. 4C-35
Alternator/Regulator Tests ................... 4C-36
TestNo. 1 (Alternator Output Test) ........4C-36
Test No. 2 (Harness Voltage Test) .........4C-36
Test No.3 (Open Diode-Trio Test) ......... 4C-36
Test No. 4 (Open Regulator Test) .......... 4C-37
Repair ...................................... 4C-38
Removal ................................. 4C-38
Disassembly ............................. 4C-38
Inspection and Cleaning .................. 4C-41
Front Bearing ............................... 4C-41
Removal ................................. 4C-41
Installation ............................... 4C-41
Slip Rings/Rear Bearing ..................... 4C-41
Removal ................................. 4C-41
Installation ............................... 4C-42
Component Tests ........................... 4C-43
Rotor .................................... 4C-43
Stator ................................... 4C-43
Rectifier Bridge/Diode Trio Assembly ...... 4C-44
Rectifier Bridge .......................... 4C-44
Diode-Trio ............................... 4C-45
Condenser ............................... 4C-45
Voltage Regulator ........................ 4C-45
Assembly ................................... 4C-46
Installation .................................. 4C-49
Drive Belt Replacement and Adjustment ...... 4C-49
ELECTRICAL SYSTEM -4C 90-1 4499--1 889
MAN DO ALTERNATOR
SPECIFICATIONS
Excitation Circuit 1.3 to 2.5 Volts
Current Output 50 Amp. Min.
Voltage Output 13.9 to 14.7 Volts
Condenser Capacity .5 MFD
TORQUE SPECIFICATIONS
FASTENER LOCATION LBS. FT. {N.m} LBS. IN. {N.m}
End Frame Screws 50-60 (6-7)
Brush Set Screws 16-20 (1-2)
Regulator Mounting Screws 40-45 (4-5)
Regulator Leads 20-30
Ground Terminal Nut 20-30
Pulley Nut 35-50 ( 48-68)
Alternator Brace to Alternator 192 (28)
Alternator Brace to Block 30 (41 )
Alternator to Mounting Bracket 35 (48)
Alternator Mounting Bracket 30 (41 )
V-Belt Tension (Note 1) Depress 1/2 ln.
NO TE 1: Depress belt with Thumb at Midway Point between
Circulating Pump Pulley and Alternator
SPECIAL TOOLS
91-76032 Magneto Analyzer
91-93572 Volt/Ohm Meter
90-1 4499--1 887
\}1
ELECTRICAL SYSTEM -4C-1
Identification
Man do
Replacement Parts Warning
AWARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion. 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.
4C-2 -ELECTRICAL SYSTEM
·.:··:·,.6f<:':{f.::
System Components
The alternator system, used on engines with Mando
Alternators consists of the alternator, battery, the ignition
switch and the wiring which connects these components.
a-Starter i -Output Lead
b -Alternator j-Purple
c -Ignition Switch k -Excitation Lead
d-Coil I -Red/Purple
e -Battery Meter m-Sensing Lead
f-Harness Plug n-Red
g-Circuit Breaker o-Resistance Wire
h-Orange
Precautions
The following precautions must be observed when
working on the alternator system. Failure to observe
these precautions may result in serious damage to the
alternator or alternator system.
1.
Do not attempt to polarize the alternator.
2.
Do not short across or ground any of the terminals
on the alternator, except as specifically instructed.
3.
Never disconnect the alternator output lead or battery
cables when the alternator is being driven by
the engine.
4.
Never disconnect regulator lead from alternator
regulator terminal when the alternator is being
driven by engine.
5.
Always remove negative (-) battery cable from battery
before working on alternator system.
6.
When installing battery, be sure to connect the negative
(-) (grounded) battery cable to negative (-)
battery terminal and the positive (+) battery cable to
positive (+) battery terminal.
7.
If a charger or booster battery is to be used. Be sure
to connect it in parallel with existing battery (positive
to positive; negative to negative).
90-1 4499--1 887
··I...,, , ....·
_.:"' ·
·
"'-..,/
Diagnosis
The alternator employs a rotor, which is supported in 2
end frames by ball bearings, and is driven (via a pulley)
r.
at approximately twice engine speed. The rotor contains
a field winding that is enclosed between 2
multiple-finger pole pieces. The ends of the field winding
are connected to 2 brushes (mounted in the rear
end frame) which make continuous sliding (or slipping)
contact with the slip rings. The current (flowing
through the field winding) creates a magnetic field that
causes the adjacent fingers of the pole pieces to
become alternate north and south magnetic poles.
A 3-phase stator is mounted directly over the rotor pole
pieces and between the 2 end frames. It consists of 3
windings wound 120° electrically out-of-phase on the
inside of a laminated core. The windings are all connected
together on one end, while the other ends are
connected to a full-wave rectifier bridge.
The rectifier bridge contains 6 diodes which are arranged
so that current flows from ground, thru the
stator and to the output terminal, but not in the opposite
direction.
When current is supplied to the rotor field winding, and
the rotor is turned, the movement of the magnetic fields
created induces an alternating current into the stator
windings. The rectifier bridge then changes this alternating
current to direct current which appears at the
output terminal. A diode trio also is connected to the
stator windings to supply current to the regulator and
the rotor field during operation.
Voltage output of the alternator is controlled by regulating
the current supplied to the rotor field. This is
accomplished by a transistorized voltage regulator
that senses the voltage at the battery and regulates the
field current to maintain alternator voltage within prescribed
limits for properly charging the battery. Current
output of the alternator does not require regulation, as
maximum current output is self-limited by the design
of the alternator. As long as the voltage is regulated
within the prescribed limits, the alternator cannot produce
excessive current. A cutout 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.
Due to the lack of residual magnetism in the rotor pole
pieces, a small amount of current must be supplied to
the rotor field to initially start the alternator charging.
This is accomplished by means of an excitation circuit
in the regulator which is connected to the ignition
switch. Once the alternator begins to produce output,
field current is supplied solely by the diode trio, as
explained, preceding.
The alternator also is equipped with a fan (mounted on
the rotor shaft) which induces air flow through the
alternator to remove the heat created by the rectifier
and stator. A capacitor also is utilized to protect the
rectifier system from high voltages and to suppress
radio noise.
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 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
battery. Battery must be at least 75% (1 .230 specific
gravity) of fully charged to obtain valid results in the
following tests. If not, charge battery, before testing
system.
3.
Inspect entire alternator system wiring for defects.
Check all connections for tightness and cleanliness,
particularly battery cable clamps and battery
terminals.
4.
Check alternator drive belt and replace if necessary.
Also, check tension and adjust if necessary, as
outlined under "Drive Belt Replacement and Adjustment".
Diagnosis on Engine
Before proceeding with the tests, perform the following
checks to eliminate possible problem areas. Also
observe "Precautions," immediately preceding, to prevent
damage to alternator system.
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 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
battery. Battery must be at least 75% (1 .230 specific
gravity) of fully charged to obtain valid results in the
following tests. If not, charge battery before testing
system.
3.
Inspect entire alternator system wiring for defects.
Check all connections for tightness and cleanliness,
particularly battery cable clamps and battery
terminals.
4.
Check alternator drive belt and replace if necessary.
Also, check tension and adjust if necessary, as
outlined under "Drive Belt Replacement and Adjustment."
90-1 4499--1 887
ELECTRICAL SYSTEM -4C-3
ALTERNATOR SYSTEM CIRCUITRY TEST
Perform the following tests, using a 0-20 volt DC voltmeter,
to check that all of the circuits between the
alternator and the other components within the alternator
system are in good condition.
Output Circuit
1.
Connect positive voltmeter lead to alternator output
terminal and negative lead to a ground terminal on
alternator.
2.
Shake engine wiring harness while observing voltmeter.
Meter should indicate approximately battery
voltage and should not vary. If no reading is
obtained, or if reading varies, check alternator output
circuit for loose or dirty connections or damaged
wiring.
20
:__1
a-Output Terminal
b-Ground Terminal
Excitation Circuit
1.
TEST 1: Remove screws which secure the regulator
to the alternator.
2.
Connect positive (+) voltmeter lead to regulator
terminal (green wire) on alternator and negative(-)
lead to ground terminal on alternator.
#
1
#2
a -Ground Terminal
b-Green Wire
c-Purple Wire
3.
Turn ignition switch to "on" position and note voltmeter
reading. Reading should be 1.3 to 2.5 volts.
4.
If no reading is obtained, an opening exists in alternator
excitation lead or in excitation circuit of regulator.
Unplug purple lead from regulator.
/\
5.
TEST 2: Connect positive voltmeter lead to purple ·.. lead and negative voltmeter lead to ground. If voltmeter
now indicates approximate battery voltage,
voltage regulator is defective and must be replaced.
If no voltage is indicated, check excitation circuit
for loose or dirty connections or damaged wiring.
6.
If reading is between .75 and 1.1 volts, rotor field
circuit probably is shorted or grounded. Disassemble
alternator and test rotor as outlined under
"Alternator Repair", following.
7.
If reading is between 6.0 and 7.0 volts, rotor field
circuit probably is open. Remove regulator and
inspect for worn brushes or dirty slip rings. Replace
brushes if less than 1" (6.5mm) long. If brushes and
slip rings are in good condition, disassemble alternator
and test rotor, as outlined following.
4C-4 -ELECTRICAL SYSTEM
90-14499--1 887
Sensing Circuit
1.
Unplug red/purple lead from voltage regulator.
2.
Connect positive voltmeter lead to red/purple lead
and negative voltmeter lead to ground terminal.
a-Output (Orange)
b-Sensing (Red-Purple)
3.
Voltmeter should indicate battery voltage. If battery
voltage is not present, check sensing circuit (red/purple
lead) for loose or dirty connections or damaged
wiring.
CURRENT OUTPUT
Perform this test to check if alternator is capable of
producing rated current output, using a 0-50 amp DC
ammeter.
A WARNING
Be sure that engine compartment is well-ventilated and
that there are no gasoline vapors present (during the
test) to prevent the possibility of an explosion and/or a
fire, should a spark occur.
1.
Disconnect negative (-) battery cable from battery.
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.
a-Output (Orange)
b -Jumper Lead
3.
Reconnect negative battery cable.
4.
Remove coil hi-tension lead from distributor cap
tower and ground it to block. Turn on all accessories
and crank engine over with starter motor for
15-20 seconds.
5.
Turn off accessories and reinstall coil hi-tension
lead. Start engine and adjust engine speed to 15002000
RPM. Quickly observe ammeter. Reading
should be at least 30 amps.
6.
If reading is low, stop engine and connect a jumper
lead between alternator output terminal and regulator
terminal. Repeat Steps 4 and 5.
7.
If reading is now within specifications, diode trio is
faulty, replace diode trio.
8.
If reading is still low with jumper lead connected,
perform "Voltage Output Test," following, to determine
if fault is in regulator or alternator.
90-14499--1 887
ELECTRICAL SYSTEM -4C-5
VOLTAGE OUTPUT
Perform this test to determine if voltage regulator is
operating correctly, using a 0-20 volt DC voltmeter.
IMPORTANT: Battery must be fully charged (1.260 or
above specific gravity) to obtain proper voltage reading
in this test. If necessary, charge with a battery
charger or run engine to charge battery.
1.
Connect positive (+) voltmeter lead to positive battery
terminal and negative (-)voltmeter lead to negative
terminal.
+
-20@
2.
Start engine and run at fast idle until engine reaches
normal operating temperature. Adjust engine speed
to 1500-2000 RPM and observe voltmeter for highest
reading. Reading should be between 13.9 and
14.7 volts.
3.
If reading is high, check for a loose or dirty regulator
ground lead connection. If connection is good
(and sensing circuit checks out good) voltage regulator
is faulty and must be replaced. Be sure to
disconnect battery cables before attempting to
remove regulator.
A WARNING
Be sure that engine compartment is well-ventilated and
that there are no gasoline vapors present to prevent the
possibility of an explosion and/or a fire, should a spark
occur.
ACAUTION
Do not allow jumper wire to contact alternator end
frame, as diode trio and regulator may be damaged.
4.
If reading is low, stop engine and remove regulator
attaching screws. Pull regulator away from alternator
end frame to gain access to field and regulator
terminals. Do not disconnect regulator terminals.
Connect a jumper lead from the ground stud to the
brush terminal that has a tan wire attached. Restart
engine and gradually increase engine speed to 1500
RPM while observing voltmeter. Do not allow voltage
to exceed 16 volts.
a-Jumper Lead
b -Ground Stud
5.
If a voltmeter reading of 14.5 volts or above is now
obtained, voltage regulator must be replaced. If
voltmeter reading is below 14.5 volts, inspect
brushes and slip rings. If brushes and slip rings are
good, alternator is faulty internally. Disassemble
alternator and test components.
4C-6 -ELECTRICAL SYSTEM
90-14499--1 887
Repair
REMOVAL
1. Disconnect batte
2. Disconnect wirin..Yh....les from battery. 3. Remove alternator bra..ss from alternator.
bolt, washer(s) and
e t.. alternator attach.
4. Loosen alternate bspacer (If used).
mg
and 1 r race to en ·
. a ternator mounting b It
gme attaching bolt
5. ..:......e
a
a
n
l
d
t
remove alterna..o; ...... v :pb
iv
l
o
t
t alternator
ernator mo r e .
spacer and nut and re
un mg bolt, washers (if used)
move alternator.
,
1. Regulator Attaching
Screw (6)
2. Lockwasher (6)
3. Flatwasher (4)
4· Regulator
5· Brush Set
6. Rubber Seal
7. Nut
8. Lockwasher (6)
9. Flatwasher (2)
10. Condenser
11. Nut
12. Lockwasher (2)
13. Flatwasher (2)
14.1nsulating Washer (3)
15.Rear End Frame
16. 1nsulating Sleeve -Lon H. Insulating Sle
g
18 N
eve -Short
. egative (-) Rectifier
19 PosT · 1 •ve (-tl Rectifier
90-14499--1 887
20.1nsulator -R
21 Cl. ectangular · IP (2)
22. Positive (+) R
..
A
ecllf1er
ttaching Screw (1)
23 Neg 1· · a •ve (-) Rect•'f'
Att ·
•er
achmg Screw (2)
24.Stator
25.Rotor
26. Front Bear
27. Front Bea
mg Retaining Plate
nng
28. Front End F rame
29. Front Bearing Retainin
Plate Screw (3)
g
30.Spacer
31 .Front E dF n rame Attach·
Screw (3)
mg
32.Fan
33.Pulley
34. Lockwasher
35.Nut
I
I
I
I
ELECTRICAL SYSTEM -4C-7
DISASSEMBLY
The following instructions are for complete disassembly
and overhaul of the alternator. In many cases, however,
complete disassembly of alternator is not required
and, in those cases, it is necessary only to
perform the operations required to repair or replace
the faulty part.
1.
Mount alternator in a vise.
2.
Disconnect regulator leads from terminals on rear
end frame. Remove regulator attaching screws,
then pull regulator away from rear end frame and
disconnect regulator field leads. Remove seal.
3.
Remove brush set attaching screws and brush set.
4.
Scribe a mark on rear end frame, stator and front
end frame to ensure proper reassembly.
5.
Remove end frame screws.
A CAUTION
Do not Insert screwdrivers more than 1/16" (1.6mm)
into openings as stator windings may be damaged.
a-Insert Screwdriver Blades into Slots
b-Rear End Frame
c-Stator
d -Front End Frame
6.
Separate rear end frome and staor assembly from
front end frame and rotor assembly using 2 screwdrivers
as shown. Use the two slots shown to
initially separate units.
7.
Place rear end frame and stator assembly on bench
with stator downward. Remove nuts, washers, insulators
and condenser from output and ground
studs.
8.
Turn end frame over (stator upward) and remove
the three screws which secure rectifiers to end
frame.
a -Rectifiers
b-Screws
9. Unsolder diode trio lead from the insulated regula
tor terminal.
a -Diode Trio
b -Diode Trio Lead
c-Insulated Regulator Terminal
4C-8 -ELECTRICAL SYSTEM
90-14499--1 887
10. Unsolder the three stator leads along with the three
coated leads from the negative (-) rectifier heat
sink. Place a needle nose pliers on diode terminal
between solder joint and diode body to help prevent
0-,. heat damage to diodes. Unsolder joints as quickly
as possible and allow diode terminal to cool before
removing pliers.
a-Negative (-) Heat Sink
b -Stator Leads (3)
c-Coated Leads (3) (2 Shown)
IMPORTANT: Do not clamp vise on rotor pole pieces
when removing pulley nut, as pole pieces may be distorted.
11. Remove
pulley nut as shown (using an oversize
V-belt or protective jaws to protect pulley). Remove
lockwasher, pulley, and fan.
12. Remove the screws and lockwashers which secure
the front bearing retaining plate.
a -Screws and Lockwashers
b-Front Bearing Retaining Plate
13. Remove front bearing from front end frame using an
arbor press. (Discard bearing).
14. 1f rotor slip rings or rear bearing require replacement,
entire rotor must be replaced. Parts can not be
purchased separately.
a -Oversize V-Belt
90-1 4499--1 887
ELECTRICAL SYSTEM -4C-9
INSPECTION and CLEANING
1.
Clean all parts with a clean, soft cloth. Do not use
solvent, or electrical components may be damaged.
2.
Inspect the following,
a.
Brush set -inspect for cracked porcelain casing,
damaged brush leads, poor brush springs or
worn brushes. Replace brush set if brushes are
less than l" (6.5mm) long.
b.
Rotor -inspect for stripped threads, scuffed pole
piece fingers or damaged bearing surfaces (because
of for bearing turning on shaft).
c.
Rotor slip rings -clean slip rings with 400 grain
(or finer) polishing cloth while spinning rotor in
a lathe. Blow off dust with compressed air.
Inspect slip rings grooves, pits, flat spots or outof-
round [.002" (.05mm) maximum] and replace,
if required.
d.
Rotor shaft bearings -inspect for damaged
seals, lack of lubrication, discoloration (from
overheating) or excessive side or end play. Hold
inner race of bearings while turning outer race.
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.
Regulator -inspect leads for damaged insulation.
g.
Front and rear end frames -inspect for cracks,
distortion, stripped threads or wear in bearing
bore (from bearing outer race spinning in bore).
End frame(s) must be replaced, if bearing has
spun. Also, inspect bearing retainer recess in
front end frame for damage.
h.
Fan -inspect for cracked or bent fins, broken
welds (bi-directional fan only) or worn mounting
hole (from fan spinning on shaft).
i.
Pulley -inspect pulley mounting bore and for
wear. Inspect drive surface of pulley sheaves for
trueness, excessive wear, or corrosion. Repair
damaged surfaces, if possible, with a fine file
and a wire brush or replace pulley. Drive surfaces
must be true and smooth, or drive belt
wear will be greatly accelerated.
j.
Alternator -if alternator has output at low
speeds, but no output at high speeds, rotor field
winding may be shorting or grounding out.
because of centrifugal force. Replace rotor, if all
other electrical components test good.
COMPONENT TESTING
Rotor
1.
(Test 1 ), rotor field circuit for opens, shorts or high
resistance. Use an ohmmeter (set on Rx1 scale), as
follows:
# 1
#2
a.
Connect one ohmmeter lead to each slip ring.
b.
Ohmmeter reading should be 4.2 to 5.5 ohms
with rotor at room term perature 70°-80° F
(21 ° -26° C).
c.
If reading is high or infinite (no meter movement).
high resistance or an open exists in the
field circuit. Check for poor connections between
field winding leads and slip ring terminals.
If cause for open or high resistance cannot be
found, connect ohmmeter directly to slip ring
terminals. If correct reading is now obtained, or
if reading is still high or infinite, replace complete
rotor assembly.
d.
If reading is low, a short exists in the field circuit.
Inspect slip rings to be sure that they are not
bent and touching outer slip ring. Also be sure
that excess solder is not shorting terminals to aft
slip ring. If cause for short cannot be found,
unsolder filed winding leads from slip ring terminals
and connect ohmmeter directly to leads.
If correct reading is now obtained, or if reading
is still low, slip rings and rotor field windings are
shorted, and complete rotor assembly must be
replaced.
4C-10 -ELECTRICAL SYSTEM
90-14499--1 887
frame.
Meter should indicate no
should not move). If continuity does exist, stator
must be replaced.
2.
{TEST 2), rotor field circuit for grounds. Use an
ohmmeter (set on Rx1 scale) as follows:
a.
Connect one lead of ohmmeter to either slip 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, rotor field circuit is
grounded. Inspect slip ring terminals to be sure
that they are not bent and touching rotor shaft.
Also be sure that excess solder is not grounding
terminals to rotor shaft. If cause for ground cannot
be found, unsolder field winding leads from
slip ring terminals and connect ohmmeter between
one of the leads and rotor shaft or pole
pieces. If continuity still exists, replace rotor
assembly. If continuity is eliminated, replace slip
rings.
Stator
IMPORTANT: Stator leads must be disconnected from
rectifier diodes and diode trio for this test.
1.
{TEST 1), stator for grounds using an ohmmeter
(set on Rx1 scale) as follows:
a.
Connect one lead of ohmmeter to one of the
stator leads and the other lead to stator frame.
Be sure that lead makes good contact with
continuity (meter
#1 #2 #2 #2
2.
{TEST 2), for opens in stator using an ohmmeter
(set on Rx1 scale) as follows:
a.
Connect ohmmeter or test lamp between each
pair of stator windings (3 different ways).
Continuity should be present in all 3 cases
(meter should move. If it does not, one or more
of the windings are open and stator must be
replaced.
3.
A short in the stator is difficult to detect without
special equipment, because of the low windings
resistance. If all other electrical components test
out good, and alternator fails to produce rated output,
stator probably is shorted and should be
replaced. Also, examine stator for heat discolorations,
as this usually is a sure sign of a short.
ELECTRICAL SYSTEM -4C-1 1
90-14499--1 887
Negative (-) Rectifier Diodes
IMPORTANT: Rectifier diodes must be disconnected
from stator for this test.
IMPORTANT: Do not use a test instrument with more
than a 12-volt source as rectifier diodes may be damaged.
1.
Connect one lead of an ohmmeter (set on Rx1
scale) to negative (-) rectifier diode heat sink and
the other lead to one of the rectifier diode terminals.
Note the reading.
2.
Reverse leads and again note reading.
3.
Meter should indicate a high or infinite resistance
(no meter movement) when connected one way and
a low reading when connected the other. If both
readings are high or infinite, diode is open. If both
readings are low, diode is shorted.
4.
Repeat Steps 1-thru-3 for 2 other rectifier diodes in
heat sink.
5.
Replace complete rectifier set, if any one of the
diodes is shorted or open.
a-Heat Sink
b-Diode Terminal
c -Test These 2 Diodes in Same Manner
4C-12 -ELECTRICAL SYSTEM
Positive (+) Rectifier Diodes and Diode Trio
IMPORTANT: Do not use a test instrument with more
than a 12-volt source (in the following test), as rectifier
diodes may be damaged.
1.
Connect one lead of an ohmmeter (set on Rx1 ''..
scale) to )" stud on positive (+) rectifier heat sink
and the other lead to one of the rectifier diode terminals.
(Note: Two of the diode terminals come up
thru the diode trio circuit board.) Note the meter
reading.
2.
Reverse leads and again note reading.
3.
Meter should indicate a high or infinite resistance
(no meter movement) when conected one way and
a low reading when connected the other. If both
readings are high or infinite, diode is open. If both
readings are low, diode is shorted.
4.
Repeat Steps 1-thru-3 for 2 other rectifier diodes in
heat sink.
5.
Replace complete rectifier set, if any one of the
diodes is shorted or open.
a-Stud
b-Repeat Test between These Terminals and Stud
.Y"\··
·
90-1 4499--1 887
6. Connect one lead of an ohmmeter (set on Rx1
scale) to the common side on the diode trio circuit
board and the other lead to the other side of one of
the three trio diodes. Note the reading.
7. Reverse leads and again note reading.
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 both
readings are high or infinite, diode trio is open. If
both readings are low, diode trio is shorted.
9. Repeat Steps 6-thru-8 for the other 2 diodes.
10. Replace positive (+) rectifier and diode trio assembly
if any one of the diodes is shorted or open.
Rx1 ((})a-Common Side of Diode Trio Circuit Board
Condenser
1. Using Magneto Analyzer (91-76032) and accompanying
instructions, perform the following condenser
tests:
a. Condenser Capacity Test (must be .5 mfd)
b. Condenser Short or Leakage Test
c. Condenser Series Resistance Test
2. Replace condenser, if test results are not within
specifications.
90-1 4499--1 887
REASSEMBLY
1. Install new front bearing into front end frame bearing
bore using an arbor press.
a-End Frame
b -Arbor Press
2. Install front bearing retaining plate, screws and
lockwashers.
a -Screws and Lockwashers
b-Front Bearing Retaining Plate
ELECTRICAL SYSTEM -4C-13
3.
Slide front end frame over rotor.
IMPORTANT: Do not clamp vise on rotor pole pieces
when tightening pulley nut (in next step), or pole
pieces may be distorted.
4.
Install spacer, 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 specifications.
A CAUTION
The insulating washers must be installed as shown or
damage to the alternator will result.
5.
Install positive (+) and negative (-) rectifier heat
sinks, as shown.
6.
Position rear end frame and stator assembly over
front end frame and rotor assembly and align scribe
marks on each (scribed during assembly). Handpress
end frames together, then install screws.
Torque screws evenly to specifications.
a-Positive (+) Rectifier Heat Sink
b-Rectangular Insulator
c -Lockwasher
d-Screw -1-1/2" (38mm) Long
e-Screw -1/2" (13mm) Long; 2 Required
f-Clip
g-Negative (-) Rectifier Heat Sink
h-Insulator
i -Rear End Frame
j -Flat Washer
k-Nut
I -Condenser
4C-1 4-ELECTRICAL SYSTEM
7.
Place brush set in end frame and secure with
mounting screws. Be sure to use outer-most mounting
holes. Torque screws to specifications.
8.
Position seal on regulator mounting surface. Connect
regulator field leads and regulator lead to
brush and regulator terminals, then mount regulator.
Torque screws to specifications. Connect
ground terminal and secure with lockwashers and
nuts. Torque nuts to specifications.
a -Brush Set (Use Outer Mounting Holes)
b-Be Sure to Connect Field Leads as Shown
c-Regulator Seal
d -Insulated Regulator Terminal
A CAUTION
Regulator field leads must be connected as shown, or
leads may be damaged by rotor slip rings during operation.
90-1 4499--1 887
INSTALLATION
1.
Position alternator in mounting bracket and install
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 at
this time.
3.
Position alternator drive belt on pulleys and adjust
tension per specifications.
4.
Tighten all fasteners securely.
r 5. Reconnect wiring to alternator and battery cables
"--"' to battery.
Drive Belt Replacement
and Adjustment
IMPORTANT: When adjusting drive belt tension (in
next step), do not apply pressure to alternator rear end
frame, as alternator may be damaged.
1.
Check belt tension by depressing belt with thumb at
midway point. Belt should depress I" (13mm).
a-Circulating Pump Pulley
b-Check Point
c -Alternator
2.
If adjustment or replacement is necessary, loosen
alternator brace attaching bolts and alternator
mounting bolt.
3.
Pivot alternator inward to replace drive belt.
4.
Pivot alternator outward, to obtain correct belt tension.
Apply pressure to alternator front end frame
only. Set new belts at high reading.
5.
Retighten alternator brace attaching bolts and alternator
mounting bolt securely.
6.
Recheck drive belt tension.
90-14499--1 887
ELECTRICAL SYSTEM -4C-15
MOTOROLA ALTERNATOR
SPECIFICATIONS
Excitation Circuit 1.3 to 2.5 Volts
Current Output 50 Amp. Min.
Voltage Output 13.9 to 14.7 Volts
Condenser Capacity .5 MFD
'..' '
TORQUE SPECIFICATIONS
FASTENER LOCATION LBS. FT. (N.m) LBS. IN. (N.m)
End Frame Screws 50-60 (6-7)
Brush Set Screws 16-20 (1-2)
Regulator Mounting Screws 40-45 (4-5)
Regulator Leads 20-30 (2-3)
Ground Terminal Nut 20-30 (2-3)
Pulley Nut 35-50 ( 48-68)
Alternator Brace to Alternator 192 (28)
Alternator Brace to Block 30 (41 )
Alternator to Mounting Bracket 35 (48)
Alternator Mounting Bracket 30 (41 )
V-Belt Tension (Note 1) Depress 1/2 ln.
NOTE 1: Depress Belt with Thumb at Midway Point between
Circulating Pump Pulley and Alternator.
SPECIAL TOOLS
91-76032 Magneto Analyzer
91 -93572 Volt/Ohm Meter
4C-16-ELECTRICAL SYSTEM 90-14499--1 887
Identification
Motorola
System Components
The alternator system, used on engines with Mando
Alternators consists of the alternator, battery, the ignition
switch and the wiring which connects these components.
Replacement Parts Warning
A WARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion. 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.
90-1 4499--1 887
a-Starter 1 -Output Lead
b -Alternator j-Purple
c -Ignition Switch k -Excitation Lead
d-Coil I -Red/Purple
e -Battery Meter m -Sensing Lead
f -Harness Plug n-Red
g-Circuit Breaker o -Resistance Wire
h-Orange
Precautions
The following precautions must be observed when
working on the alternator system. Failure to observe
these precautions may result in serious damage to the
alternator or alternator system.
1.
Do not attempt to polarize the alternator.
2.
Do not short across or ground any of the terminals
on the alternator, except as specifically instructed.
3.
Never disconnect the alternator output lead or battery
cables when the alternator is being driven by
the engine.
4.
Never disconnect regulator lead from alternator
regulator terminal when the alternator is being
driven by engine.
5.
Always remove negative (-) battery cable from battery
before working on alternator system.
6.
When installing battery, be sure to connect the negative
(-) (grounded) battery cable to negative (-)
battery terminal and the positive (+) battery cable to
positive (+) battery terminal.
7.
If a charger or booster battery is to be used. Be sure
to connect it in parallel with existing battery (positive
to positive; negative to negative).
ELECTRICAL SYSTEM -4C-17
Diagnosis
The alternator employs a rotor, which is supported in 2
end frames by ball bearings, and is driven (via a pulley)
at approximately twice engine speed. The rotor contains
a field winding that is enclosed between 2
multiple-finger pole pieces. The ends of the field winding
are connected to 2 brushes (mounted in the rear
end frame) which make continuous sliding (or slipping)
contact with the slip rings. The current (flowing
through the field winding) creates a magnetic field that
causes the adjacent fingers of the pole pieces to
become alternate north and south magnetic poles.
A 3-phase stator is mounted directly over the rotor pole
pieces and between the 2 end frames. It consists of 3
windings wound 120° electrically out-of-phase on the
inside of a laminated core. The windings are all connected
together on one end, while the other ends are
connected to a full-wave rectifier bridge.
The rectifier bridge contains 6 diodes which are arranged
so that current flows from ground, thru the
stator and to the output terminal, but not in the opposite
direction.
When current is supplied to the rotor field winding, and
the rotor is turned, the movement of the magnetic fields
created induces an alternating current into the stator
windings. The rectifier bridge then changes this alternating
current to direct current which appears at the
output terminal. A diode trio also is connected to the
stator windings to supply current to the regulator and
the rotor field during operation.
Voltage output of the alternator is controlled by regulating
the current supplied to the rotor field. This is
accomplished by a transistorized voltage regulator
that senses the voltage at the battery and regulates the
field current to maintain alternator voltage within prescribed
limits for properly charging the battery. Current
output of the alternator does not require regulation, as
maximum current output is self-limited by the design
of the alternator. As long as the voltage is regulated
within the prescribed limits, the alternator cannot produce
excessive current. A cutout 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.
Due to the lack of residual magnetism in the rotor pole
pieces, a small amount of current must be supplied to
the rotor field to initially start the alternator charging.
This is accomplished by means of an excitation circuit
in the regulator which is connected to the ignition
switch. Once the alternator begins to produce output,
field current is supplied solely by the diode trio, as
explained, preceding.
The alternator also is equipped with a fan (mounted on
the rotor shaft) which induces air flow through the
alternator to remove the heat created by the rectifier
and stator. A capacitor also is utilized to protect the
rectifier system from high voltages and to suppress
radio noise.
Diagnosis On Engine
Before proceeding with the tests, perform the following
checks to eliminate possible problem areas. Also
observe "Precautions," immediately preceding, to prevent
damage to alternator system.
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 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
battery. Battery must be at least 75% (1 .230 specific
gravity) of fully charged to obtain valid results in the
following tests. If not, charge battery before testing
system.
3.
Inspect entire alternator system wiring for defects.
Check all connections for tightness and cleanliness,
particularly battery cable clamps and battery
terminals.
4.
Check alternator drive belt and replace if necessary.
Also, check tension and adjust if necessary, as
outlined under "Drive Belt Replacement and Adjustment."
•I
4C-18-ELECTRICAL SYSTEM
90-14499--1 887
ALTERNATOR SYSTEM CIRCUITRY TEST
Perform the following tests, using a 0-20 volt DC voltmeter,
to check that all of the circuits between the
alternator and the other components within the alter
r nator system are in good condition.
.·
Output Circuit
1.
Connect positive voltmeter lead to alternator output
terminal and negative lead to a ground terminal on
alternator.
2.
Shake engine wiring harness while observing voltmeter.
Meter should indicate approximately battery
voltage and should not vary. If no reading is
obtained, or if reading varies, check alternator output
circuit for loose or dirty connections or damaged
wiring.
';. ..:
. ,--, '
90-14499--1 887
Excitation Circuit
1.
TEST 1: Connect positive (+) voltmeter lead to regulatorterminal
on alternator and negative(-) lead to a
ground terminal on alternator.
2.
Turn ignition switch to "On" position and note
voltmeter reading. Reading should be 1.5 to 2.5
volts.
#1
#2
@0-20VCM-TS -+
a-Sensing (Red-Purple)
b-Excitation (White or Purple)
c-Output (Orange or Red-White)
3.
If no reading is obtained, an opening exists in alternator
excitation lead or in excitation circuit of regulator.
Unplug white or purple lead from regulator.
4.
TEST 2: Connect positive voltmeter lead to white or
purple lead and negative voltmeter lead to ground.
If voltmeter now indicates approximate battery voltage,
voltage regulator is defective and must be
replaced. If no voltage is indicated, check excitation
circuit for loose or dirty connections or damaged
wiring.
5.
If reading is between .75 and 1.1 volts, rotor field
circuit probably is shorted or grounded. Disassemble
alternator and test rotor as outlined following.
6.
If reading is between 6.0 and 7.0 volts, rotor field
circuit probably is open. Remove regulator and
inspect for worn brushes or dirty slip rings. Replace
brushes if less than l" (6.5mm) long. If brushes and
slip rings are in good condition, disassemble alternator
and test rotor, as outlined under "Alternator
Repair."
ELECTRICAL SYSTEM -4C-19
a-Sensing (Red-Purple)
b-Excitation (Purple)
c-Output (Orange)
4C-20 -ELECTRICAL SYSTEM
5. Turn off accessories and reinstall coil hi-tension
lead. Start engine and adjust engine speed to 15002000
RPM. Quickly observe ammeter. Reading
should be at least 30 amps.
6. If reading is low, stop engine and connect a jumper
wire between alternator output terminal and regulator
terminal. Repeat Steps 4 and 5.
7. If reading is now within specifications, diode trio is
faulty. Disassemble alternator and replace diode
trio, as explained, following.
8. If reading is still low with jumper wire connected,
perform "Voltage Output Test," following, to determine
if fault is in regulator or alternator.
90-14499--1 887
7.
If reading is between 8.5 and 10.0 volts, an open
probably exists in load circuit of regulator. To be
certain that this is the problem, remove screws
which secure the regulator to the alternator. Connect
a jumper wire between regulator terminal and
field terminal. Do not allow jumper lead to touch
alternator housing. Repeat test. If jumper wire provides
correct voltmeter reading (1 .5 to 2.5 volts),
voltage regulator is faulty and must be replaced.
Sensing Circuit
1.
Unplug red/purple lead from voltage regulator.
2.
Connect positive voltmeter lead to red/purple lead
and negative voltmeter lead to ground terminal.
3.
Voltmeter should indicate battery voltage. If battery
voltage is not present, check sensing circuit (red/purple
lead) for loose or dirty connections or damaged
wiring.
CURRENT OUTPUT
Perform this test to check if alternator is capable of
producing rated current output, using a 0-50 amp DC
ammeter.
A WARNING
Be sure that engine compartment is well-ventilated and
that there are no gasoline vapors present to prevent the
possibility of an explosion and/or a fire, should a spark
occur.
1. Disconnect negative (-) battery cable from battery.
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.
a -Orange Wire and Ammeter
b -Jumper Wire
3. Reconnect negative battery cable.
4.
Remove coil hi-tension lead from distributor cap
tower and ground it to block. Turn on all accessories
and crank engine over with starter motor for
15-20 seconds.
VOLTAGE OUTPUT
Perform this test to determine if voltage regulator is
operating correctly, using a 0-20 volt DC voltmeter.
IMPORTANT: Battery must be fully charged (1.260 or
'-(
above specific gravity) to obtain proper voltage reading
in this test. If necessary, charge battery with a
battery charger or allow engine to run a sufficient
length of time to fully charge battery before taking
reading.
1.
Connect positive (+) voltmeter lead to positive battery
terminal and negative (-) voltmeter lead to negative
terminal.
2.
Start engine and run at fast idle until engine reaches
normal operating temperature. Adjust engine speed
to 1500-2000 RPM and observe voltmeter for highest
reading. Reading should be between 13.9 and
_J.. +
14.7 volts.
3.
If reading is high, check for a loose or dirty regulator
ground lead connection. If connection is good
(and sensing circuit checks out good) voltage regulator
is faulty and must be replaced. Be sure to
disconnect battery cables before attempting to
remove regulator.
A WARNING
Be sure that engine compartment is well-ventilated and
that there are no gasoline vapors present to prevent the
possibility of an explosion and/or a fire, should a spark
occur.
A CAUTION
Do not allow jumper wire to contact alternator end
frame, as diode trio and regulator may be damaged.
4.
If reading is low, stop engine and remove regulator
attaching screws. Pull regulator away from alternator
end frame to gain access to field and regulator
terminals. Do not disconnect regulator terminals.
Connect a jumper lead from the ground stud to the
brush terminal that has a tan wire attached. Restart
engine and gradually increase engine speed to 1500
RPM while observing voltmeter. Do not allow voltage
to exceed 16 volts.
a -Jumper Lead
5.
If a voltmeter reading of 14.5 volts or above is now
obtained, voltage regulator 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 and test components.
ELECTRICAL SYSTEM -4C-21
90-14499--1 887
REPAIR
REMOVAL
1.
Disconnect battery cables from battery.
2.
Disconnect wiring harness from alternator.
3.
Remove alternator brace to alternator attaching
bolt, washer(s) and spacer (if used).
4.
Loosen alternator brace to engine attaching bolt
and alternator mounting bolt, then pivot alternator
inward and remove alternator drive belt.
5.
Remove alternator mounting bolt, washers (if used),
spacer and nut and remove alternator.
c'i i:t,'l
;;··,f._,til!.
.
fl. ·..tf
·
..
f 'ff1tt ...H::rt .. t ewH.e
39 >.,·
-ALTERNATOR ASSEMBLY (55 Amp)
1. NUT
21. RETAINER
2. LOCKWASHER 22. COVER ASSEMBLY
3. PULLEY
23. CONDENSOR
4. FAN
24. WASHER
5. SPACER
25. WASHER
6. NUT
26. NUT
7. COVER ASSEMBLY 27. WASHER
8. BALL BEARING 28. LOCKWASHER
9. RETAINER
29. NUT
10. STATOR ASSEMBLY 30. WASHER
11. DIODE RECTIFIER, negative 31. THRU BOLT
12. HEAT SINK, positive 32. NUT
13. SLEEVE, insulator 33. BRUSH HOLDER ASSEMBLY
14. SLEEVE, insulator 34. SCREW
15. KEY
35. DIODE TRIO
16. ROTOR ASSEMBLY 36. SPACER
17. SLIP RING
37. GASKET
18. WASHER
38. VOLTAGE REGULATOR
19. LOCKWASHER 39. SCREW
20. SCREW
4C-22 -ELECTRICAL SYSTEM
90-14499--1 887
DISASSEMBLY
The following instructions are for complete disassembly
and overhaul of the alternator. In many cases, however,
complete disassembly is not required and, in
those cases, it is necessary only to perform the operations
requi red to repair or replace the faulty part.
1.
Mount alternator in a vise.
2.
Disconnect regulator leads from terminals on rear
end frame. Remove regulator attaching screws,
then pull regulator away from rear end frame and
disconnect regulator field leads. Remove seal.
3.
Remove brush set attaching screws and brush set.
4.
Scribe a mark on rear end frame, stator and front
end frame to ensure proper reassembly.
5.
Remove end frame screws.
A CAUTION
Do not insert screwdrivers more than 1/16" (1.5mm)
into openings as stator windings may be damaged.
6.
Separate rear end frame and stator assembly from
front end frame and rotor assembly using 2 screwdrivers,
in slots as shown.
7.
Remove (and discard) bearing retaining ring from
rear end frame.
8.
Place rear end frame and stator assembly on the
bench, stator downward. Remove nuts, washers,
insulators and condensor from rectifier mounting
studs and lift rear end frame from studs. Remove
insulating sleeves and washers from rectifier studs.
9.
Unsolder stator and diode trio leads from rectifier
diode terminals. Place a needle-nose pliers on
diode terminal between solder joint and diode body
(as shown) to help prevent heat damage to diodes.
Unsolder joints as quickly as possible and allow
diode terminal to cool before removing pliers.
10. Remove diode trio from positive rectifier heat sink.
NOTE: With alternator disassembled to this point, stator,
rectifier diodes, diode trio and rotor may be tested,
as explained under "Components Testing," following.
IMPORTANT: Do not clamp vise on rotor pole pieces
when removing pulley nut, as pole pieces may be distorted.
90-14499--1 887
ELECTRICAL SYSTEM -4C-23
11. Remove nut, lockwasher, pulley and fan (using an
old oversize V-belt or protective jaws to protect
pulley).
12. Remove key and spacer.
IMPORTANT: Do not remove front end frame from
rotor shaft, unless absolutely necessary, as front bearing
must be replaced, If It Is removed.
13. Compress ears of front bearing retainer and lift
retainerfree of recess in front end frame. Tap pulley
end of rotor shaft with a rawhide mallet to remove
rotor and front bearing assembly.
11585
4C-24 -ELECTRICAL SYSTEM
14. Remove front bearing from shaft with Universal
Puller Plate 91 -37241 or equivalent and an arbor
press, as shown. (Discard bearing).
15.1f rotor slip rings or rear bearing require replacement,
unsolder rotor field winding leads from slip
ring terminals and unwind end of leads. Remove
slip ring attaching screw, lockwasher and flat
washer and slip rings.
16.1f rear bearing requires replacement, remove with
Universal Puller Plate and arbor press. Bearing
must be replaced, if removed.
90-14499--1 887
90-1 4499--1 887
''")y;\1
INSPECTION and CLEANING
1.
Clean all parts with a clean, soft cloth. Do not use
solvent, or electrical components may be damaged.
2.
Inspect the following parts:
a.
Brush set -inspect for cracked porcelain casing,
damaged brush leads, poor brush lead solder
connections, weak or broken brush springs or
worn brushes. Replace brush set if brushes are
less than ,, (6.5mm) long.
b.
Rotor -inspect for stripped threads, worn keyway,
scuffed pole piece fingers or damaged
bearing surfaces (because of bearing turning on
shaft).
c.
Rotor slip rings -clean slip rings with 400 grain
(or finer) polishing cloth while spinning rotor in
a lathe. Blow off dust with compressed air.
Inspect slip rings for grooves, pits, flat spots or
out-of-rounders [.002" (0.5mm) maximum] and
replace, if required.
d.
Rotor shaft bearings -inspect for damaged
seals, lack of lubrication, discoloration (from
overheating) or excessive side or end play. Hold
inner race of bearings while turning outer race.
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.
Regulator -inspect leads for damaged insulation.
g.
Front and rear end frames -inspect for cracks,
distortion, stripped threads or wear in bearing
bore (from bearing outer race spinning in bore).
End frame(s) must be replaced, if bearing has
spun. Also, inspect bearing retainer recess in
front end frame for damage.
h.
Fan -inspect for cracked or bent fins, broken
welds (bi-directional fan only) or worn mounting
hole (from fan spinning on shaft).
i.
Pulley -inspect pulley mounting bore and key
groove for wear. Inspect drive surface of pulley
sheaves for trueness, excessive wear, or corrosion.
Repair, if possible, with a fine file and a wire
brush or replace pulley. Drive surfaces must be
true and smooth, or drive belt wear will be
greatly accelerated.
j.
Alternator -if alternator has output at low
speeds, but no output at high speeds, rotor field
winding may be shorting or grounding out,
because of centrifugal force. Replace rotor, if all
other electrical components test good.
COMPONENT TESTING
Rotor
1.
(TEST 1), rotor field circuit for grounds, using an
ohmmeter (set on Rx1 scale) as follows:
a.
Connect one lead of ohmmeter to either slip 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, rotor field circuit is
grounded. Inspect slip ring terminals to be sure
that they are not bent and touching rotor shaft.
Also be sure that excess solder is not grounding
terminals to rotor shaft. If cause for ground cannot
be found, unsolder field winding leads from
slip ring terminals and connect ohmmeter between
one of the leads and rotor shaft or pole
pieces. If continuity still exists, replace rotor
assembly. If continuity is eliminated, replace slip
rings.
2.
(TEST 2), rotor field circuit for opens, shorts or high
resistance, using an ohmmeter (set on Rx1 scale),
as follows:
a. Connect one ohmmeter lead to each slip ring.
b.
Ohmmeter reading should be 4.2 to 5.5 ohms
with rotor at room temperatur [70°-80° F (21°260
C)].
ELECTRICAL SYSTEM -4C-25
c.
If reading is high or infinite (no meter movement),
high resistance or an open exists in the
field circuit. Check for poor connections between
field winding leads and slip ring terminals.
If cause for open or high resistance cannot be
found, connect ohmmeter directly to slip ring
terminals. If correct reading is now obtained,
replace slip rings. If reading is still high or infinite,
replace complete rotor assembly.
d.
If reading is low, a short exists in the field circuit.
Inspect slip rings to be sure that they are not
bent and touching outer slip ring. Also be sure
that excess solder is not shorting terminals to aft
slip ring. If cause for short cannot be found,
unsolder field winding leads from slip ring terminals
and connect ohmmeter directly to leads.
If correct reading is now obtained, slip rings are
shorted and must be replaced. If reading is still
low, rotor field windings are shorted, and complete
rotor assembly must be replaced.
STATOR
IMPORTANT: Stator leads must be disconnected from
rectifier diodes and diode trio for this test.
1.
(TEST 1), Test stator for grounds, using an ohmmeter
(set on Rx1 scale) as follows:
a.
Connect one lead of ohmmeter or test lamp to
one of the stator leads and the other lead to
stator frame. Be sure that lead makes good contact
with frame.
Meter should indicate no continuity (meter
should not move). If continuity does exist, stator
is grounded and must be replaced.
#1 #2 #2 #2
2.
(TEST 2), for opens in stator, using an ohmmeter
(set on Rx1 scale) as follows:
a.
Connect ohmmeter or test lamp between each
pair of stator windings (3 different ways). Either
of the 2 leads (coming from each stator windings)
may be used.
Continuity should be present in all 3 cases
(meter should move); if it does not, one or more
of the windings are open and stator must be
replaced.
3.
A short in the stator is difficult to detect without
special equipment, because of the low windings
resistance. If all other electrical components test
out good, and alternator fails to produce rated output,
stator probably is shorted and should be
replaced. Also, examine stator for heat discolorations,
as this usually is a sign of a short.
Negative (-) Rectifier Diodes
IMPORTANT: Rectifier diodes must be disconnected
from stator for this test.
A CAUTION
Do not use a test instrument with more than a 12-volt
source as rectifier diodes may be damaged.
1.
Connect one lead of an ohmmeter (set on Rx1
scale) to negative (-) rectifier diode heat sink and
the other lead to one of the rectifier diode terminals.
Note the reading. ..:-:'
2.
Reverse leads and again note reading.
3.
Meter should indicate a high or infinite resistance
(no meter movement) when connected one way and
a low reading when connected the other. If both
readings are low, diode is shorted.
..c! ect>.• ;:;·xle
,'li.eB nolz1G.rlta:..-'.. .. Q)I a.>-0 :z:w ..
..a: ..
:z:(.')..
347-HR
4F-4 -ELECTRICAL SYSTEM
MCM 200 5.0 Litre Engine Wiring Diagram without 90 Amp Fuse
at Starter Motor (Orange Wire) (Battery Meter Circuit)
90-14499--1 887
90-14499--1 887
GROUNO SCREW ON INNER TRANSOM PLATE 12VOLTBATTERY TERMINAL
BLOCK
TRIM
SENDER
MCM 230/260 5.0 Litre LX, 5.7 Litre Engine (Battery Meter Circuit)
ELECTRICAL SYSTEM -4F-5
DISTRIBUTOR
GROUND STUD ON ENGINE FLYWHEEL HOUSING
GROUND SCREW ON INNER TRANSOM PLATE
12 VOLTBATTERY
CIRCUITBREAKER
IGNITION COIL
STARTERSLAVESOLENOID
MCM 230/260 5.0 Litre LX/5.7 Litre Engine with 90 Amp Fuse
at Starter Motor (Orange Wire) (Battery Meter Circuit)
4F-6 -ELECTRICAL SYSTEM
........::;)::;)
"' ::;) .. ,_l:1.?::;
::;)...w ...a: ::;)1::>...10...0) w ,_
a: l:
335-HR 90-14499--1 887
IGNITIONAMPLIFIER
DISTRIBUTOR
TO12 VOLT SOURCE WATER TEMPERATURE HEAT SWITCH ..(O,E,;MJ >'-v 3 TRANS. FLUID ...... ' HEAT SWITCH
(On
CIRCUITBREAKER
12 VOLTBATTERY
10 3
STARTERSLAVESOLENOID
0 I;::0.J0.Jw...
MCM 230TR/260TR 5.7 Litre TR Engine (Battery Meter Circuit)
90-14499--1 887
;::0a:
......rs:
a:
::c..,::::;
TERMINALBLOCK
TRIMSENDER
178-H2
ELECTRICAL SYSTEM -4F-7
IGNITIONAMPLIFIER
GROUND STUDON ENGINE FLYWHEEL HOUSING
GROUND ....q(.... .. GROUND SCREW ON INNER TRANSOM PLATE 12 VOLTBATTERY
·....10 3
STARTERSLAVE
SOLENOID
"' a:
MCM 230/260/300 5.0 Litre LX/5.7 Litre Alpha One/350-454 Magnum
without 90 Amp Fuse at Starter Motor (Orange Wire)
(Battery Meter Circuit)
4F-8-ELECTRICAL SYSTEM
335-HRA
90-14499--1 887
DISTRI BUTOR
ALTERNATOR
90-14499--1 887
60 AMP
CIRCUIT
BREAKER
12 VOLT
BATTERY
10 3
TARTER
SLAVE
OLENOID
,a: )Ca:0 I ...JI w.. a)..a:w '0> _,_,_,
MCM 300 Tempest TRS Engine (Battery Meter Circuit)
Vw<..."'ri'I2i'0
_,_"'ri'I2
..0a:
_,w..-' a:O.:>a: ..::>1"-
w::> _,"' ....r
:>..w.. a::> l:l..J
0 .. "'w
178-HR-A
ELECTRICAL SYSTEM -4F-9
DISTRIBUTOR
IGNITIONAMPLIFIER
ALTERNATOR
TO12 VOLT SOURCE AUDIO WATER TEMPERATURE WARNING HEAT SWITCH • BUZZER ..(OnEngme)
\).. ...." -' TRANS. FLUID ........ '\' HEAT SWITCH
PRESSURESWITCH(OnEngine)
CIRCUITBREAKER
IGNITIONCOIL
12 VOLTBATTERY
STARTERMOTOR
TARTERSLAVEOLENOID
I a: ..IX w-1 (I).. crw 1o
MCM 330 (B-W) Engine (Battery Meter Circuit)
4F-10-ELECTRICAL SYSTEM
TRIMSENDER
178-H
90-14499--1 887
IGNITIONAMPLIFIER
TO12 VOLT SOURCE AUDIO WARNING SYSTEM WATER TEMPERATURE HEAT SWITCH ..,o,,..,;..•
\lt. .. ;;:I TRANS. FLUID HEATSWITCH(On Engine)
OILPRESSURESWITCH(OnEngine)
CIRCUITBREAKER
12VOLTBATTERY
·....10 3
TARTERSLAVE 0
.. .. .. ..ex"" •O
MCM 330 (B-W) Engine with 90 Amp Fuse at Starter
Motor (Orange Wire) (Battery Meter Circuit)
90-14499--1 887
(.)<...J"' I 0...J"'
..0"'
....i..(.) z<..
... .....J... ..... .. 3..:>11)
:r..
...J O "' "'
TERMINALBLOCK
TRIMSENDER
ELECTRICAL SYSTEM -4F-11
TARTER
SLAVE
OLENOID
DISTRIBUTOR
I Q ..... a:a: Cl
.... ....-i
CIRCUIT
BREAKER
I a:Q I .. ..J a: 141> ... lit a:-' Ia:l f;I 0..J...> ..J
..J..J
...>
IGNITION
AMPLIFIER
<{,_..JIDX3:I
z03: a:
NEUTRAL START
SAFETY SWITCH ... ....i3:I z
TO 12 VOLT SOURCE
SWITCH
(On Engine
AUDIO WARNING SYSTEM
WATER TEMPERATURE
HEAT SWITCH
(On Eng..ne) 3 TRANS. FLUID'f HEAT SWITCH
...'b'->J/
12 VOLT
BATTERY
TERMINAL
BLOCK
TRIM
SENDER
178·H2
MCM 330 (B-W) Engine Wiring Diagram without
90 Amp Fuse at Starter Motor (Orange Wire)
(Battery Meter Circuit)
4F-12-ELECTRICAL SYSTEM 90-14499--1 887
SPARK PLUGS
WATER
TEMPERATURE
SENDER
r".'\1
z
.."
...
z
<(
a:
0
....ENGINE o,.,(JOIL PRESSURE 11.,(..SENDER
(,Q,.,,. 'fi((J..
..::::" ..>
I .. ...01
><(
a: ..a:i.!. ..a: ..fl("'('"" NEUTRAL SAFETY SWITCH (ON TRANSMISSION)
.. z.. .. <(a:0
512-1 1
MCM 370/400TRS Engine (Ammeter Circuit)
90-14499--1 887 ELECTRICAL SYSTEM -4F-13
..a:' 6
>I
..
.. NEUTRALSAFETY SWITCH
ION TRANSMISSION!
4F-14 -ELECTRICAL SYSTEM
DISTRIBUTOR
'i.. ENGINE
OIL PRESSURE SENDER
......
MIE 230/260 5.0/5.7 Litre Engine (Battery Meter Circuit)
90-14499--1 887
w ...
....... ....... a:"-
;:,a:...::.
w
w
::> ... ... X" :::;
ELECTRICAL SYSTEM -4F-15
IGNITIONAMPLIFIER
TO12 VOLT SOURCE AUDIO WARNING SYSTEM WATER TEMPERATURE HEAT SWITCH ..10" '"';"'' ..:J"-...... -' TRANS. FLUID '\,....... 'f HEAT SWITCH PRE....R.... -..SWITCH .."..:J
(On Engine ,..
CIRCUITBREAKER
12 VOLTBATTERY
TARTERSLAVEOLE NOlO wo.. cr ..cr0 I ..Iu..-i (I)..cr w 'o> -'-' -' w
-' II) ....I xit
.. Iz ..it-'0
w-' ...a:
I -'0 II)
'2
..J ...a:
NOTE: Taped back brownwhite
wire may be used for
an accessory. LOAD MUST
NOT EXCEED 5 AMPS.
MIE 230/260 5.0/5.7 Litre Engine with 90 Amp Fuse
at Starter Motor (Orange Wire) (Battery Meter Circuit)
342-H
4F-16 -ELECTRICAL SYSTEM 90-14499--1 887
0
BREAKER ...
II:
...
...
IGNITION ...
II:
AMPLIFIER
...I0 ...
II:
0 "'
... u
II: "
...... ... X
... ....CD
I
s: s:
CD
TO 12 VOLT SOURCE AUDIO WARNING SYSTEM
WATER TEMPERATURE
SWITCH
Engtne)
TARTER
SLAVE
OLENOID
0
... I Cl: lit: Q:
0 I .. 1"' ....J CIJ .. CDCl: "' 0 w
> I ... ... ...
... ...
... ... ...
... a:.. :::l
> _,
CIRCUIT .. .. =
X ..,::::;
:::l
-' CD ....X
...
...:::l
...CD
12 VOLT NOTE: Taped back brownBATTERY
white wire may be used for
-' TRANS FLUID an accessory. LOAD MUST
'\ "/' HEAT SWITCH
z NOT EXCEED 5 AMPS.
(On Engine)
OIL 342-H
PRESSURE
SWITCH
(On Engine)
MIE 230/260 5.0/5.7 Litre Engine without 90 Amp Fuse
at Motor (Orange Wire) (Battery Meter Circuit)
90-14499--1 887 ELECTRICAL SYSTEM -4F-17
DISTRIBUTOR
TO12 VOLT SOURCE AUDIO WARNING SYSTEM AUDIO WATER TEMPERATURE WARNING ..HEAT SWITCH _ BUZZER (On Engine) \)"' ....'-..J TRANS. FLUID '\...... '1' HEAT SWITCH
PRESSURESWITCH(On Engine)
CIRCUITBREAKER
STARTERMOTOR
NEUTRAL START SAFETY SWITCH
12 VOLTBATTERY
10 3
TARTERSLAVEOLENOID
0 I ..Iw..J CD..a:loU I 0> ..J..J
NOTE
l:C>::;
NOTE: Taped back brownwhite
wire may be used for
an accessory. LOAD MUST
NOT EXCEED 5 AMPS.
178-H
MIE 340 7.4 Litre Engine (Battery Meter Circuit)
4F-18 -ELECTRICAL SYSTEM 90-14499--1 887
TO12 VOLT SOURCE AUDIO WARNING SYSTEM AUDIO WATER TEMPERATURE WARNING HEAT SWITCH -BUZZER ..(On Eng..ne) .. v X ..Iz..
0
.. ..0 >,a.0 ...
...::>"' ....X2
..
NOTE: Taped back brownwhite
wire may be used for
an accessory. LOAD MUST
NOT EXCEED 5AMPS.
MIE 340 7.4 Litre Engine with 90 Amp Fuse at Starter Motor
(Orange Wire) (Battery Meter Circuit)
4F-20 -ELECTRICAL SYSTEM 90-14499--1 887
(0'?
......(0
'P..
CDCD .....
mrm0-lJ)0)>r(/l-<(/)-l
m.. .. ,..
AIR
TEMPERA TVRE
SENSOR
..
AIR
VALVE..c--.... -:;:-
OIL
PRES URE
SENSOR
)
...-•
RECTIFIER
FUEL ..
..
WATER TEMPERATURE
SENSOR i
EFI
STARTER
SOLENOK>
CIRCUIT
BREAKER
TEMPERATURE
)
IGNITION
AMPLIFIER
11(-t NEUTRAL
SAFETY SWITCH
(On Transmission!
4F-22 -ELECTRICAL SYSTEM
ENGINE
PRESSURE
SENDER
111u
GROUND
WATER TEMPERATURE
EAT SWITCH
(On Engine)
g TRANS. FLUID :1 HEAT SWITCH
SWITCH
(On
MCM 575
WATER
TEMPERATURE
SENDER
7
1 5
.,. 2 4
10 3
895-H
90-14499--1 887
"..u
WATER ..
..
TEMPERATURE
SENDER
SWITCH
AUDIO WARNING SYSTEM
TO 12 VOLT SOURCE
10 3
\)
"
...
WATER TEMPERATURE
HEAT SWITCH
On Engine)
;il
TRANS FLUID
HEAT SWITCH
,_ (On Engine)
\)..4
90-1 4499--1 887
ELECTRICAL SYSTEM -4F-23
GROUND STUD ON ENGINE FLYWHEEL HOUSING
GROUND SCREW ON INNER TRANSOM PLATE
4F-24-ELECTRICAL SYSTEM
12 VOLTBATTERY
10 3
STARTERSLAVESOLENOID
454 Magnum, 7.4 Litre (Bravo One Drive)
a a:::; ..... a5 .. z a:"'
WIRINGHARNESS
TRIMSENDER
1058-H
90-14499--1 887
ALTf.RNATOH
90-14499--1 887
NfUTAAL START
SAF£TY S\"JI TCH
12 VOLTBATTERY
MIE 5.7 Ski Engine
STARTERSLAVESOLENOID
a:I
-m X3::I z3::0
1-i:
a:
"' ........ ........a:"-=>"' <>.=>
1"-0"'
w::> .....m ...X..
::>...w ...a:::>I ::>...Jo"-m"' ...a: I!::?
NOTE: Taped back brownwhite
wire may be used for
an accessory. LOAD MUST
NOT EXCEED 5 AMPS.
342-HR
ELECTRICAL SYSTEM -4F-25
NOTE 1: Connect Wi res Together with Screw and
Hex Nut; Apply Liquid Neoprene to Connection
and Slide Rubber Siever over
Connection.
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 lt.
NOTE 3: 4 = 4 Cyl.; 6 = 6 Cyl.; 8 = 8 Cyl.
1 =4 Cyl.; 2 = 6 Cyl.; 3 =8 Cyl.
WATERTEMPERATURE
SLUE SLUE
1 & 2
REO-PURPLE
ORANGE ORANGE
a:I3:0.J... w>
c..,a: I..... .....,
OIL
TEMPERATURE :
ct I
... ..,
4F-26 -ELECTRICAL SYSTEM
Instrument Wiring with Battery Meter Circuit
/--------
I II I!;.. J,.lr _......
a: I3:0... ...w>
400-H
90-14499--1 887
NOTE 1: Connect Wires Together with Screw and
Hex Nut; Apply Liquid Neoprene to Connection
and Slide Rubber Siever 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
Connected to lt.
WATER
TEMPERATURE AMMETER
....0wa:I
....J..J
w>
BLUE BLUE
1 & 2
GRAY 0wa:I
....J..Jw>
OIL
TEMPERATURE
871-H
Instrument Wiring with Ammeter Circuit
90-1 4499--1 887 ELECTRICAL SYSTEM -4F-27
NOTE 1: Connect Wires Together with Screw and
Hex Nut; Apply Liquid Neoprene to Connection
and Slide Rubber Siever 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
Connected to lt.
z
..
:z:Cl >
..
a:
...
Cl
Cl
... z ..
a: .. a:
0:
I
g
WATER
,j
TEMPERATURE
...
>
TAN
.. LIGHT BLUE
BLUE
GRAY
a:
,j
1 S. 2
,j
...
>(/,----;:::::::---------BROWN -WHITE ..I
NOTE: Taped Back Brown
White Wire May Be Used for
An Accessory. LOAD MUST
NOT EXCEED 5 AMPS.
Instrument Wiring MIE 5.7L Ski
4F-28 -ELECTRICAL SYSTEM
90-14499--1 887
SECONDARY STATION
J i
ConMet 'M,.. Toet"*wt1t1 lc,.. encltt.x
-.. .. end IHcle ,......., .....,.
owrConneetaon
I
I
I
L---------
------,
I
PRIMARY STATION
I
III
{-))NOTE2 I
,.USE
I
---1+1
I
II
Conn.c:t WI,... T.tMf
wtth ac,.....m ....
Nut, Apply Uqukt
..toC..Uon
•nd lltot Au..r SIMft
o...., Conn.etlon
Y..Jow/RH
Y .. low/Red
NOTES: 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).
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.
Dual Station Wiring
Using a Neutral Safety Swtich in Only One Remote Control
(Ammeter Circuit)
90-14499--1 887
ELECTRICAL SYSTEM -4F-29
SECONDARY STATION
I I t I
-
-
I
IL--
-
-,
PRIMARY STATION I
WA,_ OIL I
I I I
I
-
c:ooo-o -T
... .... .... .... __ .._
NOTES: 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).
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.
Dual Station Wiring
Using a Neutral Safety Swtich in Both Remote Control
(Ammeter Circuit)
4F-30 -ELECTRICAL SYSTEM
90-14499--1 887
. "-....../.
+)
SECONDARY STATION
OILPftlUUftE
))•on>
(
\
-..-NOTE 3
ConMe1 WI'" Toe-1Mfwtth ScNW Mod ..... Hut Apply liquid
..to ConMCtkHI
•nd llkh Rubb.r OWf ConMCtlon
L----------------1
PRIMARY STATION
I
BATTERY METER
(-))•on>
(+)
Yellow/Red
COnMICI WI'" T.ttMof
wfth ScNW •net ....
Nut. Apply Uqukf
..to Conn.ctSon
•nd Sikh Rubbtr sa....
o...-Conn.etlon
NOTES: 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).
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.
3.
Tape back and insulate with at least 4 layers of electrical tape.
Using a Neutral Safety Swtich in Only One Remote Control
(Battery Meter Circuit)
90-14499--1 887
ELECTRICAL SYSTEM -4F-31
SECONDARY STATION
OIL ... .._.
--1-1
"'NOTII --(/
+1
' '
-.. NOTE 3
TGge'lhet'wtth Sc,.. •net .... Nut. Apply Uqutd
Neopr.ne to Connection
•net Slide Rubber 11 .. .,.ower Connection
L----------
PRIMARY STATION
-1-L., ': NOTE 2-1+1/ /
Connect Wires Together
with Screw and Hex
Nut. Apply Liquid
Neoprene to Connection
and Slide Rubber Sleeve
over Connection
ConMct WII'H Together
wtlh 8cNW end He1
Nut. -· Liquid
Neopnne to Connection
Mel Slkle Rubber .....,_
over Connection
ower Connec;Hon
NOTES: 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).
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.
3.
Tape back and insulate with at least 4 layers of electrical tape.
Dual Station Wiring
Using a Neutral Safety Switch in Both Remote Controls
(Battery Meter Circuit)
4F-32 -ELECTRICAL SYSTEM
90-14499--1 887
SECONDARY STATION
PRIMARY STATION
I
ConMct WI'" Togd'tef
.nhlc,.. .ndttex ...... -....... -.. .. and ... Rubber ...... o.....Connection
' II
---
--1-1 "'-.NOTI! I /---1+1
c-t-T....
ec... 8ndttex __ .._-.. .. llftd lllde RubbM --.. -eo..L--------------
--1-1 '-...._,_ NO'T1! 2 ---1+1/
-l
I
I
I
I
I
I
I
I
I
-eo..
NOTES: 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).
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.
Dual Station Wiring with
Neutral Safety Swtich in Engine Wiring Harness
(Ammeter Circuit)
ELECTRICAL SYSTEM -4F-33
90-1 4499--1 887
SECONDARY STATION
PRIMARY STATION
eonn.et _,,... Together wtth Ierew end He• Nut.-Liq<>ld-ooc-enct.. A....._,....._ -c.on-
I
--(-)
"'MOTU
---(+) \\ --'-NOTE3
c:on.-t-Twtth
lc..w end .... y..__ ..c-L
_____
BATTERY METER
ConMCI WI,.. Together
with Sc,.w •ndHex
Nut. Apply Liquid
Neoprwne toConnection
•nd Slide Rubber Sleewe 011., Connection
--lIIIIIIIII I
NOTES: 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).
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.
3. Tape back and insulate with at least 4 layers of electrical tape.
4F-34 -ELECTRICAL SYSTEM
Dual Station Wiring with
Neutral Safety Swtich in Engine Wiring Harness
(Battery Meter Circuit)
90-14499--1 887
BATTERY METER GAUGES
EARLY STYLE
LATER STYLE
a -Lamp Mounting Hole
b -Gauge Mounting Studs
c -Terminal Not Used
d-Purple (or White) Jumper Wire from This Terminal to I (or +)
Terminal on Water Temperature or Oil Pressure Gauge
e-Black Jumper Wire from This Terminal to Ground Terminal
on Water Temperature or Oil Pressure Gauge
AMMETER GAUGES
To Harness Red-White or Orange
To Key Switch Red-White or Orange
To Ground Black
To Harness Red or Red/Purple
To Instrument Gauges
EARLY STYLE
LATER STYLE
Pre BIA
Color Code BIA Color Code
a.
White Wire Jumper
(Supplied in Kit) That
Is Connected to
Nearest 1 2-Volt Supply
b.
Red with White Stripe
Wire
c.
Red Wire
d.
Black Wire
a.
Purple Wire
b. Orange Wire
c.
Red with
Purple Stripe
Wire
d.
Black Wire
White or Purple
Leads to
a.
To 12-Volt Switched
Terminal on Adjacent
Gauge or to Accessory
Side of Ignition Switch
b.
To "Batt" Side of
Alternator
c.
To Battery or to "Batt"
Side of Starter
Solenoid
d. To Ground
90-14499--1 887
ELECTRICAL SYSTEM -4F-35
(a) Black Wire (a) Black
(b) White Wire (b) Purple
(c) Orange Wire (c) Light Blue
'\.
(a) Ground
(b) Switched 12-Volt
Terminal
(c) Sender Lead
140-H CONNECT TO AN "I" TERMINAL OF AN ADJACENT
.. \ .
WATER TEMPERATURE GAUGE
00 0
Earlier Model
Pre BIA
Color Code BIA Color Code Leads lo -
MerCrulser
Color Code BIA Color Code Leads to
a. Black Wire a. Black a. Ground
b. While Wire b. Purple b. Switched 12-Volt
Terminal
c. Green Wire c. Tan c. Sender Lead
CLOCK
CONNECT TO A TERMINAL ON AN ADJACENT GAUGE OR TO ANOTHER SUITABLE GROUND
GAUGE OR TO ANY SWITCHED 12-VOLT TERMINAL
OIL PRESSURE GAUGE
00 0
4F-36 -ELECTRICAL SYSTEM 90-14499--1 887
CRUISE LOG
EARLY STYLE
TO 12 VOLT
SOURCE
LATER STYLE
a -Connect to ignition switch activated
12-volt positive (+) source
b-Connect to negative (-) ground
0
90-1 4499--1 887
C:..CJ1•....'l j·-i..niftf!,'i; to ho:.'..
FUEL GAUGE AND SENDER
FUEL GAUGE
(Blue or Brass
NO TE "A ": Connect to "lgnition" terminal or "Accessory" terminal
of ignition switch.
Case)
(Note "A")
FUEL GAUGE
(Black Case)
NOTE "B": Connect to negative battery terminal or suitable ground.
A WARNING
Buzzer is not external ignition-proof, therefore, DO
NOT mount buzzer in engine or fuel tank compartments.
WATER TEMPERATURE
HEAT SWITCH
AUDIO
WARNING
BUZZER
Audio Warning System Wiring Diagram
ELECTRICAL SYSTEM -4F-37
CoMtec-l ..._ T... .. .MIIc .... 11"4 .... . ""' ·-L
..toc.......c-.,. .......... ......,. ...... -c-Key
Switch Installation when Using Ammeter and
BIA Color-Coded Wiring Harness.
C.O.W..Ct WI'" Top.,_.,..... lc,.. eftd .... -·-·....to Cofwtc'*' .............. "'*'" ...... -c--
Key Switch Installation when Using Battery Meter and
BIA Color-Coded Wiring Harness ACAUTION Neutral start safety switch MUST BE USED In cranking circuit. If remote
control does not Incorporate this switch, It must be part of engine wiring.
NOTE 1: If engine is equipped with a neutral safety switch (on the engine or transmission),
connect yellow/red ignition switch wire directly to yellow/red wiring harness wire with
screw, nut and sleeve. A neutral safety switch MUST BE used in starting circuit to prevent
accidental starting of engine when in gear.
4F-38 -ELECTRICAL SYSTEM 90-14499--1 887
('-FUEL SYSTEM
FUEL DELIVERY SYSTEM
and FUEL PUMPS
Index
Page
Identification ........................•...•.... 5A-1
Replacement Parts Warning ................... 5A-1
Torque Specifications ........................ 5A-2
Tools/Lubricants/Sealants .................... 5A-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Precautions .................................. 5A-3
Fuel Delivery System ......................... 5A-3
Recommendations ........................ 5A-3
Description ............................... 5A-3
Water Separating Fuel Filter ................... 5A-3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
Fuel Pump Fuel Filter Replacement ............ 5A-5
Sight Tube ................................... 5A-5
Inspection ................................ 5A-5
Testing Fuel Pump ........................... 5A-6
AC PUMP (DUAL DIAPHRAGM)
Replacement .............................. 5A-6
AIRTEX PUMP
Replacement .............................. 5A-7
CARTER PUMP
Replacement .............................. 5A-7
BOSCH ELECTRIC PUMP
Replacement .............................. 5A-8
FUEL SYSTEM -SA 90-14499--1 887
Identification
Airtex Pump
AC Pump (Dual Diaphragm)
Carter Pump
90-14499--1 88 7
18394
18396
20575EFI Bosch Electric Pump
Replacement Parts Warning A WARNING Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
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.
FUEL SYSTEM -5A-1
Torque Specifications
Fastener Location
AC Airtex Carter
Lbs. Ft. (N.m) Lbs. ln. (N.m) Lbs. Ft. (N.m) Lbs. ln. (N.m) Lbs. ln. (N.m) Lbs. Ft. (N.m)
Fuel Inlet Fitting* 10-18 (1 4-25) 10-1 8(14-25) 10-18 (14-25)
Fuel Line to Fuel
Inlet Fitting
Securely Securely Securely
Fuel Line to Fuel
Outlet Fitting
Securely Securely Securely
Fuel Outlet Fitting
NOTE 1 10-1 8 (1 4-25) 10-1 8 (1 4-25) 10-18 (14-25)
Fuel Pump to Block 20 (27) 20 (27) 20 (27)
*NOTE 1: Coat fuel line inlet and outlet fitting threads
with Loctite Pipe Sealant with Teflon, DO
NOT use teflon tape. Torque to specifica
tions.
Tools/Lubricants/Sealants
TOOLS OBTAINED LOCALLY
Fuel Pressure Gauge
LUBRICANTS/SEALANTS
92-34227 Quicksilver Perfect Seal
92-42649 Quicksilver Needle Bearing Gasket
SEALANTS OBTAINED LOCALLY
Loctite Pipe Sealant with Teflon
Specifications
Type of Fuel Pump AC Airtex Carter Bosch
Pump Pressure (1 000 RPM)
Pump Pressure (1 800 RPM)
5.25-6.5 PSI
(36-44 kPa)
5.5-7.0 PSI
(38-48 kPa)
5.25-6.5 PSI
(36-44 kPa)
39 PSI (Note 1)
(267.5 kPa)
Push Rod Length
5.76 in.
(146.304mm)
. 344 in.
(8.7376mm)
5.76 in.
(1 46.304mm)
. 344 in .
(8.7376mm)
5.76 in.
(1 46.304mm)
.344 in .
(8.7376mm)
Push Rod Movement
NOTE 1: Refer to EFI Troubleshooting for testing
pump with complete EFI system.
5A-2 -FUEL SYSTEM 90-14499--1 887
Precautions
A WARNING
ALWAYS disconnect battery cables from battery BEFORE
working on fuel system to prevent fire or explosion.
AWARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". DO NOT smoke or allow sources of spark or
flame in the area while changing fuel filters. Wipe up
any spilled fuel immediately.
A WARNING
Make sure that no fuel leaks exist, before closing
engine hatch.
A CAUTION
DO NOT operate engine without cooling water being
supplied to seawater pickup pump or pump impeller
will be damaged, and subsequent overheating damage
may result.
Fuel Delivery System
Recommendations
A WARNING
Boating industry standards (BIA, ABYC, etc.) federal
standards and Coast Guard regulations MUST BE
adhered to when installing fuel delivery system.
When designing and installing fuel delivery system, the
following information MUST BE observed:
1.
Fuel tank should be mounted below carburetor
level, if possible. If tank is mounted above carburetor
level, gravity feed may cause carburetor fuel
inlet needle to unseat, and flooding may result.
2.
Fuel pickup should be at least 1" (25mm) from the
bottom of the fuel tank to prevent picking up water
or other impurities.
3.
Fuel lines used MUST BE Coast Guard approved
(USCG type A) and MUST NOT BE SMALLER
THAN 3/8" (9.5mm) 1.0. 1/4" (6.4mm) 1.0. EFI
return line. On installations where long lines or
numerous fittings are required, larger size lines
should be used.
4.
Fuel line should be installed free of stress and firmly
secured to prevent vibration and/or chafing.
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.
90-14499--1 887
Description
The fuel system consists of a fuel tank(s), a water
separating fuel filter (if so equipped), a fuel pump, and
a carburetor.
The fuel is stored in the fuel tank. When the engine is
cranking or running, fuel is drawn from the fuel tank,
through the water separating filter (if so equipped), by
a mechanically operated fuel pump. The fuel pump is
operated by the engine camshaft.
The fuel is pushed through the fuel pump to the carburetor
where it is metered and fed to the engine.
Water Separating Fuel Filter
NOTICE
Refer to "Precaution", in this section, BEFORE
proceeding.
The water separating fuel filter is standard on some
engines and can also be purchased as an option for
engines not equipped with it.
The fuel filter consists of the fuel filter base and filter
element.
a-Filter Mounting Base
b-Filter Element
c -Sealing Rings
d -Replacement Element
FUEL SYSTEM -5A-3
IMPORT ANT: If installing water separating fuel filter as
an option, filter should be located between fuel tank
and fuel pump. Also fuel inlet and outlet lines must be
connected correctly for filter to work properly. Follow
instructions supplied with water separating fuel filter
kit.
A CAUTION
Coat fuel line fitting threads with either Loctite No. 69
hydraulic sealant or Loctite pipe sealant with teflon (do
not use teflon tape). Torque to specifications.
a-Fuel Outlet if "C"is the Inlet
b-Fuel Inlet if "D" is the Outlet
c-Fuel Inlet if "A" is the Outlet
d -Fuel Outlet if "B" is the Inlet
, .
5A-4 -FUEL SYSTEM
90-14499--1 887
Replacement
1.
Disconnect negative and positive battery leads
from battery.
r--2.
Remove filter element from mounting base by turn
\....../
ing counterclockwise. You may need a filter wrench
to break element loose.
IMPORTANT: Element cannot be cleaned and reused,
it must be replaced.
a -Remove Old Filter
b -Lubricate Sealing Rings with Engine Oil
c-Install New Filter (Tighten Securely By Hand Only)
Replacing Water Separating Fuel Filter
3.
Lubricate sealing rings with SAE engine oil.
4.
Install new element. Tighten securely by hand.
5.
Start engine (making sure water is supplied to cooling
system) and check for fuel leaks.
Sight Tube
Inspection
Fuel pumps are equipped with a sight tube. Evidence of
fuel in the sight tube indicates a ruptured diaphragm
and fuel pump must be replaced immediately.
a-Sight Tube
b-Fuel Pump
90-14499--1 887
FUEL SYSTEM -SA-5
Testing Fuel Pump
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
1.
Remove fuel line from outlet side of fuel pump.
2.
Install fuel pressure test gauge to outlet side of fuel
pump using T-fitting and appropriate adaptors.
A CAUTION
Coat fuel line inlet fitting threads with Loctite pipe
sealant with teflon (do not use teflon tape). Torque to
specifications.
3.
Connect fuel line (previously removed from pump)
to other side ofT -fitting on fuel pressure test gauge
using appropriate adaptors.
4.
Start engine and run at R.P.M. listed in specifications.
5.
Fuel pressure should be within specifications. If
not, repair or replace fuel pump.
6.
Remove fuel pressure gauge and adaptors. Reconnect
fuel line to fuel pump. Tighten to specifications.
a-Fuel Tank
b -Anti-Siphon Valve
c -Water Separating Fuel Filter (Optional)
d-Fuel Pump
e-Carburetor
f -Fuel Filler
g-Vent Hose
h-Pressure Test Gauge
i-Fuel Line
j -Sight Tube
AC Pump (Dual Diaphragm)
NOTICE
Refer to "Precautions", In this section, BEFORE
proceeding.
IMPORTANT: The AC fuel pump cannot be repaired. If
the fuel pump fails it must be replaced.
Replacement
1.
Disconnect fuel inlet and outlet lines at fuel pump.
A CAUTION
Plug fuel lines after disconnecting from fuel pump to
eliminate any chance of fuel siphoning into bilge.
2.
Remove sight tube.
3.
Remove 2 fuel pump mounting screws, pump and
gasket.
4.
Remove mounting plate bolts, mounting plate,
gasket, and push rod.
5.
Check push rod length. See Specifications.
6.
Check push rod movement by installing push rod in
engine, install a dial indicator against end of push
rod, and turning engine over one complete revolution.
Push rod should have total movement as
shown in specifications.
7.
Coat push rod with Quicksilver Needle Bearing
Grease and install in engine.
8.
Apply Perfect Seal to both sides of mounting plate
gasket. Then, install gasket, plate, and mounting
'bolts. Tighten securely.
9.
Apply Perfect Seal to both sides of fuel pump
gasket.
10. 1nstall
gasket, fuel pump and mounting bolts.
Torque bolts to specifications.
11.1nstall fuel inlet and outlet fittings to fuel pump.
Torque fittings to specifications. Tighten flare fittings
securely.
12.1 nstall sight tube.
13. Start engine and check for fuel leaks.
A CAUTION
Coat fuel line inlet fitting threads with Loctite pipe
sealant with teflon (do not use teflon tape). Torque to
specifications.
SA-6 -FUEL SYSTEM
90-14499--1 887
Airtex Pump
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
IMPORTANT: The Airtex pump cannot be repaired. If
the fuel pump fails it must be replaced.
Replacement
1.
Remove fuel inlet and outlet lines at fuel pump.
A CAUTION
Plug fuel lines after disconnecting from fuel pump to
eliminate any chance of fuel siphoning into bilge.
2.
Remove sight tube.
3.
Remove 2 fuel pump mounting screws, pump, and
gasket.
4.
Remove mounting plate bolts, mounting plate,
gasket, and push rod.
5.
Check push rod length. See Specifications.
6.
Check push rod movement by installing push rod in
engine, install a dial indicator against end of push
rod, and turning engine over one complete revolution.
Push rod should have total movement as
r"
shown in specifications.
""-" 7.
Coat push rod with Quicksilver Needle Bearing
Grease and install in engine.
8.
Apply Perfect Seal to both sides of mounting plate
gasket. Then, install gasket, plate, and mounting
bolts. Tighten securely.
9.
Apply Perfect Seal to both sides of fuel pump
gasket.
10. 1nstall
gasket, fuel pump and mounting bolts.
Torque bolts to specifications.
11.1nstall fuel inlet and outlet fittings to fuel pump.
Torque fittings to specifications. Tighten flare fittings
securely.
12.1nstall sight tube.
13.Start engine and check for fuel leaks.
A CAUTION
Coat fuel line inlet fitting threads with Loctite pipe
sealant with teflon (do not use teflon tape). Torque to
specifications.
Carter Pump
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
IMPORTANT: The Carter pump cannot be repaired. If
the fuel pump fails it must be replaced.
Replacement
1.
Remove fuel inlet and outlet lines at fuel pump.
A CAUTION
Plug fuel lines after disconnecting from fuel pump to
eliminate any chance of fuel siphoning into bilge.
2.
Remove sight tube.
3.
Remove 2 fuel pump mounting screws, pump, and
gasket.
4.
Remove mounting plate bolts, mounting plate,
gasket, and push rod.
5.
Check push rod length. See Specifications.
6.
Check push rod movement by installing push rod in
engine, install a dial indicator against end of push
rod, and turning engine over one complete revolution.
Push rod should have total movement as
shown in specifications.
7.
Coat push rod with Quicksilver Needle Bearing
Grease and install in engine.
8.
Apply Perfect Seal to both sides of mounting plate
gasket then install gasket, plate, and mounting
bolts. Tighten securely.
9.
Apply Perfect Seal to both sides of fuel pump
gasket.
10. 1nstall
gasket, fuel pump and mounting bolts.
Torque bolts to specifications.
11.1nstall fuel inlet and outlet fittings to fuel pump.
Torque fittings to specifications. Tighten flare fittings
securely.
12.1 nstall sight tube.
13. Start engine and check for fuel leaks.
A CAUTION
Coat fuel line inlet fitting threads with Loctite pipe
sealant with teflon (do not use teflon tape). Torque to
specifications.
90-14499--1 887
FUEL SYSTEM -SA-7
Bosch Electric Pump
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
IMPORTANT: The Bosch fuel pump cannot be repaired.
If the fuel pump fails it must be replaced.
Replacement
1. Disconnect fuel inlet and outlet lines at fuel pump.
A CAUTION
Plug fuel lines after disconnecting from fuel pump to
eliminate any chance of fuel siphoning into bilge.
2.
Remove all electrical leads.
3. Remove 2 fuel pump mounting clamps, and pump.
4.
Install pump and pump mounting clamps. (Tighten
securely.)
5.
Install all electrical leads.
6.
Connect fuel inlet and outlet lines.
7. Start engine and check for fuel leaks.
A CAUTION
Coat fuel line inlet fitting threads with Loctite pipe
sealant with teflon (do not use teflon tape). Torque to
specifications.
5A-8 -FUEL SYSTEM
90-14499--1 887
FUEL SYSTEM
MERCARB® 2 BARREL
m
Index
Page
Identification ................................. 58-1
Replacement Parts Warning ................... 58-1
Torque Specifications 58-1
...... ..................
Tools ........................................ 58-1
Specifications .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2
Description 58-2
.............. .... ......... .......
Precautions .................................. 58-2
Maintenance 58-3
....................... ... ....... Flame Arrestor 58-3
. .... .......................
Flame Arrestor with Carburetor Cover 58-3
......
Fuel Inlet Filter .. .......................... 58-4
Choke Inspection 58-4
.........................
Adjustments 58-4
... ....... ...... .................
Float Level 58-4
.......... ......................
Float Drop 58-5
........................... .....
Pump Rod 58-6
............................ ....
Choke Setting ..... ....... ................. 58-6
Choke Unloader ........................... 58-7
Preliminary Idle Speed and Mixture ......... 58-7
Final Idle Speed and Mixture 58-8
.... ........... Repair 58-9
.......................... .............
Removal 58-9
.... ..............................
Installation ................................ 58-9
Disassembly 58-9
.............. ................
Choke Housing Assembly ..............58-1 1
Air Horn .............................. 58-1 1
Float Assembly . ...... .................58-1 3
Needle and Seat Assembly .............58-13
Cleaning and Inspection ...... ............58-16
Reassembly ............ ................ ..58-1 7
Throttle Body Assembly ......... ...... 58-17
Needle and Seat Assembly .............58-20
Float Assembly ........ ......... .......58-21
Air Horn Assembly .................... 58-22
Choke Housing Assembly ............. .58-24
FUEL SYSTEM -58 90-14499--1 887
Identification
a -Part Number
b-Date Code
Carburetor Part Number Location
Date Code Expalnation: Example 4501
First Figure is Year
4 = 1984, 5 = 1985, etc.
Second Figure is Month
5 = May, 6 = June, 7 = July, etc.
X= October, Y = November, Z = December
Third and Fourth Figure is Day of Month
01 = First day, 02 = Second day, etc.
a -Single Idle Mixture Needle
MerCarb Carburetor
Replacement Parts Warning
A WARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
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.
Torque Specifications
a -Part Number
Part Number Tag Location
90-1 4499--1 887
Fastener Location Lbs. Ft. (N.m)
Carburetor to Manifold
Fuel Line to Carburetor 18 (24)
Fuel Inlet Filter Nut 18 (24)
Tools
MERCURY MARINE SPECIAL TOOLS
91 -59339 Tachometer
91 -36392 Universal Carburetor Gauge
BORROUGHS TOOL and EQUIPMENT
2429 N. BURDICK ST.
KALAMAZOO, Ml 49007
(616) 345-5163
BT 81 288 Float Gram Scale
FUEL SYSTEM -5B-1
Specifications
UNIT OF MEASUREMENT
in. (mm)
CARBURETOR ADJUSTMENT SPECIFICATIONS
(Note 1)
Engine Model MCM 200 5.0 Litre
Carburetor Type MerCarb® 35mm
Carburetor Number 1389-8488A2 1389-9670
Float Level (Note 2) 5/8 (1 5.8)
Float Drop (Note 2) 1-3/4 (44.5)
Pump Rod 1-5/32 (29)
Choke Setting Index Marks Aligned
Idle Mixture Screw
Preliminary Setting
1-1/4 Turns
Float Weight 9 Grams Max.
Primary Jet Size 1.7mm
Power Valve Size 1mm
NOTES: 1.
All measurements are ± 1/64" (.4mm).
Information contained in this chart supercedes
all service bulletins and service
information printed in 1984 and earlier.
2.
Measurement is taken from gasket. Fuel
inlet needle is spring loaded. Before
checking raise float and allow to fall by
itself. DO NOT FORCE downward by
hand.
Description
This MerCarb carburetor is a two bore carburetor and
has a separate fuel feed for each venturi. This model
also is equipped with an electric choke. A removable
venturi cluster (secured to float bowl assembly) has the
calibrated main well tubes and pump jets built into it.
The venturi cluster is serviced as a unit. The serviceable
main metering jets are fixed orifice type that work
together with fixed air bleeds to properly meter the
correct fuel/air mixture to the engine.
Precautions
A WARNING
Always disconnect battery cables from battery BEFORE
working on fuel system to prevent fire or explosion.
A WARNING
Be careful when cleaning flame arrestor and crankcase
ventilation hose; gasoline is extremely flammable and
highly explosive under certain conditions. Be sure that
ignition key is "OFF". DO NOT smoke or allow sources
of spark or open flame in area when cleaning flame
arrestor and crankcase ventilation hose.
A WARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". DO NOT smoke or allow sources of spark or
flame in the area while changing fuel filter. Wipe up any
spilled fuel immediately.
A WARNING
Make sure no fuel leaks exist, before closing engine
hatch.
A CAUTION
DO NOT operate engine without cooling water being
supplied to water pickup holes in gear housing, or
water pump impeller will be damaged and subsequent
overheating damage to engine may result.
58-2 -FUEL SYSTEM
90-14499--1 887
Maintenance
Flame Arrestor with Carburetor Cover
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
1. Remove in the following order:
a.
Nut.
b. Sealing washer.
c.
Carburetor cover.
d.
Hose clamps and crankcase ventilation hoses From
flame arrestor and rocker arm covers.
e. Flame arrestor -Lift from carburetor.
Clean and inspect:
a.
Clean flame arrestor in solvent and blow dry with
compressed air.
b. Clean crankcase ventilation hoses.
c.
Inspect crankcase ventilation hoses for cracks
or deterioration, and replace if necessary.
3. Install in the following order:
a. Flame arrestor -Place on carburetor.
.\....._.,
b . Crankcase ventilation hoses and hose clamps To
flame arrestor and rocker arm covers.
c.
Carburetor cover.
d. Sealing washer.
e. Nut -Tighten securely.
a-Nut
b-Washer
c-Carburetor Cover
d-Clamps
e-Crankcase Ventilation Hoses
f -Flame Arrestor
Flame Arrestor with Carburetor Cover
90-1 4499--1 887
FUEL SYSTEM -58-3
Fuel Inlet Filter
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
1.
Remove in the following order:
a.
Fuel line from fuel inlet filter nut.
b.
Fuel inlet filter nut.
c.
Large gasket.
d.
Filter.
e.
Spring.
f.
Small gasket -From inside filter nut.
Choke Inspection
The choke does not require any periodic maintenance;
however, if a choke malfunction is suspected, the following
should be done:
1.
With engine 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 sluggishly,
clean with carburetor choke cleaner. Follow
directions on can.
Adjustments
a-Fuel Line
b-Fuel Inlet Filter Nut
c-Gasket (Large)
d -Gasket (Small)
e-Filter
f-Spring
Carburetor Fuel Inlet Filter
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.
e.
Fuel inlet filter nut -Torque to specifications.
f.
Fuel line -Torque to specifications.
NOTICE
Refer to "Precautions", In this section, BEFORE
proceeding.
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.
Using Universal Carburetor Gauge. measure from
gasket to toe of float.
a -See Specifications
Measuring Float Level
58-4 -FUEL SYSTEM
90-1 4499--1 887
a -Measure from This Point to Gasket
Toe of Float
3.
Bend float arm up or down at point shown to obtain
specified dimension.
4.
Visually check float alignment after adjustment.
a -Bend Float Arm at this Point
Adjusting Float Level
Float Drop
1.
Hold air horn right-side-up to allow float to hang
free.
2.
Using Universal Carburetor Gauge, measure from
gasket to toe of float.
392-H
a -See Specifications
Measuring Float Drop
3.
Bend float assembly tang, as shown to obtain specified
dimension.
4.
Recheck BOTH float level and float drop.
a -Float Assembly Tang
Adjusting Float Drop
90-1 4499--1 887
FUEL SYSTEM -58-5
Pump Rod
1.
Back out idle speed screw until it no longer contacts
idle cam.
a-Idle Speed Screw
b -Idle Cam
Backing Out Idle Speed Screw
2.
With throttle valves completely closed, measure
from flame arrestor mounting surface to top of
pump rod.
3.
Carefully bend pump rod (where shown) to obtain
specified dimension.
392-H
a -See Specifications
Measuring Pump Rod
392-H
Adjusting Pump Rod
Choke Setting
Normal choke setting is such that scribed mark on
cover is in line with long case mark on choke housing.
a -Marks on Choke Cover and Choke Housing
b-Leaner
c-Richer
Choke Setting
If choke adjustment is necessary:
1.
Loosen 3 choke cover retaining screws and adjust
as shown.
2.
Tighten 3 choke cover retaining screws securely.
,:,<;,
58-6 -FUEL SYSTEM
90-14499--1 887
Choke Unloader
1. Hold throttle valves completely open.
2. Gently press down on choke plate.
3. Using an .080 in. (2.0mm) drill rod, or appropriate
gauge, slide rod between upper edge of choke plate
and air horn assembly. Rod should just slide
through. If adjustment is required, proceed to Step
4.
4. Bend tang on throttle lever, if necessary, to obtain
specified dimension.
a-.080 ln. (2.0mm) Drill Rod .b -Choke Plate
c-Air Horn
Checking Choke Unloader
a-Tang
b-Throttle Lever
Adjusting Choke Unloader
a-Idle Speed Screw
b-Idle Cam
Preliminary Adjustment of Idle Speed Screw
16930
Preliminary Idle Speed and Mixture
IMPORTANT: The following adjustments will provide a
sufficient idle speed and mixture for starting engine.
Final adjustments must be made with engine running.
1. Turn idle speed screw in until it just contacts idle
cam: then, turn screw in an additional two turns .
IMPORT ANT: DO NOT turn idle mixture needle tightly
against seat (in the following step), as damage to seat
and/or needle may result.
2. Turn idle mixture needle in until they lightly seat;
then, back needle out 1-1/4 turns.
16923
a-Idle Mixture Needle
Preliminary Idle Mixture Adjustment
90-14499--1 887 FUEL SYSTEM -58-7
Final Idle Speed and Mixture
IMPORTANT: Boat must be in the water and engine at
normal operating temperature to accurately check and
adjust idle speed and mixture.
Carburetor should be set so that engine idles smoothly
within range given under "Specifications", with boat in
the water, engine at normal operating temperature and
drive unit in forward gear. To 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.
1.
Connect an accurate shop tachometer to engine.
IMPORTANT: DO NOT turn idle mixture needle tightly
into seat, as damage to needle and/or seat may result.
a-Idle Mixture Needle
Carburetor Idle Mixture Needle
;. '...
58-8 -FUEL SYSTEM
2.
If a new or rebuilt carburetor has been installed,
turn idle mixture needle in (clockwise) until it lightly
contacts seat; then, back out needle 1-1/4 turns.
This will provide a sufficient setting to allow starting
engine.
3.
Start engine and run at 1500 RPM until engine
reaches normal operating temperature.
A WARNING
DO NOT leave the helm unoccupied while performing
idle speed and mixture adjustments, following. BE
CAREFUL NOT TO ACCIDENTALLY ACCELERATE
ENGINE WHILE PERFORMING ADJUSTMENTS.
4.
With boat in open water, place remote control in
forward gear, idle position.
5.
Disconnect throttle cable brass barrel from anchor
stud. Be sure not to lose spacer on anchor stud.
6.
Adjust idle speed adjustment screw to obtain specified
RPM.
7.
With engine running at specified RPM, adjust idle
mixture needle as follows:
a.
Turn idle mixture needle inward (clockwise)
until the engine speed begins to drop due to lean
mixture.
b.
Turn idle mixture screw outward (counterclockwise)
until the speed begins to drop due to rich
mixture.
c.
Turn screw inward to a point between these two
extremes to obtain maximum engine smoothness
and RPM.
d.
Readjust idle speed adjusting screw, if necessary,
to obtain specified RPM.
IMPORTANT: Refer to "Section 2 (Removal, Installation
and Alignment)" for throttle cable installation and
adjustment.
a-Idle Speed Adjustment Screw
Idle Speed Adjusting Screw
90-14499--1 887
·-.._/
Repair
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Removal
IMPORTANT: Carburetor malfunctions are, in many
cases, caused by the presence of dirt, water or other
foreign matter in carburetor. To aid in diagnosis, carefully
remove carburetor from engine without draining
fuel from bowl. Contents of fuel bowl may, then, be
inspected for contamination as carburetor is disassembled.
1.
Remove ventilation hose from flame arrestor; then,
remove flame arrestor.
IMPORTANT: Place a clean cloth in bores of carburetor
to prevent dirt and foreign material from falling into
bores.
2.
Turn fuel supply off at fuel tank.
Disconnect throttle cable from carburetor.
Remove swivel link assembly from carburetor.
5.
Remove fuel line from fuel inlet nut.
6.
Remove fuel pump sight tube from carburetor.
r 7. Disconnect electric choke.
8. Remove carburetor attaching nuts and washers and
remove carburetor.
9.
Remove and discard gaskets.
IMPORTANT: Place a clean cloth over intake manifold
opening to prevent dirt or foreign material from entering
manifold.
Installation
1.
Thoroughly clean gasket surfaces.
2.
Place new carburetor base gasket on intake manifold.
Install carburetor and secure with nuts and
washers. Torque to specifications.
3.
Connect fuel line to fuel inlet nut and torque to
specifications.
4.
Conncet fuel pump sight tube to fitting on carburetor.
5.
Connect electric choke wires to choke cover.
6.
Check to ensure that 8-12 threads of link rod are
exposed from swivel; then, attach swivel link assembly
to throttle lever, using nut and washer.
7.
Move intermediate throttle lever back-and-forth
and check for binding in throttle linkage. If binding
occurs, remove swivel link assembly from throttle
lever and adjust link (by turning link rod), as
required, to eliminate binding.
8.
Install throttle cable, as explained, in "Section 2".
9.
Install flame arrestor and crankcase ventilation
hose.
10. Reconnect battery cables to battery.
11. Start engine and check for gasoline leaks. If leaks
exist, STOP ENGINE IMMEDIATELY and recheck
connections.
12. Adjust
idle speed and idle mixture, as outlined
under "Adjustments" preceding.
Dissassembly
The following is a step-by-step procedure for completely
over-hauling carburetor removed from engine.
In many cases, however, complete overhaul is not
necessary and, in these cases, only the steps required
to repair the carburetor malfunction should be performed.
Read the instructions carefully to prevent
doing any unnecessary steps.
IMPORTANT: Before performing any service on carburetor,
it is essential that carburetor be placed in a
holding fixture to prevent possible damage to throttle
valves.
90-1 4499--1 887
FUEL SYSTEM -58-9
',•<''
4342-
-16
15
1-Air Horn
2-Gasket
3-Screw
4-Screw
5 -Lockwasher
6-Nut -Fuel Inlet
7-Gasket
8-Gasket
9-Spring
10 -Filter
11 -Inlet Needle and Seat
12 -Baffle Plate
13-Pin
14 -Float
15 -Float Bowl
16 -Venturi Cluster
17-Gasket
18 -Screw
19 -Screw
5B-10-FUEL SYSTEM
MerCarb Two-Barrel
20 -Lockwasher
21 -Gasket
22 -Gasket
23 -Power Valve Assembly
24 -Gasket
25 -Jet
26 -Gasket
27 -Pump Shaft and Lever Assembly
28 -Screw
29 -Washer
30 -Clip -Retainer
31 -Accelerator Pump Assembly
32 -Spring
33 -Clip -Retainer
34 -Strainer
35 -Check Ball
36-Cam -Idle
37 -Screw
38 -Throttle Body
392-H
39 -Gasket
40 -Idle Mixture Adjusting Needle
41 -Spring
42 -Screw -Idle Speed Adjusting
43 -Spring
44 -Screw
45 -Lockwasher
46 -Choke/Housing
47 -Gasket
48 -Screw
49 -Lever Assembly
50 -Screw
51 -Rod -Choke
52 -Rod -Accelerator Pump
53 -Accelerator Pump Shaft and Lever Assembly
54 -Washer -(Outer)
55 -Washer -(Inner)
90-1 4499--1 887
90-14499--1 887
FUEL SYSTEM -58-11
AIR HORN CHOKE HOUSING ASSEMBLY
1.
Remove fuel inlet filter nut, washers, spring, and
filter, as outlined.
1. Remove choke cover as shown.
2.
Remove accelerator pump rod retaining clip. Pivot
rod (as required) until retaining ear on rod and slot
in pump shaft and lever assembly align, allowing
rod to be pulled out.
a-Screws..
b -Retainers Remove
c -Choke Cover
Removing Choke Cover
2.
Remove choke lever as shown.
3. Remove choke housing assembly as shown.
('
a -Accelerator Pump Rod
b-Retainer Clip
c-Pump Shaft and Lever Assembly
Removing Accelerator Pump Rod
384-H
a -Screw -Choke
b -Choke Lever
Removec -Screws -Choke Housing Assembly
d-Gasket (If Equipped)
e-Choke Housing
Removing Choke Lever and Choke Housing Assembly
3. Remove idle cam screw. Also, remove choke rod by
pivoting rod (as required) until retaining ear on rod
and slot in choke lever align, allowing rod to be
pulled out.
a -Idle Cam Screw
b-Idle Cam
c-Choke Rod
Removing Idle Cam
a-Choke Rod
b -Choke Lever
c-Slot
Removing Choke Rod
58-12 -FUEL SYSTEM
16926
4. Remove air horn as shown.
16922
a-Air Horn Attaching Screws
Air Horn Attaching Screw Location
16933
a-Air Horn -Carefully Lift Off
b -Float Bowl Assembly
Carefully Removing Air Horn
90-14499--1 887
5. Invert air horn and carefully lay on bench.
6. Remove float hinge pin and lift float assembly from
air horn. Check float weight as shown.
.. 7. Remove air horn gasket.
a-Float Hinge Pin
b -Float Assembly
c-Air Horn Gasket
Removing Float Assembly and Air Horn Gasket
a -Grams Scale
b-Float
Checking Float Weight
90-14499--1 887
18219
a-Baffle
Removing Baffle
8. Remove baffle.
9. Remove needle assembly.
10. Remove needle seat and gasket.
a-Needle Assembly
b-Needle Seat
c-Gasket
Removing Needle Assembly, Needle Seat and Gasket
FUEL SYSTEM -58-13
a -"Spring Loaded Type" Needle
b -"Solid Type" Needle Types
of Needle and Seat Assemblies
18082
11. Loosen accelerator pump screw. Slide pump shaft
and lever assembly (and washer) out of air horn;
then, remove accelerator pump assembly and pump
lever.
a -Accelerator Pump Screw
b -Pump Shaft and Lever Assembly
c-Accelerator Pump (2cc Pump Shown)
d -Pump Lever
Removing Pump Shaft and Lever Assembly and
Accelerator Pump Assembly
SB-14 -FUEL SYSTEM
18154
12. Remove retainer clip and washer from pump shaft
and lever assembly; then, remove accelerator pump
assembly.
a-Accelerator Pump Assembly (2cc Pump Shown)
b-Retainer Clip
c -Pump Shaft and Lever Assembly
4cc Accelerator Pump
18156
21064
IMPORTANT: Choke valve and shaft and lever assembly
is not serviceable. If valve and/or shaft and lever
assembly is worn or damaged, air horn assembly must
be replaced.
90-14499--1 887
FLOAT BOWL ASSEMBLY
1. Remove accelerator pump return spring from pump
well.
(' 2. Carefully remove retainer clip, strainer, and check
ball from pump well.
a -Accelerator Pump Return Spring
b-Retainer Clip
c-Strainer
d -Check Ball
e-Pump Well
392-H
Removing Accelerator Pump Return Spring, Retainer
Clip, Strainer, and Check Ball (2cc Pump Only)
a-Large Pump Bore
b -Long Groove
Float Bowl Assembly for 4cc Accelerator Pump
90-14499--1 887
21067
a -Small Pump bore
b -Short Groove
Float Bowl Assembly for 2cc Accelerator Pump
3. Remove power valve assembly and gasket.
a -Power Valve Assembly
b-Gasket
Removing Power Valve Assembly
FUEL SYSTEM -5B-15
4. Remove main metering jets and gaskets.
a-Main Metering Jets -Gaskets Not Seen in Photo
Removing Main Metering Jets
IMPORTANT: Use care when removing venturi cluster
to prevent damaging brass tubes protruding from bottom
of cluster. DO NOT REMOVE TUBES. These tubes
are permanently pressed into the venturi cluster and
are not replaceable.
5. Remove three venturi cluster screws, and carefully
remove cluster and venturi gasket.
a -Screws/Lockwashers
Removing Venturi Cluster Attaching Screws
SB-16 -FUEL SYSTEM
a -Venturi Cluster Brass Tubes
b-Gasket
Carefully Remove Venturi Clusters
THROTTLE BODY ASSEMBLY
16935
IMPORTANT: Use extreme care when handling throttle
body, so as not to damage throttle valves.
1. Place float bowl assembly upside down. Remove
three throttle body assembly attaching screws and
lockwashers, and remove throttle body and gasket
from float bowl.
a-Screws
b -Lockwashers
c -Throttle Body -Gasket Not Seen in Photo
Separating Throttle Body from Float Bowl Assembly
90-14499--1 887
2. Remove idle mixture adjusting needle and spring.
a-Idle Mixture Adjusting Needle
b-Spring
Removing Idle Adjusting Needle and Spring
3. Remove idle speed screw and spring,if replacement
is necessary.
a -Idle Speed Screw
b-Spring
Removing Idle Speed Screw and Spring
IMPORTANT: DO NOT remove throttle valves. If any of
the throttle body parts are found to be worn or damaged,
complete throttle body assembly MUST BE
replaced. Throttle body assembly can be cleaned in
carburetor cleaner.
90-14499--1 887
Cleaning and Inspection
IMPORTANT: DO NOT use a wire or drill to clean jets,
passages, or tubes in carburetor, as this may enlarge
orifices and seriously affect carburetor calibration. A CAUTION Do not leave carburetor in carb cleaner for more than
two hours.
IMPORTANT: DO NOT clean float bowl gasket surfaces
with a gasket scraper or knife, as sealing bead
will be damaged and float bowl replacement will be
necessary. A CAUTION The float assembly, float needle, accelerator pump
plunger, and fuel filter MUST NOT BE immersed in
carburetor cleaner, as they will swell, harden, and/or
distort.
a -Accelerator Pump Plunger (2cc Pump Shown)
b-Float Needle
c-Fuel Filter
d -Float Assembly
18155
Items Which MUST NOT BE Immersed in Carburetor
Cleaner
FUEL SYSTEM -56-17
a -Idle Mixture Needle
b-Spring
Installing Idle Mixture Adjusting Needle and Spring
1.
Thoroughly clean all metal parts in a commercial
carburetor cleaner, until all deposits have been
removed. Follow manufacturer's instructions of
cleaner being used for proper cleaning and rinsing
procedure. Dry parts with compressed air.
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 carburetor
cleaner with a clean, dry cloth.
4.
Carefully inspect all carburetor parts for wear and
damage; pay particular attention to the following:
a.
Float Needle and Seat: If float needle or seat is
worn or damaged, replace with a new needle and
seat assembly.
IMPORTANT: Float needle and seat are factory
matched and tested and should be replaced as a set
only.
b.
Float Assembly and Hinge Pin: Check pontoon
density (to see if it is saturated with fuel), by
comparing weight of float with specifications. If
pontoon weight is high, float assembly must be
replaced. Check hinge pin and holes for wear.
c.
Fuel and Air Passages: Passages must be perfectly
clean for proper carburetor operation.
d.
Accelerator Pump Plunger and Return Spring:
Inspect pump plunger cup, pump plunger spring
(on pump assembly) and return spring.
e.
Power Piston Spring: Check power piston spring
for weakness or distortion.
f.
Idle Mixture Needle: Inspect idle mixture needle.
If damaged, needle must be replaced.
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 thru 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 Assembly:
Check shaft and lever assembly for excessive
looseness in air horn assembly. Check choke
valve and shaft and lever assembly for binding
thru entire operating range, making sure valve
opens and closes completely. Air horn assembly
must be replaced if choke valve and shaft and
lever assembly are worn or damaged.
j.
Inspect Casting for visible damage. Inspect
gasket surfaces. Inspect accelerator pump
plunger well for scoring or deposits.
Reassembly
THROTTLE BODY ASSEMBLY
IMPORTANT: DO NOT force idle mixture needle
against seat as damage to needle and/or seat will
result.
1.
Screw idle mixture needle (and spring) into throttle
body until they lightly seat; then, back out needle
1-1/4 turns as a preliminary idle mixture setting.
Final adjustment will be made with engine running.
Refer to "Adjustments".
58-18-FUEL SYSTEM
90-14499--1 887
2. Thread idle speed screw and spring into throttle
lever.
a-Idle Speed Screw
b-Spring
Installing Idle Speed Screw
3. Turn float bowl assembly upside-down and place
new throttle body gasket on bowl, making sure
gasket is properly positioned on locating dowel.
a-Throttle Body Gasket
b -Locating Dowel
Throttle Body Gasket Properly Positioned on Float
Bowl Assembly
90-14499--1 887
4. Install throttle body assembly on float bowl assembly,
making sure that screw holes in gasket line up
with screw holes in throttle body. Tighten screws
evenly and securely.
a-Screws
b -Lockwashers
c-Throttle Body Assembly
Installing Throttle Body Assembly on Float Bowl
Assembly
FLOAT BOWL ASSEMBLY
IMPORTANT: Place float bowl and throttle assemblies
in holding fixture to prevent throttle valves from being
damaged.
a-Venturi Cluster
b-Gasket
Placing Gasket on Venturi Cluster
16942
FUEL SYSTEM -5B-19
1. Place new gasket over venturi cluster brass tubes.
Carefully, install venturi cluster in float bowl, using
three screws. gaskets and lockwashers as shown.
Tighten screws evenly and securely.
a -Venturi Cluster
b -Center Screw (With Smooth Shank)
c -Outer Screws
d -Fiber Washer
e -Lockwashers t -Metal Gaskets
Installing Venturi Cluster
2. Install main metering jets and gaskets in bottom of
float bowl assembly; tighten jets securely.
a -Main Metering Jets
Installing Main Metering Jets
SB-20 -FUEL SYSTEM
3. Install power valve assembly and gasket in bottom
of float bowl assembly and tighten securely.
a -Power Valve Assembly
b-Gasket
Installing Power Valve Assembly
4. Place check ball in pump well; then, install strainer
and retainer clip.
a-Check Ball
b-Strainer
c-Retainer Clip
Installing Check Ball, Strainer, and Retainer Clip
(2cc Pump Only)
90-14499--1 887
5. Place accelerator pump return spring in pump well.
a -Accelerator Pump Return Spring
b-Pump Well
Installing Accelerator Pump (2cc Pump Only)
AIR HORN ASSEMBLY
IMPORTANT: Accelerator pump assembly MUST BE
installed correctly. lf pump assembly is installed incorrectly,
top of pump assembly will contact air horn castIng.
1. If accelerator pump assembly was removed from
pump lever, secure pump assembly to pump lever
with washer and retainer clip, as shown.
a-Accelerator Pump Assembly (2cc Pump Shown)
b-Retainer Clip
c -Pump Lever
18156
Securing Accelerator Pump Assembly to Pump Lever
2. Insert pump shaft and lever assembly (and washer)
into air horn; then, align indexed hole in pump lever
with shaft and lever assembly and slide shaft allthe-
way into lever so that shoulder on shaft is hitting
lever. Tighten set screw securely.
a -Pump Lever
b-Set Screw
c -Pump Shaft and Lever Assembly
d-Washer
e-Air Horn
Installing Accelerator Pump Assembly and Pump Shaft
and Lever Assembly
3. Install needle seat and gasket, using appropriate
width screwdriver.
a-Needle Seat b-Gasket c-Screwdriver
Installing Needle Seat and Gasket
90-14499--1 887 FUEL SYSTEM -58-21
IMPORTANT: Float needle and needle seat are factory
matched and tested and should be replaced as a set
only.
4. Place needle assembly in needle seat.
a-Needle Assembly
b-Needle Seat
Installing Needle Assembly
5. Install baffle.
a-Baffle
Installing Baffle
56-22 -FUEL SYSTEM
16944
6. Place new gasket on air horn.
a-Gasket
Installing Air Horn Gasket
7. Install float assembly and hinge pin. Pivot float
assembly up-and-down on hinge pin to ensure it
moves freely.
a -Float Assembly
b-Float Hinge Pin
Installing Float Assembly and Hinge Pin
90-14499--1 887
8. Place air horn on float bowl, making sure accelerator
pump is correctly positioned in fuel well. Lower
air horn straight down to install.
16933
a-Air Horn
.b -Float Bowl Assembly
Carefully Installing Air Horn
9. Install seven short and one long air horn attaching
screws. Tighten screws evenly and securely.
a -Seven Short Screws
b -One Long Screw
Installing Air Horn Attaching Screws
90-14499--1 887
16922
10. Place end of choke rod in choke lever and collar
assembly.
a-Choke Rod
b-Choke Lever and Collar Assembly
Installing Choke Rod
11. Place idle cam on choke rod .
16940
a -Idle Cam
b-Choke Rod
Installing Idle Cam
FUEL SYSTEM -58-23
12. Secure idle cam (with choke rod installed on cam)
on float bowl assembly, using screw. Check that
cam is free to move without binding.
16926
a -Screw b -Idle Cam c-Choke Rod
Securing Idle Cam to Float Bowl Assembly
13. Place accelerator pump rod (end with ear) in hole in
pump shaft and lever assembly.
16938
a-Accelerator Pump Rod
b-Pump Shaft and Lever Assembly
Installing Accelerator Pump Rod
58-24 -FUEL SYSTEM
14.1nsert remaining end of accelerator pump rod into
hole in throttle lever and secure with retainer clip.
a -Accelerator Pump Rod
b -Throttle Lever
c -Retainer Clip
Securing Accelerator Pump Rod to Throttle Lever
90-14499--1 887
CHOKE HOUSING ASSEMBLY
IMPORTANT: Not all MerCarb carburetors are
equipped with choke housing gasket. This gasket is
not necessary for choke housing installation; therefore,
if replacement gasket is not available, choke
housing may be installed on air horn assembly without
gasket.
1. Place new choke housing gasket (if equipped) in
position on air horn making sure that, when installing
choke housing assembly, locating pin on housing
inserts into hole in gasket.
a-Gasket
b-Choke Housing Assembly Gasket Locating Pin
Installing Choke Housing Assembly Gasket
90-14499--1 887
2. Secure choke housing assembly to air horn with
two attaching screws. Tighten screws securely.
3. Fasten choke lever to choke shaft assembly with
screw, as shown.
4. Place choke cover on choke housing. Be sure hook
on end of heating coil engages with choke lever.
Rotate choke cover until alignment marks (made at
disassembly} line up.
a-Choke nous•ng ""'"'"'"'u'Y b-Choke Housing Assembly Attaching Screws
c -Choke Lever
d Choke
Lever Screw
384-H
Installing Choke Housing Assembly and Choke Lever
Assembly to Air Horn
5. Secure choke cover with three screws and retainers,
being sure ground terminal is fastened under
bottom screw.
a-Screws
b-Retainer
c -Choke Cover
Installing Choke Cover
,II
384-H
FUEL SYSTEM -5B-25
FUEL SYSTEM
ROCHESTER 4 BARREL
Index
Page
Identification ................................. 5C-1
Replacement Parts Warning ................... SC-1
Torque Specifications ........................ 5C-1
Tools ........................................ SC-1
Specifications ................................ SC-2
Description .................................. SC-6
Precautions ...........................•"• ..... SC-6
Important Service Information ................. 5C-6
Maintenance ................................. SC-7
Flame Arrestor ............................ SC-7
Fuel Filter ................................. SC-7
Adjustments ................................. SC-8
Accelerator Pump ......................... 5C-8
Air Valve Dashpot ......................... SC-9
Air Valve Spring Windup ................... SC-9
Float Level ............................... SC-10
Choke Coil Rod .......................... SC-11
Vacuum Break ........................... SC-11
Preliminary Idle Speed and Mixture ........ SC-12
Final Idle Speed and Mixture .............. SC-12
Repair ...................................... SC-13
Removal ................................. SC-13
Installation ............................... SC-14
Disassembly ............................. SC-17
Air Horn .............................. SC-17
Float Bowl ............................ SC-19
Float Weight .......................... SC-21
Throttle Body ......................... SC-21
Cleaning and Inspection .................. SC-21
Reassembly .............................. SC-23
Throttle Body ......................... SC-23
Float Bowl ............................ SC-23
Air Horn .............................. SC-27
"'
FUEL SYSTEM -SC 90-1 4499--1 887
Identification
Replacement Parts Warning
AWARNING Electrical, Ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
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.
90-14499--1 887
Torque Specifications
Tools
MERCURY MARINE SPECIAL TOOLS
91 -36392 Universal Carburetor Gauge
91-59339 Tachometer
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Carburetor to
132 (15)
Manifold
Fuel Line To
18 (24)
Carburetor
Fuel Inlet Filter
18 (24)
Nut
KENT-MOORE TOOL GROUP
1600 EXECUTIVE DRIVE
JACKSON, MICHIGAN 49203 TEL. (517) 788-6210
J9789-118 Carburetor Stand
J22769 Needle Valve Seat Remover
WAGNER INSTRUMENTS
P.O. BOX 1217
GREENWICH, CT. 06836 (203) 869-9681
Model G.D. 150 Gram Scale (With Round Tip)
BORROUGHS TOOL & EQUIPMENT CORP.
2429 N. BURDICK ST.
KALAMAZOO, MICH. 49007 (616) 345-5163
BT-8128 B Float Scale
BT-8420 A Float Level Gauge
TORX® SCREWDRIVERS
Later Rochester Quadrajet carburetors will have a
"star" shaped socket in the head of the screw. A
TORX® screwdriver must be used on this type of screw.
The three sizes used are #9, #20 and #25.
FUEL SYSTEM -SC-1
MCM Carburetor
Specifications
Model
(Serial Number)
Carb
Type
(Note 1)
Mercury No.
(Manufacturer No.)
Primary
Jet Size
Primary
(Secondary)
Metering Rods
Hanger
(Note 2)
MCM 230, 5.0 Litre LX
(6899269 and Above)
Rochester
4MV
1347-8296
(1 7080565)
.069 1n.
.042 ln.
(DE)
F
MCM 230TR
(ALL)
Rochester
4MV
1347-8290
(1 7080564)
.067 ln.
.036 1n.
(DL)
K
MCM 260, 5.7 Litre
(6890706 and Above)
Rochester
4MV
1347-8292
(1 7080561)
.068 ln.
.041 ln.
(OW-DE)
D
MCM 260TR
(ALL)
Rochester
4MV
1347-8289
(1 7080562)
.069 ln.
.036 1n.
(CH)
.042 1n .
(CL)
p
pMCM 350 Magnum
(ALL)
Rochester
4MV
1347-9415
(1 7085013)
. 069 ln.
MCM 300 Tempest
(6668677 and Above)
Rochester
4MV
1347-7498A6
(1 7059280)
.068 1n.
.041 ln.
(CH)
F
MCM 330 B-W, 7.4 Litre
(6920832 and Above)
Rochester
4MV
1347-8291
(1 7080563)
.069 1n.
.042 ln.
(DB)
F
MCM 454 Magnum
(Alpha)
Rochester
4MV
1347-8291
(1 7080563)
. 069 1n.
.042 ln .
(DB)
F
MCM 370, 454 Magnum
(Bravo)
6721 143 and Above
Rochester
4MV
134 7-7 498A2
(1 7059280)
.068 ln.
.041 ln.
(DA)
F
MCM 400 Cyclone
(6844279 and Above)
Rochester
4MV
1347-7498A2
(1 7059280)
.068 1n.
.041 ln.
(DA)
F
NOTES:
1.
Rochester Quadrajets are 4MV or 4MC type. The "V" or "C" designates choke type, NOT bore size. This information
supercedes all previous service bulletins and service information.
2.
Hanger size may vary from this chart. Install same size hanger which was removed from the carburetor.
5C-2 -FUEL SYSTEM
90-14499--1 887
MIE Carburetor
Specifications
Model
{Serial Number)
Carb
Type
{Note 1)
Mercury No.
{Manufacturer No.)
Primary
Jet Size
Primary
{Secondary)
Metering Rods
Hanger
{Note 2)
MIE 230, 5.0 Litre
(6901 030 and Above)
Rochester
4MC
1347-8290
(1 7080564)
.067 ln.
.036 ln.
(DL)
K
MIE 260, 5.7 Litre
(6885892 and Above)
Rochester
4MC
1347-8289
(1 7080562)
.069 ln.
.036 1n.
(CH) p
MIE 5.7 Ski
(A338553 and Above)
Rochester
4MC
1347-941 5
(1 708501 3)
.069 1n.
.042 1n.
(CL) p
MIE 340, 7.4 Litre
(A307953 and Above)
Rochester
4MC
1347-8288
(1 7080560)
.069 1n.
.042 ln.
(CL)
F
NOTES:
1.
Rochester Quadrajets are 4MV or 4MC type. The "V" or "C" designates choke type, NOT bore size. This information
supercedes all previous service bulletins and service information.
2.
Hanger size may vary from this chart. Install same size hanger which was removed from the carburetor.
90-14499--1 887
FUEL SYSTEM -5C-3
UNIT OF MEASUREMENT
in. (mm)
MCM Carburetor Adjustment Specifications (Note 1)
MCM 370
MCM 3308-W MCM 400
MCM 350 MCM 300
MCM 454 Cyclone
Engine Model MCM 230 MCM 230TR MCM 260 MCM 260TR
Magnum Tempest
Magnum 454 Magnum
5.0 Litre LX 5.7 Litre 7.4 Litre (1988)
Make & Model Rochester 4MV
Carb. 17059292 17080564 17059288 17080562 17085013 17059280 17059290 17059288
Manufacturer 17057282 17057298 17057287 17059280
Number 17080565 17080561 17080563
Float Level
15/64
(5.9)
Pump Rod Hole
Inner
Location
Accelerator Pump 23/64 •·
(Note 2) (9.1 )
Air Valve Dash Pot .025
(Air Valve Rod) (.64)
Vacuum Break
.080
[5/64 (2.0)]
Air Valve Spring 3/8 Turn 3/8 Turn 1/2 Turn 3/8 Turn 3/8 Turn 1/2 Turn 1/2 Turn 5/8 Turn
Wind Up 70-90 Gr. 60-75 Gr. 70-90 Gr. 70-90 Gr. 70-90 Gr. 70-90 Gr. 80-95 Gr. 70-90 Gr.
Choke Coil Rod Top of Rod Even
(Note 3) With Bottom of Hole
Idle Mixture Screw
2-3 Turns
Preliminary Setting
Float Weight (Max) 9.88 Gr.
NOTES: 1.
All measurements are± 1/64" (.4mm). Information contained in this chart supercedes all service bulletins
printed in 1984 and earlier.
2.
Accelerator pump measurement taken from flame arrestor surface to pump stem with throttle plates
closed.
3.
Choke valve must be closed, choke rod in bottom of choke lever slot, and choke coil rod pushed down to
end of travel.
5C-4 -FUEL SYSTEM
90-14499--1 887
UNIT OF MEASUREMENT
in. (mm)
MIE Carburetor Adjustment Specifications (Note 1)
Engine Model
MIE 230,
5.0 Litre MIE 5.7 Ski
MIE 260
5.7 Litre
MIE 340
7.4 Lit..e
Make & Model Rochester 4MV
Carb.
Manufacturer
Number
17080564 17085013 1708562 17080560
Float Level
15/64
(5.9)
Pump Rod Hole Location Inner
Accelerator Pump
(Note 2)
23/64
(9.1)
Air Valve Dash Pot
(Air Valve Rod)
.025
(.64)
Vacuum Break
.080
[5/64 (2.0))
..
Air Valve Spring
Wind Up
3/8 Turn
60-75 Gr.
3/8 Turn
75-85 Gr.
3/8 Turn
70-90 Gr.
3/4 Turn
80-95 Gr.
Choke Coil Rod
(Note 3)
Top of Rod Even
With Bottom of Hole
Idle Mixture Screw
Preliminary Setting
2-3 Turns
Float Weight (Max) 9.88 Gr.
NOTES: 1.
All measurements are± 1/64" (.4mm). Information contained in this chart supercedes all service bulletins
printed in 1984 and earlier.
2.
Accelerator pump measurement taken from flame arrestor surface to pump stem with throttle plates
closed.
3.
Choke valve must be closed, choke rod in bottom of choke lever slot, and choke coil rod pushed down to
end of travel.
90-14499--1 887
FUEL SYSTEM -5C-5
Description
The Quadrajet carburetor has 2 stages in operation.
The primary (fuel inlet) side has small bores with a
triple venturi set-up equipped with plain tube nozzles.
Its metering principles are similar to the most plain
tube carburetors which use the venturi principle. The
triple venturi stack up, plus smaller primary 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 rods positioned
by a manifold vacuum responsive piston.
Secondary side has 2 very large bores which have
greatly increased air capacity to meet present day and
future engine demands. Air valve principle is used in
secondary side for metering control and supplements
fuel flow from primary bores.
Using air valve principle, fuel is metered in direct proportion
to air passing thru secondary bores.
Fuel reservoir is centrally located to avoid problems of
fuel slosh causing engine turn cut-out and delayed fuel
to carburetor bores. Float system uses a single float
pontoon for ease in servicing the unit.
Precautions
A WARNING
Always disconnect battery cables from battery BEFORE
working on fuel system to prevent fire or explosion.
A WARNING
Be careful when cleaning flame arrestor and crankcase
ventilation hose; gasoline is extremely flammable and
highly explosive under certain conditions. Be sure that
ignition key is "OFF". DO NOT smoke or allow sources
of spark or open flame in area when cleaning flame
arrestor and crankcase ventilation hose.
A WARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". DO NOT smoke or allow sources of spark or
flame in the area while changing fuel filter. Wipe up any
spilled fuel immediately.
A WARNING
Make sure no fuel leaks exist, before closing engine
hatch.
A CAUTION
DO NOT operate engine without cooling water being
supplied to water pickup holes in gear housing, or
water pump impeller will be damaged and subsequent
overheating damage to engine may result.
5C-6 -FUEL SYSTEM
Important Service Information
NOZZLE DEFLECTOR, MIE 230/260/340 STRAIGHT
INBOARD AND V-DRIVE
If you receive a complaint of high speed surging on a
MIE engine equipped with a Quadrajet carburetor, the
problem can be cured by installing a nozzle deflector
(P/N 1397-9422) as shown.
a -Nozzle Deflector
b -Locating Bosses
When installing the nozzle deflector, inspect the air
horn for the 2 locating holes as shown. If the locating
holes are in the air horn, the nozzle deflector can be
installed as is. If the air horn does not have these locating
holes, the 2 bosses on the nozzle deflector must be
carefully removed so the air horn will fit flush on the
float bowl.
a -Locating Holes
90-14499--1 887
Maintenance
Flame Arrestor
NOTICE
Refer to "Precautions" in this section BEFORE
proceeding.
1.
Remove (in the following order):
a.
Nut
b.
Sealing Washer
c.
Carburetor Cover
d.
Hose Clamps and Crankcase Ventialtion Hoses From
Flame Arrestor and Rocker Arm Covers
e.
Flame Arrestor -Lift from Carburetor
2.
Clean and Inspect:
a.
Clean flame arrestor in solvent and blow dry with
compressed air.
b.
Clean crankcase ventilation hoses
c.
Inspect crankcase ventilation hose for cracks or
deterioration, and replace if neccessry.
3.
Install (in the following order):
a.
Flame Arrestor -Place on Carburetor
b.
Crankcase Ventilation Hose and Hose Clamps
-To Flame Arrestor and Rocker Arm Covers
c.
Carburetor Cover
d.
Sealing Washer
e.
Nut -Tighten Securely.
Fuel Filter
NOTICE
Refer to "Precautions" in this section BEFORE
proceeding.
1.
Remove;
•
Fuel line from fuel inlet filter nut
•
Fuel inlet filter nut
•
Large gasket
•
Filter
•
Spring
•
Small gasket -From inside filter nut
a-Fuel Line
b,-Fuel Inlet Filter Nut
c-Gasket (Large)
d -Gasket (Small)
e-Filter
f-Spring
Changing Fuel Filter
2.
Clean filter nut and spring.
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 specifications
•
Fuel line -Tighten to specifications
a-Nut · d-Clamps
b-Washer e-Crankcase Ventilation Hoses
c -Carburetor Cover f -Flame Arrestor
Flame Arrestor with Carburetor Cover
FUEL SYSTEM -5C-7 90-1 4499--1 887
Adjustments
NOTICE
Refer to "Precautions" In this section BEFORE
proceeding.
Accelerator Pump
1. Back out idle stop screw until it no longer contacts
throttle lever.
a -Idle Stop Screw
b -Throttle lever
Backing Out Idle Stop Screw
2. Pump rod must be in inner hole of lever.
a-Pump Rod
b-Inner Hole
Pump Rod Location
SC-8 -FUEL SYSTEM
3. Close throttle valves completely and measure from
flame arrestor mounting surface to top of pump
plunger stem.
a -Flame Arrestor Mounting Surface
b-Pump Plunger Stem
Measuring pump plunger Height
4. While supporting lever, bend tip of pump lever to
obtain specified dimension.
a -Tip of Pump Lever
b -Support as Shown
Adjusting Pump Plunger Height
90-14499--1 887
Air Valve Dashpot
1. Seat vacuum break diaphragm and close air valve
completely. Bend rod to adjust gap to specifica
.. tions.
a -Push in Completely
b-Bend Here to Adjust
c -Specified Gap
d-Fully Closed
Adjusting Oashpot Link R
90-14499--1 887
,5 Q Ct>;IJ ..fit y v J{ 4i1 s Q. v-.s A:: R;c..IA
Air Valve Spring Windup
1. Rotate gram scale until air valve begins to open,
check scale reading.
c-Contact Area of Arm on Air Valve
d-Rotate
Checking Air Valve
2. To adjust spring windup, hold tension spring screw
and loosen allen head screw.
3. Adjust tension and retighten allen screw securely.
c -Loosen Allen Head Screw
Adjusting Air Valve
FUEL SYSTEM -5C-9
Float Level
1. Start engine to fill float bowl, run at idle and insert
float gauge into hole next to flame arrestor stud.
a -Gauge Hole
b -Gauge (BT -8420A)
Installing Float Gauge
2. Tap float gauge down lightly to assure free movement.
a-Gauge
Tapping Float Gauge
5C-10 -FUEL SYSTEM
3. Take gauge reading at top of carburetor casting.
a-Read Here
Checking Float Level with Gauge
4. If float requires adjustment hold hinge pin firmly,
turn carburetor upside down and measure from
casting surface to toe of float with universal carburetor
gauge. Check specifications.
5. Bend at float arm notch for adjustment to specifications.
a-Hinge Pin
b-Universal Carburetor Gauge
Adjusting Float
90-14499--1 887
Choke Coil Rod
1. Push choke coil rod down.
a -Vacuum Break Choke Lever
b -Choke Coil Rod
Pushing Choke Rod Down
2. Choke coil rod top must be even with bottom of hole
in vacuum break choke lever.
a-Top of Rod
b -Bottom of Hole
Checking Choke Rod Adjustment
90-14499--1 887
3. Bend rod to adjust.
Bending Choke Coil Rod
Vacuum Break
1. Seat vacuum break control diaphragm.
a-Vacuum Break Control Diaphragm
Seating Vacuum Break Control Diaphragm
2. Rotate vacuum break choke lever counterclockwise
until tang contacts vacuum break rod. Choke rod
must be at bottom of choke shaft lever slot.
a-Tang
b-Choke Rod
c -Vacuum Break Rod
Rotating Choke Lever
FUEL SYSTEM -SC-11
3. Bend tang as necessary to obtain specified choke
valve gap.
a-Tang
b -Specified Gap
Checking Vacuum Break and Unloader Adjustment
Preliminary Idle Speed and Mixture
Initial start setting, make final adjustments with engine
running.
1.
Turn idle stop screw until contact with throttle lever.
18098
a-Idle Stop Screw
b -Throttle Lever
Idle Stop Screw and Throttle
2.
Turn idle needles until LIGHTLY seated then back
out 2 to 3 turns.
a -Idle Needles
Idle Mixture Needles
IMPORTANT: Do not turn idle mixture screws tightly
against seat, as damage to seat and/or needle may
result.
5C-12 -FUEL SYSTEM
Final Idle Speed and Mixture
IMPORTANT: Boat MUST BE in the water and engine
at normal operating temperature to accurately check
and adjust idle speed and mixture.
Carburetor should be set so that engine idles smoothly,
with boat in the water, engine at normal operating
temperature and drive unit in forward gear. To 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.
1.
Connect a shop tachometer to engine.
IMPORTANT: DO NOT turn idle mixture needles
tightly into seat, as damage to needle and/or seat may
result.
2.
If a new or rebuilt carburetor has been installed,
turn each idle mixture needle until it LIGHTLY contacts
seat, then back out 2 to 3 turns. This will
provide a sufficient setting to allow starting the
engine.
3.
Start engine and run at 1500 RPM until engine
reaches normal operating temperature.
A WARNING
DO NOT leave the helm unoccupied while performing
idle speed and mixture adjustments, following. BE
CAREFUL NOT TO ACCIDENTALLY ACCELERATE
ENGINE WHILE PERFORMING ADJUSTMENTS. ..
4.
With boat in open water, place remote control in
forward gear, idle position.
5.
Disconnect throttle cable brass barrel from anchor
stud. BE SURE NOT TO LOSE SPACER ON
ANCHOR STUD.
6.
Adjust idle speed adjustment screw to obtain specified
RPM.
7.
With engine running at specified RPM, adjust idle
mixture needles as follows:
a.
Turn idle mixture needle inward (clockwise)
until the engine speed begins to drop due to lean
mixture.
b.
Turn idle mixture screw outward (counterclockwise)
u nti I the speed begins to drop due to a rich
mixture.
c.
Turn screw inward to a point between these two
extremes to obtain maximum engine smoothness
and RPM.
d.
Repeat procedure with other needle.
e.
Readjust idle speed adjusting screw, if neces
sary, to obtain specified RPM.
IMPORTANT: Refer to "Section 2" for throttle cable
installation and adjustment.
90-1 4499--1 887
Repair
NOTICE
Refer to "Precautions" in this section BEFORE
proceeding.
IMPORTANT: Carburetor malfunctions are, in many
cases, caused by the presence of dirt, water or other
foreign matter in carburetor. To aid in diagnosis, carefully
remove carburetor from engine without draining
fuel from bowl. Contents of fuel bowl may, then, be
inspected for contamination as carburetor is disassembled.
Removal
1. Remove flame arrestor.
2. Disconnect choke spring rod.
a-Choke Rod
b-Clip
Removing Choke Spring Rod
90-14499--1 887
3. Disconnect sight tube (if equipped).
a-Sight Tube
Removing Sight Tube
IMPORTANT: Place a clean cloth in bores of carburetor
to prevent dirt and foreign material from falling into
bores.
4. Turn off fuel supply at the fuel tank. 5. Disconnect fuel line.
a-Fuel Line
Removing Fuel Line
FUEL SYSTEM -5C-13
6. Disconnect throttle cable.
a -Throttle Cable
Removing Throttle Cable
7.
Disconnect cable end guide.
a-Cable End Guide
Removing Cable End Guide
8.
Remove retaining nuts and bolts, remove carburetor
and cable bracket.
IMPORTANT: Place a clean cloth over intake manifold
opening to prevent dirt or foreign material from entering
manifold.
9.
Remove old gasket from carburetor and manifold.
a-Bolts
b-Nuts
c -Cable Bracket
Removing Carburetor
Installation
1.
Install new gasket onto manifold.
2.
Install carburetor and throttle bracket and torque to
specifications.
a-Mounting Bolts
b-Nuts
c-Throttle Bracket
Installing Carburetor
SC-14-FUEL SYSTEM
90-14499--1 887
3. Connect fuel line and torque to specifications.
a-Fuel Line
Connecting Fuel Line
4. Connect fuel sight tube.
a -Sight Tube
Connecting Sight Tube
90-14499--1 887
5. Connect choke link and install retaining clip.
a Choke
Link
b-Clip
Connecting Choke Spring Rod
6. To install throttle cable refer to "Section 2, Removal,
Installation, and Alignment".
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 ENG INE IMMEDIATELY and recheck
connections.
10.Adjust idle speed and idle mixture, as outlined
under "Adjustments" preceding.
FUEL SYSTEM -SC-15
1 -Air Horn Assembly
2-Screw
3-Hanger
4 -Metering Rod, secondary
5-Screw
6-Screw
7-Screw
8-Lever
9-Roll Pin
10-Pump
11 -Spring
12-Needle and Seat
13-Gasket
14-Pull Clip
15-Gasket
16-Metering Rod, primary
17 -Jet, primary
18-Float Assembly
19-Pin, hinge-float
20-Lever. intermediate choke
21 -Rod
22-Clip
23 -Rod
24 -Clip
25-Screw
26-Control
27 -Hose
28-Power Piston
29 -Retainer, power piston
30-Retainer, pump discharge ball
31 -Ball, pump discharge
32 -Spring, power piston
33-Insert, float bowl
34 -Float Bowl
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
44 -Idle Needle
45-Screw
Exploded View -4MV/4MC Quadrajet
(Rochester Carburetor)
5C-16 -FUEL SYSTEM 90-14499--1 887
Disassembly
IMPORTANT: Place carburetor on a holding fixture to
prevent throttle valve damage.
AIR HORN
1. Remove vacuum pump rod clip and rod.
a-Rod Clip
Removing Clip
a-Rod
Removing Vacuum Pump Rod
90-14499--1 887
2. Remove choke shutter clip and rod.
a-Clip
Removing Choke Rod Clip
a-Rod
Removing Choke Rod
FUEL SYSTEM -5C-17
3. Drive roll pin back and remove accelerator pump
lever and rod.
a-Roll Pin (Not Shown)
b-Pump Lever
c-Rod
Removing Accelerator Pump Lever
4. Remove screw, secondary metering rods and
hanger.
a -Air Horn Screws
Air Horn Screws
18112
a-Screw
b -Metering Rods
c-Hanger
Removing Metering Rods and Hanger
SC-18 -FUEL SYSTEM
a-Air Horn
Removing Air Horn
5. Remove air horn screws and air horn.
90-14499--1 887
FLOAT BOWL
1. Remove pump plunger, return spring and gasket.
a -Pump Plunger
b -Return Spring
c-Gasket
Removing Gasket and Accelerator Pump.
2. Remove insert block, power piston and spring.
a -Insert Block
b -Power Piston
c-Spring
Removing Insert Block and Power Piston
90-14499--1 887
3. Remove float assembly, needle and retaining pin.
a-Float Assembly
b-Needle
c -Retaining Pin
Removing Float and Inlet Needle
4. Remove fuel inlet seat and gasket.
a -Fuel Inlet Seat
b-Gasket
Removing Inlet Seat
FUEL SYSTEM -5C-19
5.
Remove primary metering jets, pump discharge
check ball retainer and check ball.
a -Primary Metering Jets
b-Pump Discharge Retainer
c-Check Ball (Not Visible)
Removing Primary Jets and Retainer and Check Ball
6.
Remove Baffle.
a-Baffle
Removing Baffle
7.
Remove vacuum control assembly and hose.
a -Vacuum Control Assembly
b-Hose
Removing Vacuum Control
8.
Remove fuel inlet filter nut, gaskets, filter and
spring.
a-Nut
b-Gaskets
c-Filter
d-Spring
Removing Fuel Inlet Filter Assembly
5C-20 -FUEL SYSTEM
90-14499--1 887
9. Separate throttle body from float bowl and remove
gasket.
a -Attaching Screws
b -Throttle Body
c-Gasket
d -Float Bowl
Removing Throttle Body
,-. FLOAT WEIGHT
1. Assemble float scale to instructions with scale.
2. Check float weight to specifications.
a -Float Scale
b-Float
Checking Float Weight
3. Replace float if it exceeds specifications.
90-14499--1 887
18219
THROTTLE BODY
1. Remove idle mixture screws and springs.
a-Screw
b-Spring
Removing Idle Mixture Screws
18185
IMPORTANT: Throttle body should not be disassembled
any further than shown. Throttle body Is serviced
as an assembly.
Cleaning and Inspection A CAUTION Rubber, or plastic parts, pump plungers or diaphragms
cannot be immersed In carburetor cleaner. The delrin
air valve cam will withstand normal carburetor cleaner.
1. Clean carburetor in immersion type cleaner.
2. Blow out passages with compressed air. Do not drill
thru passages.
3. Inspect tor wear: • Idle mixture needles
• Float needle and seat
• Casting surfaces
• All levers
• Fast idle cam
• Power piston
• Accelerator pump seal
4. Check all valves for binding.
FUEL SYSTEM -SC-21
5. Check vacuum break unit for leaks.
a. Depress plunger and seal hose connection. A CAUTION Do not leave carburetor in carb cleaner for more than
two hours.
a-Plunger
b -Hose Connection
Seating Plunger
b. Maintain seal on hose connection, plunger must
remain seated. If plunger extends, replace unit.
Plunger Seated and Hose Connection Sealed
SC-22 -FUEL SYSTEM
IMPORTANT: The idle fuel pickup tubes have a smaller
J.D. at the bottom than the top. Do not drill.
6. Clean idle fuel pickup tubes with a fine wire (approx. .020" O.D.) and blow out all channels with com
..pressed air.
a-Idle Fuel Pickup Tubes
b -Channel Restrictions
Cleaning Idle Passages
IMPORTANT: If engine is experiencing a rough idle
situation and cannot be smoothed out with idle adjustment
screws, drill out the channel restrictions to .055",
using a No. 54 drill. Blow out channel with compressed
air to clean out. Some later model carburetors already
have this operation completed.
90-14499--1 887
Reassembly
THROTTLE BODY
NOTICE
Refer to "Adjustments" for all adjustment procedures.
IMPORTANT: Seat idle mixture screws lightly or damage
to needles and seats will result.
1.
Install idle mixture needles and springs until lightly
seated, then back out 2 to 3 turns.
a-Idle Mixture Needles and Springs
Installing Idle Mixture Needles
2.
Install new gasket and assemble throttle body to
float bowl. Tighten securely.
18184
a-Attaching Screws
b -Throttle Body
c-Gasket
d -Float Bowl
Installing Throttle Body
90-14499--1 887
FLOAT BOWL
NOTICE
Refer to "Important Service Information"
BEFORE proceeding.
IMPORTANT: Place carburetor on a holding fixture to
prevent damage to throttle valve.
1.
Install baffle plate.
a-Baffle Plate
Installing Baffle Plate
2.
Install intermediate choke lever and vacuum break
control bracket assembly.
a.
Using choke rod, suspend intermediate choke
lever in float bowl cavity so that flat sided hole
aligns with hole in side of float bowl.
a-Choke Rod
b -Choke Lever
c -Flat Sided Hole
Installing Choke Rod and Lever
FUEL SYSTEM -SC-23
b. Insert choke shaft on vacuum break control
assembly to engage flat sided hole of choke
lever, and secure with screw. Tighten securely.
a-Choke Rod
b-Choke Shaft
c-Vacuum Break Control Assembly
Installing Choke Rod to Vacuum Break
3. Install pump discharge check ball, retainer and
primary main metering jets. Tighten securely.
a-Check Ball (Not Shown)
b-Retainer
c-Primary Main Metering Jets
Installing Check Ball, Retainer and Primary Jets
SC-24 FUEL
SYSTEM
IMPORTANT: Float needle and seat should be replaced
as a set only.
4. Install float needle seat and gasket.
a -Float Needle Seat
b-Gasket
Installing Needle Seat and Gasket
5. Installing float needle and float assembly.
a. Install pull clip onto needle.
a-Pull Clip
b-Needle
Installing Pull Clip on Needle
18105
90-14499--1 887
b. If a new float or needle and seat are used, bend
float arm slightly upward at notch for easier
adjustment.
18106
a-Float
b Float
Arm Notch
Bending Float Arm
c. Hook needle pull clip over edge of float arm
closest to pontoon.
a-Pull Clip
b-Float Arm
Proper Installation of Pull Clip
18191
d. Install retaining pin into float arm and install
float and needle into bowl.
a-Float
b-Needle
c-Hinge Pin
Installing Float and Needle
IMPORTANT: Top of hinge pin must extend above
casting by .010 for good pin retention.
e. Check float adjustment (refer to "Adjustment" in
this section).
6. Install power piston spring.
a-Power Piston Spring
Installing Power Piston Spring
90-14499--1 887 FUEL SYSTEM -SC-..
7. Install primary main metering rods in power piston
hanger, and connect spring as shown.
a -Power Piston Hanger
b-Tension Spring
c -Metering Rods
Installing Primary Metering Rods
18107
8. Install power piston assembly, guiding metering
rod tips into main metering jets.
a -Power Piston Assembly
b-Metering Rod Tip in Main Metering Jet
Installing Power Piston Assembly
SC-26 -FUEL SYSTEM
9. Push power piston retainer down until flush with
casting.
a -Power Piston Retainer
Seating Power Piston
10.1nstall filler block.
a-Filler Block
Installing Filler Block
11. 1nstall accelerator pump plunger spring.
a-Spring
Installing Pump Return Spring
90-14499--1 887
AIR HORN
1. Install new gasket and sl ide tab under power piston
hanger.
a -Power Piston Hanger
b -Gasket Tab
Proper Installation of Gasket
2. Install accelerator pump plunger.
a-Plunger
Installing Accelerator Pump
3. Install air horn.
a-Air Horn
Installing Air Horn
4. Install 9 attaching screws. Tighten securely in
sequence as numbered.
a-Long
b-Short
c -Countersunk
Attaching Screw Installation
IMPORTANT: Hanger size may vary from specification
chart. Manufacturer varies hanger size to make up differences
in carburetor castings. Always install the
same size hanger as was removed from the carburetor.
Difference in hangers is the hole location, which
affects secondary fuel metering.
a -Hole Location Changes Fuel Metering
b-Richer
c-Leaner
Hanger Size
680-H
90-14499--1 887 FUEL SYSTEM -5C-27
a -Pump Lever Rod
Installing Pump Lever Rod
8. Install rod into lever inner hole and place lever into
a-Hanger
18188 casting mount.
a-Screw
a-Rod
b-Lever
c -Inner Hole
d -Casting Mount
Locating Pump Lever Rod.
90-14499--1 887
5. Install secondary metering rods into hanger with
upper ends toward each other as shown.
b -Metering Rods
Installing Metering Rods
6.
Install metering rods and hanger and secure with
screw. Tighten securely.
18176
b -Metering Rods
c-Hanger
Installing Hanger Assembly
5C-28 -FUEL SYSTEM
7. Install pump lever rod.
9. Press roll pin into place using a screwdriver.
a-Roll Pin
Installing Roll Pin
10.1nstall bottom end of choke shutter rod into intermediate
choke lever in float bowl.
a -Choke Shutter Rod
Install Choke Shutter Rod to Intermediate Choke Lever
90-14499--1 887
11.1nstall upper end of choke shutter rod into the
choke blade lever, install clip onto choke shutter
rod.
a -Choke Shutter Rod
b-Clip
c -Choke Blade Lever
Installing Upper End of Choke Shutter Rod
12.1nstall rod into air valve lever.
a-Rod
b -Air Valve Lever
Installing Air Valve Rod
FUEL SYSTEM -SC-29
13. 1nstall rod into vacuum break arm and install clip.
a-Rod
b -Vacuum Break Arm
c-Clip
Installing Rod to Break Arm
14.1nstall vacuum break hose onto carburetor fitting.
a-Fitting
b-Hose
Installing Vacuum Hose
SC-30 -FUEL SYSTEM
15.1nstall vacuum break hose onto vacuum dashpot
fitting.
a-Hose
b -Dashpot Fitting
Installing Vacuum Hose to Dashpot
90-14499--1 887
FUEL SYSTEM
HOLLEY 4 BARREL
Model 4150
m
'\...,_/ .
Index
Page
Identification ................................. 5D-1
Replacement Parts Warning ................... 5D-1
Torque Specifications ........................ 5D-1
Tools ........................................5D-1
Specifications ................................ 5D-1
Description .................................. 5D-2
Precautions .................................. 5D-2
Maintenance ................................. 5D-2
Flame Arrestor ............................ 5D-2
Fuel Filters ................................ 5D-3
Choke Inspection ......................... 5D-3
Adjustments ................................. 5D-3
Preliminary Float Adjustment ...............5D-3
Final Float Adjustment ..................... 5D-4
Accelerator Pump ......................... 5D-4
Choke Adjustment. ........................ 5D-5
Preliminary Idle Speed and Mixture ......... 5D-5
FinalIdle Speed and Mixture ............... 5D-6
Repair ....................................... 5D-7
Modifications ............................. 5D-7
Removal .................................. 5D-7
Installation ................................ 5D-8
Disassembly .............................. 5D-8
Choke Housing ........................ 5D-8
FuelBowls and Metering Bodies ......... 5D-9
Carburetor Body ...................... 5D-12
Throttle Body ......................... 5D-12
Cleaning and Inspection .................. 5D-13
Reassembly .............................. 5D-14
Throttle Body ......................... 5D-14
Carburetor Body ...................... 5D-14
Fuel Bowls and Metering Bodies ........ 5D-15
Choke Housing ....................... 5D-17
,,
FUEL SYSTEM -50
90-1 4499--1 887
Identification
a-Part Number
b-"MOD" (Certain Models)
Figure 1. Holley Part Number Location
Replacement Parts Warning
A WARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
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.
Torque Specifications
Fastener Location Lbs. Ft. (N.m)
Carburetor to
Manifold
20 (27)
Fuel Line To
Carburetor
18 (24)
Fuel Inlet Filter
Nut
Securely
Tools
MERCURY MARINE SPECIAL TOOLS
91 -59339 Tachometer
91 -36392 Universal Carburetor Gauge
BORROUGHS TOOLS AND EQUIPMENT
2429 N. BURDICK ST.
KALAMAZOO, MICHIGAN 49007
(616) 345-5163
BT8128B Float Gram Scale
Specifications
MCM 420
Engine Model 440/460
Cyclone
Make Holley
Model 41 50
Holley Part No. 4781
Mercury Part No. 1393-8862
Main Primary Jets .084
Main Secondary Jets .084
Accelerator Pump .015 (.4mm)
Accelerator Pump
Check Ball
.01 5" (4mm)
Bottom of
Float Adjustment Sight Plug Hole
±1/32" (.8mm)
Float Weight
15.6 Grams
Max.
Choke Setting
Index Marks
Aligned
Preliminary Idle
Mixture Setting
2 Turns
90-14499--1 887 FUEL SYSTEM -50-1
Description
The model 4150 is a 4 bore Holley carburetor with an
electrically operated automatic choke. The Holley
model 4150 is a dual feed, double pump carburetor.
This means each fuel bowl has a seperate fuel inlet and
there 2 accelerator pumps, one for the primary side and
one for the secondary side. Between the fuel bowls and
the carburetor body, metering bodies are located. The
metering bodies contain the main jets, power valve,
and the majority of the metered passages in the carburetor.
Both the primary and secondary floats have an
external float adjustment.
Precautions
A WARNING
Always disconnect battery cables from battery BEFORE
working on fuel system to prevent fire or explosion.
AWARNING
Be careful when cleaning flame arrestor and crankcase
ventilation hose; gasoline is extremely flammable and
highly explosive under certain conditions. Be sure that
ignition key "OFF". Do not smoke or allow sources of
spark or open flame in area when cleaning flame arrestor
and crankcase ventilation hose.
A WARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". Do not smoke or allow sources of spark or flame
in the area while changing fuel filter. Wipe up any
spilled fuel immediately.
A WARNING
Make sure no fuel leaks exist, before closing engine
hatch.
A CAUTION
Do not operate engine without cooling water being
supplied to water pickup holes in gear housing, or
water pump impeller will be damaged and subsequent
overheating damage to engine may result.
50-2 -FUEL SYSTEM
Maintenance
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Flame Arrestor
1.
Remove (in the following order):
a.
Nut.
b.
Washer (Not Shown).
c.
Hose clamps and crankcase ventilation hoses From
flame arrestor and rocker arm covers.
d.
Flame arrestor -Lift from carburetor.
2.
Clean and Inspect:
a.
Clean flame arrestor by blowing it out with compressed
air.
b.
Clean crankcase ventilation hoses.
c.
Inspect crankcase ventilation hose for cracks or
deterioration, replace if neccessry.
3.
Install (in the following order):
a.
Flame arrestor-Place on carburetor.
b.
Crankcase ventilation hoses and clamps -To
flame arrestor and rocker arm covers.
c.
Washer (Not Shown).
d.
Nut -Tighten securely, do not overtighten.
a-Nut
b -Flame Arrestor
c -Crankcase Ventilation Hoses
f-Clamps
Flame Arrestor
·····.. .
90-1 4499--1 887
Fuel Filters Adjustments
NOTICE NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Carburetor inlet filters are located in float chamber
assemblies behind fuel inlet fittings. To replace filters
proceed as follows:
1. Remove fuel line from fuel inlet filter nuts.
2. Remove fuel inlet filter nut, gasket, filter and spring
from each float chamber assembly. (Discard gasket
and filter).
3. Clean nuts and springs in solvent and dry with
compressed air.
4. Install spring, new filter (with open end outward),
gasket and fuel inlet filter nut into each float
chamber assembly (in that order). Tighten nut
securely.
5. Reconnect fuel line and tighten securely.
6. Run engine and check for gasoline leaks.
Choke Inspection
The choke does not require any periodic maintenance;
however, if a choke malfunction is suspected, the following
should be done:
1. With engine 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 sluggishly,
clean with carburetor choke cleaner. Carefully
follow directions on can.
a-Fuel Line Fittings
b -Fuel Filter Nut
c -Filter Nut Gasket
Fuel Inlet Filter
90-1 4499--1 887
d-Filter
e-Spring
Refer to "Precautions", in this section, BEFORE
proceeding.
Preliminary Float Adjustment
IMPORTANT: The preliminary float adjustment will
provide a sufficient setting for starting the engine. Final
float adjustments must be made with engine running.
1. Invert float bowl as shown.
2. Loosen locking screw and turn float adjustment nut
to adjust float.
3. Proper float adjustment is achieved when parting
line on float is parallel with fuel bowl. Parting line
must be parallel all the way around float.
a-Float c-Fuel Bowl (Inverted)
b-Float Parting Line d-Parallel All The Way Around Float
Preliminary Float Setting
a -Locking Screw
b-Adjustment Nut
Adjusting Float Level
4. Repeat this procedure for both floats.
FUEL SYSTEM -50-3
Final Float Adjustment
1. With carburetor mounted on engine, start engine
and leave run for several minutes.
2. While engine is running remove sight plug on primary
fuel bowl.
3. Loosen locking screw and turn adjustment nut
slowly until fuel can be seen even with the bottom of
the sight plug hole.
a-Locking Screw
b -Adjustment Nut
c -Sight Plug Hole
d -Raises Fuel Level
e-Lowers Fuel Level
Final Float Adjustment
4. Tighten locking screw securely being careful not to
let adjustment nut turn.
5. Reinstall sight plug and gasket.
6. Repeat this procedure for secondary side of carburetor.
SD-4 -FUEL SYSTEM
Accelerator Pump
1. With engine shut off, move throttle arm to W.O.T.
position.
2. While holding throttle arm in W.O.T. position push
down on primary accelerator pump lever.
a -Pump Lever -Push Down
b -Feeler Gauge
c -Adjustment Screw and Nut
Primary Accelerator Pump Adjustment
3. With a feeler gauge check for clearance between
adjustment screw and accelerator pump lever. Adjust
screw and nut to specifications.
4. Repeat procedure for secondary accelerator pump.
a -Pump Lever -Push Down
b -Feeler Gauge
c-Adjustment Screw and Nut
Secondary Accelerator Pump Adjustment
90-14499--1 887
Choke Adjustment
1.
Normal choke setting is such that scribed mark on
choke cover is in line with center mark on choke
housing.
,---.
a -Choke Housing Mark
b -Choke Cover Mark
c -Richer Adjustment
d -Leaner Adjustment
e -Cover Retaining Screws (One Not Shown)
Choke Adjustment
2.
If choke adjustment is necessary:
a.
Loosen 3 choke cover retaining screws and
adjust as shown.
b. Tighten 3 choke cover retaining screws securely.
90-14499--1 887
Preliminary Idle Speed and Mixture
IMPORT ANT: The following adjustments will provide a
sufficient setting to start engine. Final adjustments
must be made with engine running.
1.
Turn idle speed screw in until it just contacts idle
stop, then turn screw in one additional turn.
a -Idle Speed Screw
Idle Speed Screw
IMPORTANT: Do not turn idle mixture needles tightly
against seat (In the following step), as damage to seat
and/or needle may result.
2.
Turn idle mixture needles in until they LIGHTLY
SEAT; then back out 2 turns.
a -2 Idle Mixture Screws -Only One Shown
b-Primary Fuel Bowl
Idle Mixture Screws
FUEL SYSTEM -50-5
Final Idle Speed and Mixture
IMPORTANT: Boat must be in the water and engine at
normal operating temperature to accurately check and
adjust idle speed and mixture.
Carburetor should be set so that engine idles smoothly
within range given under "Specifications", following,
with boat in the water, engine at normal operating
temperature and drive unit in forward gear. to 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.
1.
Connect a shop tachometer to engine.
IMPORTANT: Do not turn idle mixture needle tightly
into set (in next step), as damage to needle and/or seat
may result.
2.
If a new or rebuilt carburetor has been installed,
turn idle mixture needles in (clockwise) until it
LIGHTLY contacts seat; then, back out needle 2
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.
A WARNING
Do not leave the helm unoccupied while performing
idle speed and mixture adjustments, following. BE
CAREFUL NOT TO ACCIDENTALLY ACCELERATE
ENGINE WHILE PERFORMING ADJUSTMENTS.
a-2 Idle Mixture Scews -Only One Shown
b-Primary Fuel Bowl
Idle Mixture Adjustment
4.
With boat in open water, place remote control in
forward gear, idle position.
5.
Disconnect throttle cable brass barrel from anchor
stud.
6.
Adjust idle speed adjustment screw to obtain specified
RPM.
7.
With engine running at specified RPM, adjust mixture
needle, as follows:
a.
Turn idle mixture needle inward (clockwise)
until the engine speed begins to drop due to lean
mixture.
b.
Turn idle mixture screw outward (counterclockwise)
until the speed begins to drop due to lean
mixture.
c.
Turn screw inward to a point between these two
extemes to obtain maximum engine smoothness
and RPM.
d.
Repeat procedure with other needle.
e.
Readjust idle speed adjustment screw, if necessary,
to obtain specified RPM.
IMPORTANT: Refer to "Section 2, Part H" for throttle
cable installation and adjustment.
a -Idle Speed Screw
Idle Speed Adjustment
.'-._./' .
50-6 -FUEL SYSTEM
90-14499--1 887
Repair
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Modifications
IMPORTANT: There may be several modifications
made to the Holley carburetor. The carburetor will
have "MOD" etched into casting at location shown in
"Identification" photo.
THROTTLE BODY
1.
Vacuum tube is removed and a 1/8" NPT pipe plug
is installed.
a -Vacuum Tube is Removed
PRIMARY METERING BODY
1.
The idle feed holes are drilled to .040".
2.
A 1/8" NPT pipe plug is installed in the vacuum
hole.
3 .. 084" jets are installed in both the primary and
secondary metering blocks.
CARBURETOR BODY
1.
The original bowl vents are removed, the holes are
drilled to .316" and new "J" tube vents are installed.
a-New "J" Tube Bowl Vents
Removal
IMPORTANT: Carburetor malfunctions are, in many
cases, caused by the presence of dirt, water or other
foreign matter in carburetor. To aid in diagnosis, carefully
remove carburetor from engine without draining
fuel from bowl. Contents of fuel bowl may, then, be
inspected for contamination as carburetor is disassembled.
1.
Remove crankcase ventilation hoses from flame
arrestor; then, remove flame arrestor.
IMPORTANT: Place a clean cloth in bores of carburetor
to prevent dirt and and foreign material from falling
into bores.
2.
Turn fuel supply off at fuel tank.
3.
Disconnect throttle cable from carburetor.
4.
Remove fuel lines. Refer to "Fuel Inlet Filter".
5.
Remove fuel pump sight tube.
6.
Disconnect electric choke.
7.
Remove carburetor attaching nuts and washers and
remove carburetor.
8.
Remove and discard gaskets.
IMPORTANT: Place a clean cloth over intake manifold
opening to prevent dirt or foreign material from entering
manifold.
a -Idle Feed Holes
b -Plug Installed in This Hole
90-14499--1 887
FUEL SYSTEM -50-7
Installation
1.
Thoroughly clean gasket surfaces. Use care to prevent
gasket material from entering intake manifold.
2.
Place new carburetor base gasket on intake manifold.
Install carburetor and secure with nuts and
washers. Torque to specifications.
3.
Connect fuel lines to fuel inlet nuts and torque to
specifications.
4.
Connect fuel pump sight tube.
5.
Connect electric choke wires to choke cover.
6.
Move throttle lever back-and-forth and check for
binding in throttle link..ge.
7.
Install throttle cable, as explained, in "Section 2.
8.
Install flame arrestor and crankcase ventilation
hoses.
9.
Reconnect battery cables to battery.
10.Start engine and check for gasoline leaks. If leaks
exist, STOP ENGINE IMMEDIATELY and recheck
connections.
11. Adjust idle speed and idle mixture, as outlined
under "Adjustments", preceding.
Disassembly
The following is a step-by-step procedure for completely
overhauling carburetor removed from engine.
In many cases, however, complete overhaul is not
necessary and, in these cases, only the steps required
to repair the carburetor malfunction should be performed.
Read the instructions carefully to prevent
doing any unnecessary steps.
IMPORT ANT: Before performing any service on carburetor,
it is essential that carburetor be placed in a
holding fixture to prevent possible damage to throttle
valves.
CHOKE HOUSING
1.
Remove choke cover.
0
a-Choke Cover Retaining Screws
b -Choke Cover
c -Choke Cover Retainer
d-Gasket
Removing Choke Cover
2.
Remove choke rod retaining clip.
a -Choke Housing d -Vacuum Hose
b-Housing Retaining Screws e-Choke Rod Retaining Clip
.__.,/.. ·
c-Ground Wire
f -Choke Rod
Removing Choke Rod Retaining Clip
50-8 -FUEL SYSTEM
90-14499--1 887
a -Locking Screw
b-Adjustment Nut
c-Float Retaining Screws
d-Float
Removing Needle Seat and Float
3.
Remove choke housing.
18583
a-Choke Housing
b-Retaining Screws
c -Ground Wire
d -Vacuum Hose
Removing Choke Housing
FUEL BOWLS and METERING BODIES
IMPORTANT: As the rest of the carburetor is disassembled
all of the parts from the primary side (of the
carburetor) should be kept separated from secondary
side parts. This will assure all of the parts are installed
properly upon reassembly.
1.
Remove fuel inlet filter nuts, gaskets, filters, and
springs as outlined.
2.
Remove idle mixture screws and gaskets.
18582
a-Gaskets
b -Idle Mixture Screws
c-Idle Mixture Chamber (Only 1 Shown)
Removing Idle Mixture Screws
90-14499--1 887
3.
Remove primary and secondary fuel bowls.
18585
a-Fuel Bowl Retaining Screws and Gaskets (Gaskets Not Shown)
(If Used)
b-Primary Fuel Bowl
c -Secondary Fuel Bowl
d-Screws Used on 440/460 Cyclone
e-Gasket
Removing Fuel Bowls
IMPORTANT: Carburetors used on the 440/460
Cyclone engines will have long thru-bolts holding the
fuel bowls onto the carburetor. Early carburetors used
will be as shown. Later models may have long thrubolts
also.
4.
Remove needle seat and float assembly from fuel
bowls.
a.
Loosen locking screw.
b.
Turn adjustment nut counterclockwise to remove
needle seat assembly.
c.
Remove float retaining screws and remove float.
18589
FUEL SYSTEM -50-9
IMPORTANT: Needle seat and needle are factory
assembled and must be serviced as an assembly.
o-o
o-
o-o 0-6 o-o
a-Fuel Bowl
b-Float
c-Float Retaining Screws
d -Locking Screw
e-Gasket
f -Adjustment Nut
g-Gasket
18596
h -Needle and Seat Assembly
i-"0" Ring
Needle and Seat and Float Assembly Removed
4. Remove accelerator pump assembly, sight plug and
gasket.
a-Fuel Bowl
b-Gasket
c-Sight Plug
d -Pump Return Spring
e-Pump Diaphragm
f-Pump Housing
g-Pump Housing Retaining Screws
h-Pump Check Valve -NOT REMOVABLE
Accelerator Pump Removed
SD-1 0-FUEL SYSTEM
\ 0olQ
18597
5. Accelerator pump check balls are not removable.
Check for clearance between ball and retainer.
Check ball must be free to move as specified.
a-Retainer
b-Check Ball
c -Refer to "Specifications"
Accelerator Pump Check Ball
6. Remove attaching springs, studs, gaskets, primary,
and secondary metering bodies from carburetor.
IMPORTANT: Some model carburetors will have long
thru-bolts instead of the attaching springs and studs.
a-Attaching Springs (If Used)
b-Gaskets
c-Primary Metering Body
d -Secondary Metering Body
e-Gasket
f-Studs (If Used)
g -Thru-Bolt Used on 440/460 Cyclone Engines
h-Gasket
Removing Metering Bodies
o=-t t0 0
18586
90-14499--1 887
a -Primary Metering Body
b -Power Valve
c -Secondary Metering Body (No Power Valve)
d -Float Bowl Vent Tubes
Metering Body Identification
18595
7. Remove power valve from primary metering body.
Power valve cannot be serviced separately, if defective
it must be replaced.
a -Primary Metering Body
b-Gasket
c -Power Valve
Power Valve Removed
90-14499--1 887
18590
8. Remove main fuel jets from primary and secondary
metering bodies.
a -Main Fuel Jets
Main Fuel Jets Removed
9. Remove float bowl vent tubes. Pry down on tip of
vent tube with a small screwdriver and pull out. Vent
tubes are held on place with small locating pin.
IMPORTANT: Locating pins should not be removed
from metering bodies.
a-Small Screwdriver
b -Float Bowl Vent Tube
Removing Float Bowl Vent Tubes
FUEL SYSTEM -50-11
CARBURETOR BODY
1.
Remove 2 screws which hold accelerator pump discharge
needles in place.
a-Screws
Accelerator Pump Discharge Needle Retaining Screws
2. Remove pump discharge needles and components.
_...---0
a-Screws
b-Gaskets
c-Bushings
d-Gaskets
e-Needles
Pump Discharge Needle Removed
18598
IMPORTANT: Choke valves should not be removed
from carburetor body, if damaged, carburetor body
should be replaced.
a -Remove 6 Screws
Removing Throttle Body 18601
2. Remove carburetor body and gasket from throttle
body.
18587
a -Carburetor Body
b-Gasket
c -Throttle Body
THROTTLE BODY
1.
Remove 6 screws which hold throttle body to carburetor
body.
Throttle Body Removed From Carburetor Body
IMPORTANT: Further disassembly of the throttle body .. is normally not required. Throttle valves should not be
removed. If throttle valves are damaged, throttle body
should be replaced.
FUEL SYSTEM
5D-12-
90-14499--1887
Cleaning and Inspection
Carbon, varnish, gum, dirt, and water contaminants in
the carburetor or on exterior moving parts of the carburetor
often are responsible for carburetion malfunctions.
Therefore, carefully observe the following cleaning
and inspection procedure, to obtain effective carburetor
repair.
(
IMPORTANT: Do not use a wire or drill to clean jets,
passages, or tubes in carburetor, as this may enlarge
orifices and seriously affect carburetor calibration.
A CAUTION
Do not leave carburetor in carb cleaner for more than
two hours.
IMPORTANT: Do not clean float bowl gasket surfaces
with a gasket scraper or knife, as sealing bead will be
damaged and component replacement will be necessary.
A CAUTION
Any plastic, rubber, or neoprene parts should not be
immersed in carburetor cleaner, as they will swell,
harden or distort.
IMPORTANT: All gaskets, "0" rings, and seals should
be replaced during carburetor repair.
1.
Thoroughly clean all metal parts in a commercial
carburetor cleaner, until all deposits have been
removed. Follow manufacturer's instructions of
cleaner being used for proper cleaning and rinsing
procedure. Dry parts with compressed air.
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 carburetor
cleaner with a clean, dry cloth.
4.
Carefully inspect all carburetor parts for wear and
damage; pay particular attention to the following:
a.
Float Needle and Seat: If float needle or seat is
worn or damaged, replace with a new needle and
seat assembly.
IMPORTANT: Float needle and seat are factory assembled.
Needle and seat cannot be serviced separately.
b.
Float Assembly and Hinge Pin: Inspect float
pontoon for deterioration and porosity. Check
pontoon density (to see if it is saturated with
fuel), by comparing weight of float with specifications.
If pontoon weight is high, float assembly
MUST BE replaced. Shake float. If float contains
fuel inside, float is leaking and must be
replaced. Check hinge pin and holes for wear.
0 c. Fuel and Air Passages: Passages MUST BE perfectly
clean for proper carburetor operation.
a-Scale
b-Float
Checking Float Weight
d.
Accelerator Pump Diaphragm and Return
Spring: Inspect pump diaphragm, check ball,
discharge needles, and return spring.
e.
Power Piston Spring: Check power piston spring
for weakness or distortion.
f.
Idle Mixture Needles: Inspect idle mixture needles.
If damaged, needles MUST BE replaced.
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 thru 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.
Choke Valve and Shaft and Lever Assembly:
Check shaft and lever assembly for excessive
looseness in air horn assembly. Check choke
valve and shaft and lever assembly for binding
thru entire operating range, making sure valve
opens and closes completely. Carburetor body
assembly MUST BE replaced if choke valve and
shaft and lever assembly are worn or damaged.
j.
Inspect casting for visible damage. Inspect gasket
surfaces.
FUEL SYSTEM -50-13
90-1 4499--1 887
Reassembly
THROTTLE BODY
1. Assemble throttle body to carburetor body using
a new gasket, being careful to line up gasket and
carburetor body with locating pins in throttle body.
a-Carburetor Body
b -New Gasket
c -Throttle Body
d -Locating Pins
Installing Throttle Body
18587
2. Install throttle body attaching screws and tighten
evenly and securely.
a -6 Attaching Screws
Installing Attaching Screws
50-14 -FUEL SYSTEM
18601
CARBURETOR BODY
1. Install pump discharge needles into carburetor
body in order shown. Tighten screws securely.
a-Screws
b-Gaskets
c-Bushings
d-Gaskets
e-Needles
Installing Pump Discharge Needles
a-Pump Discharge Needle Retaining Screws
Retaining Screws Installed
18598
18599
90-14499--1 887
FUEL BOWLS and METERING BODIES
1. Install fuel bowl vent tubes into metering bodies,
vent tube must be pushed in far enough to lock into
locating pin.
a-Vent Tube
b-Locating Pin
Installing Vent Tubes 2. Install primary and secondary main fuel jets.
a -Main Fuel Jets
Installing Main Fuel Jets
90-14499--1 887
18591
3. Install power valve and new gasket in primary
metering body.
a-Primary Metering Body
b-Gasket
c -Power Valve
Installing Power Valve
18590
4. Assembly metering bodies to carburetor body in
order shown.
IMPORTANT: On 440/460 Cyclone carburetors this
operation cannot be performed until fuel bowls are
assembled because the carburetor has through bolts in
place of the springs.
a-Springs
b-Gasket
c -Primary Metering Body
d -Secondary Metering Body
e-Gasket
f -Studs {If Used}
g-Thru-Bolts (440/460 Cyclone)
h-Gasket
Installing Metering Bodies
18586
FUEL SYSTEM -50-15
5. Install accelerator pump assembly as shown.
6. Install sight plug and gasket. Tighten screws securely.
a-Fuel Bowl e-Diaphragm
b-Gasket f-Pump Housing
c-Sight Plug g-Screws
d-Spring h -Check Ball
Installing Accelerator Pump 7. Assemble needle seat as shown.
a -Locking Screw
b-Gasket
c -Adjustment Nut
d-Gasket
e -Needle Seat Assembly
f-"0" Ring
Needle Seat Assembly
50-16 -FUEL SYSTEM
o..o
\0oi
18507
18596
8. Assemble float, spring, hinge, and hinge pin as
shown.
18592
a-Float
b-Hinge Pin
c-Hinge
d-Spring
Assembling Float
9. Install float, and float retaining screws. Tighten
screws securely. Install needle seat assembly. Adjust
float to specifications. See "Adjustments" in
this section.
a-Locking Screw
b -Adjustment Nut
c-Float Retaining Screws
d-Float
Installing Float and Needle Seat
18589
90-14499--1 887
10.1nstall fuel bowls as shown. Tighten screws securely.
a-Screw and Gaskets (If Used)
b -Primary Fuel Bowl
c -Secondary Fuel Bowl
d -Thru-Bolts (440/460 Cyclone)
e-Gasket
Installing Fuel Bowls
0
18585
11. Install fuel inlet filter components, fuel inlet gasket,
and nut as shown. Tighten nut securely.
17585 a-Spring c-Gasket
b-Filter (Open End Towards Nut) d-Fuel Inlet Nut
Installing Filter and Inlet Nut
12. Install idle mixture screws and gaskets. Lightly seat
needle, then back out 2 turns.
IMPORTANT: Do not tighten idle mixture needles
against seats or damage to needle and/or seat may
result.
a-Gaskets
b-Needles
c -Idle Mixture Hole (Only One Shown)
Installing Idle Mixture Screws
90-14499--1 887
0
18582
CHOKE HOUSING
1. Install choke housing as shown. Tighten screws
securely.
a-Choke Housing
b-Screws
c-Ground Wire
d -Vacuum Hose
Installing Choke Housing
2. Install choke rod retaining clip.
a-Choke Housing
b-Screws
c-Ground Wire
d-Vacuum Hose
e-Choke Rod Retaining Clip
f-Choke Rod
Retaining Clip Installed
18583
FUEL SYSTEM -50-17
3. Install choke cover as shown. Adjust choke to
"Specifications". Tighten screws securely. Be sure
to hook choke heat element into choke lever.
a -Choke Cover Retaining Screws
b -Choke Cover
c-Retainer
d-Gasket
Install Choke Cover
50-18 -FUEL SYSTEM
18584
90-14499--1 887
FUEL SYSTEM
HOLLEY 4 BARREL
Model 4500
Index
Page
Identification .................................5E-1
Replacement Parts Warning ................... 5E-1
Torque Specifications 5E-1
........................
Tools ........................................ 5E-1
Specifications ................................5E-1
Description 5E-2
..................................
Precautions ..................................5E-2
Maintenance 5E-2
.................................
Flame Arrestor 5E-2
............................
Fuel Filters ................................ 5E-3
Adjustments 5E-3
.................................
Preliminary Float Adjustment ...............5E-3
Final Float Adjustment ..................... 5E-4
Accelerator Pump 5E-4
.........................
Preliminary Idle Speed and Mixture .........5E-5
Final Idle Speed and Mixture ............... 5E-5
Repair 5E-6
.......................................
Removal 5E-6 ...
..................................
Installation ................................5E-6
Disassembly 5E-7
..............................
Fuel Bowls and Metering Bodies .........5E-7
Throttle Body 5E-10
.........................
Cleaning and Inspection 5E-1 2
..................
Reassembly ..............................5E-13
Throttle Body 5E-1 3
.........................
Fuel Bowls and Metering Bodies ........5E-14
FUEL SYSTEM -5E 90-1 4499--1 887
Identification
a -Part Number
Holley Part Number Location
Replacement Parts Warning
A WARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
(
'-._...
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.
Torque Specifications
MCM 575
Fastener Location
Lbs. Ft. (N.m)
Carburetor to
Manifold
20 (27)
Fuel Line To
Carburetor
18 (24)
Fuel Inlet Filter
Nut
Securely
Tools
MERCURY MARINE SPECIAL TOOLS
Tachometer
91 -59339
91 -36392
Universal Carburetor Gauge
BORROUGHS TOOLS AND EQUIPMENT
2429 N. BURDICK ST.
KALAMAZOO, MICHIGAN 49007
(616) 345-5163
BT81 28B Float Gram Scale
Specifications
Engine Model
MCM 575
Make
Holley
Model
4500
Holley Part No.
8082
Mercury Part No. 1393-8862
Main Primary Jets .088 thru .092
Main Secondary Jets .088 thru .092
Accelerator Pump .015 (.4mm)
Accelerator Pump
.015" (4mm)
Check Ball
Bottom of
Float Adjustment Sight Plug Hole
±1/32" (.8mm)
15.6 Grams
Float Weight
Max.
Preliminary Idle
1-1/4 Turns
Mixture Setting
90-1 4499--1 887
FUEL SYSTEM -SE-1
Description
The Holley model 4500 is a dual feed, double pump
carburetor. This means each fuel bowl has a seperate
fuel inlet and there 2 accelerator pumps, one for the
primary side and one for the secondary side. Beween
the fuel bowls and the carburetor body, metering
bodies are located. The metering bodies contain the
main jets, power valve, and the majority of the metered
passages in the carburetor. Both the primary and
secondary floats have an external float adjustment.
Precautions
A WARNING
Always disconnect battery cables from battery BEFORE
working on fuel system to prevent fire or explosion.
AWARNING
Be careful when cleaning flame arrestor and crankcase
ventilation hose; gasoline is extremely flammable and
highly explosive under certain conditions. Be sure that
ignition key "OFF". Do not smoke or allow sources of
spark or open flame in area when cleaning flame arrestor
and crankcase ventilation hose.
A WARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". Do not smoke or allow sources of spark or flame
in the area while changing fuel filter. Wipe up any
spilled fuel immediately.
A WARNING
Make sure no fuel leaks exist, before closing engine
hatch.
A CAUTION
Do not operate engine without cooling water being
supplied to water pickup holes in gear housing, or
water pump impeller will be damaged and subsequent
overheating damage to engine may result.
Maintenance
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Flame Arrestor
1.
Remove (in the following order):
a.
Nut.
b.
Washer (Not Shown).
c.
Hose clamps and crankcase ventilation hoses From
flame arrestor and rocker arm covers.
d.
Flame arrestor -Lift from carburetor.
2.
Clean and Inspect:
a.
Clean flame arrestor by blowing it out with compressed
air.
b.
Clean crankcase ventilation hoses.
c.
Inspect crankcase ventilation hose for cracks or
deterioration, replace if neccessry.
3.
Install (in the following order):
a.
Flame arrestor -Place on carburetor.
b.
Crankcase ventilation hoses and clamps -To
flame arrestor and rocker arm covers.
c.
Washer (Not Shown).
d.
Nut -Tighten securely, do not overtighten.
a-Nut
b -Flame Arrestor
c -Crankcase Ventilation Hoses
f-Clamps
Flame Arrestor
5E-2 -FUEL SYSTEM
90-14499--1 887
Fuel Filters
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Carburetor inlet filters are located in float chamber
assemblies behind fuel inlet fittings. To replace filters
proceed as follows:
1.
Remove fuel line from fuel inlet filter nuts.
2.
Remove fuel inlet filter nut, gasket, filter and spring
from each float chamber assembly. (Discard gasket
and filter).
3.
Clean nuts and springs in solvent and dry with
compressed air.
4.
Install spring, new filter (with open end outward),
gasket and fuel inlet filter nut into each float
chamber assembly (in that order). Tighten nut
securely.
5.
Reconnect fuel line and tighten securely.
6.
Run engine and check for gasoline leaks.
a -Fuel Line Fittings
b-Fuel Filter Nut
c-Filter Nut Gasket
Typical Fuel Inlet Filters
17584
d-Filter
e-Spring
Adjustments
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Preliminary Float Adjustment
IMPORTANT: The preliminary float adjustment will
provide a sufficient setting for starting the engine. Final
float adjustments must be made with engine running.
1.
Invert float bowl as shown.
2.
Loosen locking screw and turn float adjustment nut
to adjust float.
3.
Proper float adjustment is achieved when parting
line on float is parallel with fuel bowl. Parting line
must be parallel all the way around float.
a -Float
c -Fuel Bowl (Inverted)
b -Float Parting Line d -Parallel All The Way Around Float
Preliminary Float Setting
a -Locking Screw
b -Adjustment Nut
Adjusting Float Level
4.
Repeat this procedure for both floats.
90-14499--1 887
FUEL SYSTEM -SE-3
Final Float Adjustment
1. With carburetor mounted on engine, start engine
and leave run for several minutes.
2. While engine is running remove sight plug on primary
fuel bowl.
3. Loosen locking screw and turn adjustment nut
slowly unti I fuel can be seen even with the bottom of
the sight plug hole.
a-Locking Screw
b-Adjustment Nut c-Sight Plug Hole
d -Raises Fuel Level
e-Lowers Fuel Level
Final Float Adjustment
4. Tighten locking screw securely being careful not to
let adjustment nut turn.
5. Reinstall sight plug and gasket.
6. Repeat this procedure for secondary side of carburetor.
SE-4 -FUEL SYSTEM
Accelerator Pump
1. With engine shut off, move throttle arm to W.O.T.
position.
2. While holding throttle arm in W.O.T. position push ..
down on primary accelerator pump lever.
a -Pump Lever-Push Down
b -Feeler Gauge
c-Adjustment Screw and Nut
Accelerator Pump Adjustment
3. With a feeler gauge check for clearance between
adjustment screw and accelerator pump lever. Adjust
screw and nut to specifications.
4. Repeat procedure for secondary accelerator pump.
90-14499--1 887
Preliminary Idle Speed and Mixture
IMPORTANT: The following adjustments will provide a
sufficient setting to start engine. Final adjustments
must be made with engine running.
(
1.
Turn idle speed screw in until it just contacts idle
stop then turn screw in one additional turn.
a-Idle Speed Screw
b-Idle Stop
Idle Speed Screw
IMPORT ANT: Do not turn idle mixture needles tightly
against seat (in the following step), as damage to seat
and/or needle may result.
2.
Turn idle mixture needles in until they LIGHTLY
SEAT; then back out 1-1/4 turn.
a-4 Idle Mixture Screws -Only 2 Shown
Idle Mixture Screws
Final Idle Speed and Mixture
IMPORTANT: Boat must be in the water and engine at
normal operating temperature to accurately check and
adjust idle speed and mixture.
Carburetor should be set so that engine idles smoothly
within range given under "Specifications", following,
with boat in the water, engine at normal operating
temperature and drive unit in forward gear. to 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.
1.
Connect a shop tachometer to engine.
IMPORTANT: Do not turn idle mixture needle lightly
into set (in next step), as damage to needle and/or seat
may result.
2.
If a new or rebuilt carburetor has been installed,
turn idle mixture needles 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.
AWARNING
Do not leave the helm unoccupied while performing
idle speed and mixture adjustments, following. BE
CAREFUL NOT TO ACCIDENTALLY ACCELERATE
ENGINE WHILE PERFORMING ADJUSTMENTS.
a-Four Idle Mixture Screws -Only Two Shown
90-14499--1 887
FUEL SYSTEM -5E-5
4.
With boat in open water, place remote control in
forward gear, idle position.
5.
Disconnect throttle cable brass barrel from anchor
stud.
6.
Adjust idle speed adjustment screw to obtain specified
RPM.
7.
With engine running at specified RPM, adjust mixture
needle, as follows:
a.
Turn idle mixture needle inward (clockwise)
u nti I the engine speed begins to drop due to lean
mixture.
b.
Turn idle mixture screw outward (counterclockwise)
until the speed begins to drop due to lean
mixture.
c.
Turn screw inward to a point between these two
extemes to obtain maximum engine smoothness
and RPM.
d.
Repeat procedure with other needle.
e.
Readjust idle speed adjustment screw, if necessary,
to obtain specified RPM.
IMPORTANT: Refer to "Section 2, Part H" for throttle
cable installation and adjustment.
a -Idle Speed Screw
b -Idle Stop
Idle Speed Adjustment
Repair
NOTICE
Refer to "Precautions", in this section, BEFORE
proceeding.
Removal
IMPORTANT: Carburetor malfunctions are, in many
cases, caused by the presence of dirt, water or other
foreign matter in carburetor. To aid in diagnosis, carefully
remove carburetor from engine without draining
fuel from bowl. Contents of fuel bowl may, then, be
inspected for contamination as carburetor is disassembled.
1.
Remove crankcase ventilation hoses from flame
arrestor; then, remove flame arrestor.
IMPORTANT: Place a clean cloth in bores of carburetor
to prevent dirt and and foreign material from falling
into bores.
2.
Turn fuel supply off at fuel tank.
3.
Disconnect throttle cable from carburetor.
4.
Remove fuel lines. Refer to "Fuel Inlet Filter".
5.
Remove fuel pump sight tube.
6.
Remove carburetor attaching nuts and washers and
remove carburetor.
7.
Remove and discard gaskets.
IMPORTANT: Place a clean cloth over intake manifold
opening to prevent dirt or foreign material from entering
manifold.
Installation
1.
Thoroughly clean gasket surfaces. Use care to prevent
gasket material from entering intake manifold.
2.
Place new carburetor base gasket on intake manifold.
Install carburetor and secure with nuts and
washers. Torque to specifications.
3.
Connect fuel lines to fuel inlet nuts and torque to
specifications.
4.
Connect fuel pump sight tube.
5.
Move throttle lever back-and-forth and check for
binding in throttle linkage.
6.
Install throttle cable, as explained, in "Section 2.
7.
Install flame arrestor and crankcase ventilation
hoses.
SE-6 -FUEL SYSTEM
90-14499--1 887
..
"'..
8. Reconnect battery cables to battery.
9. Start engine and check for gasoline leaks. If leaks
exist, STOP ENGINE IMMEDIATELY and recheck
connections.
10. Adjust idle speed and idle mixture, as outlined
under "Adjustments", preceding.
Disassembly
The following is a step-by-step procedure for completely
overhauling carburetor removed from engine.
In many cases, however, complete overhaul is not
necessary and, in these cases, only the steps required
to repair the carburetor malfunction should be performed.
Read the instructions carefully to prevent
doing any unnecessary steps.
IMPORT ANT: Before performing any service on carburetor,
it is essential that carburetor be placed in a
holding fixture to prevent possible damage to throttle
valves.
FUEL BOWLS and METERING BODIES
IMPORTANT: As the rest of the carburetor is disassembled
all of the parts from the primary side (of the
carburetor) should be kept separated from secondary
side parts. This will assure all of the parts are installed
properly upon reassembly.
1. Remove fuel inlet filter nuts, gaskets, filters, and
springs as outlined.
2. Remove idle mixture screws and gaskets.
21174
a-Gaskets
b -Idle Mixture Screws
c-Idle Mixture Chamber (Only 1 Shown)
Removing Idle Mixture Screws
90-14499--1 887
3. Remove primary and secondary fuel bowls.
a -Fuel Bowl Retaining Screws and Gaskets
b-Fuel Bowl
c -Fuel Bowl Gasket
Removing Fuel Bowls
21 172
4. Remove needle seat and float assembly from fuel
bowls.
a. Loosen locking screw.
b. Turn adjustment nut counterclockwise to remove
needle seat assembly.
c. Remove float retaining screws and remove float.
a -Locking Screw
b-Adjustment Nut
c-Float Retaining Screws
d-Float
Removing Needle Seat and Float
FUEL SYSTEM -SE-7
IMPORT ANT: Needle seat and needle are factory
assembled and must be serviced as an assembly.
18596
a-Fuel Bowl
b-Float
c-Float Retaining Screws
d -Locking Screw
e-Gasket
f-Adjustment Nut
g-Gasket
h -Needle and Seat Assembly
i-"0" Ring
Needle and Seat and Float Assembly Removed
4.
Remove accelerator pump assembly, sight plug and
gasket.
.. t
&}0
21170
a-Fuel Bowl
b-Gasket
c -Sight Plug
d -Pump Return Spring
e -Pump Diaphragm
f -Pump Housing
g-Pump Housing Retaining Screws
h -Pump Check Valve -NOT REMOVABLE
Accelerator Pump Removed
5E-8 -FUEL SYSTEM
90-14499--1 887
5.
Remove primary, and secondary metering bodies
from carburetor.
21173
a -Attaching Screws and Gaskets
b-Gaskets
c-Metering Body
Removing Metering Bodies
6.
Remove power valves from both metering bodies.
Powervalve cannot be serviced separately, if defective
it must be replaced.
18590
a -Metering Body b-Gasket
c -Power Valve
Power Valve Removed
7.
Remove main fuel jets from metering bodies.
a-Main Fuel Jets
Main Fuel Jets Removed
8.
Remove float bowl vent tubes. Pry down on tip of
vent tube with a small screwdriver and pull out. Vent
tubes are held on place with small locating pin.
IMPORTANT: locating pins should not be removed
from metering bodies.
a -Small Screwdriver
b -Float Bowl Vent Tube
Removing Float Bowl Vent Tubes
90-14499--1 887
FUEL SYSTEM -5E-9
THROTTLE BODY
1. Remove 2 screws which hold accelerator pump
discharge nozzle in place.
a-Screws
Accelerator Pump Discharge Nozzle Retaining Screws 2. Remove pump discharge nozzles and components.
a-Screws
b-Gaskets
c-Nozzles
d-Gaskets
e-Needles
Pump Discharge Nozzles Removed
18598
IMPORTANT: Further disassembly of the throttle body
is normally not required, but if throttle body must be
serviced, order parts from:
Holley Replacement Parts Division
11955 East Nine Mile Road
Warren, Ml 48090
SE-10-FUEL SYSTEM
1. Remove accelerator pump levers.
a-Stud b-Lever
c-Clip
Accelerator Pump Lever Removed
21317
2. Loosen throttle linkage screws. (Do not remove).
a-Throttle Linkage Screws
90-14499--1 887
NOTE: Throttle plate screw ends must be filed flush
with throttle shaft before removing.
3. Remove throttle plate screws.
Removing Throttle Plate Screws
4. Actuate throttle to wide open position. Slide throttle
plates out off throttle shafts.
Removing Throttle Plates
90-14499--1 887
5. Remove throttle linkage and pivot bracket screws.
21323
Removing Pivot Bracket Screw
6. Remove throttle shafts and linkage.
a-Throttle Shafts
b-Throttle Plates
c-Primary Linkage
d -Pivot Arm and Secondary Linkage
e -Pivot Arm Screw and Flat Washer
f -Pivot Screw Lock Washer
g-Linkage Screws
21322
FUEL SYSTEM -5E-1 1
Cleaning and Inspection
Carbon, varnish, gum, dirt, and water contaminants in
the carburetor or on exterior moving parts of the
carburetor often are responsible for carburetion malfunctions.
Therefore, carefully observe the following
cleaning and inspection procedure, to obtain effective
carburetor repair.
IMPORTANT: Do not use a wire or drill to clean jets,
passages, or tubes in carburetor, as this may enlarge
orifices and seriously affect carburetor calibration.
A CAUTION
Do not leave carburetor in carb cleaner for more than
two hours.
IMPORTANT: Do not clean float bowl gasket surfaces
with a gasket scraper or knife, as sealing bead will be
damaged and component replacement will be necessary.
A CAUTION
Any plastic, rubber, or neoprene parts should not be
immersed in carburetor cleaner, as they will swell,
harden or distort.
IMPORTANT: All gaskets, "0" rings, and seals should
be replaced during carburetor repair.
1.
Thoroughly clean all metal parts in a commercial
carburetor cleaner, until all deposits have been
removed. Follow manufacturer's instructions of
cleaner being used for proper cleaning and rinsing
procedure. Dry parts with compressed air.
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 carburetor
cleaner with a clean, dry cloth.
4.
Carefully inspect all carburetor parts for wear and
damage; pay particular attention to the following:
a
Float Needle and Seat: If float needle or seat is
worn or damaged, replace with a new needle and
seat assembly.
IMPORTANT: Float needle and seat are factory assembled.
Needle and seat cannot be serviced separately.
b.
Float Assembly and Hing Pin: Inspect float
pontoon for deterioration and porosity. Check
pontoon density (to see if it is saturated with
fuel), by comparing weight of float with specifications.
If pontoon weight is high, float assembly
MUST BE replaced. Shake float. If float contains
fuel inside, float is leaking and must be
replaced. Check hinge pin and holes for wear.
a-Scale
b-Float
Checking Float Weight
c.
Fuel and Air Passages: Passages MUST BE perfectly
clean for proper carburetor operation.
d.
Accelerator Pump Diaphragm and Return
Spring: Inspect pump diaphragm, check ball,
discharge needles, and return spring.
e.
Power Piston Spring: Check power piston spring
for weakness or distortion.
f.
Idle Mixture Needles: Inspect idle mixture needles.
If damaged, needles MUST BE replaced.
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 thru 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.
Inspect casting for visible damage. Inspect gasket
surfaces.
5E-12 -FUEL SYSTEM
a-Throttle Return Spring Location
90-14499--1 887
Reassembly
THROTTLE BODY
1.
Install throttle linkage and throttle shaft.
Installing Throttle linkage and Shafts
IMPORTANT: Be sure throttle return spring is in correct
location when installing throttle shafts.
2. Install throttle linkage and pivot bracket screw. Do
not tighten.
Installing Throttle linkage Screws
3.
Install throttle plate with stamped number facing
toward metering plate and up toward Venturi.
a-Throttle Plate
b -Stamp Number
Installing Throttle Plates
4.
Install new throttle plate screws. Stake throttle plate
screws through top of Venturi. Throttle shaft must
be supported when staking screws.
A CAUTION
Improper installation of throttle plates, shafts and linkage
could result in a sticking throttle causing uncontrolled
engine speed or parts could loosen and enter
engine.
5.
Tighten all throttle linkage screws.
6.
Install accelerator pump levers.
FUEL SYSTEM -SE-13
CARBURETOR BODY
1. Install pump discharge nozzles, needles, and gaskets
into carburetor body in order shown. Tighten
screws securely.
a-Screws
b-Gaskets
c-Nozzle
d-Gaskets
e-Needles
o---
0 0 0
Installing Pump Discharge Needles
a Pump
Discharge Needle Retammg Screws
Retaining Screws Installed
SE-14 -FUEL SYSTEM
18598
FUEL BOWLS and METERING BODIES
1. Install fuel bowl vent tubes into metering bodies,
vent tube must be pushed in far enough to lock into
locating pin.
18593
a-Vent Tube
b -Locating Pin
Installing Vent Tubes
2. Install primary and secondary main fuel jets.
18591
a -Main Fuel Jets
Installing Main Fuel Jets
90-14499--1 887
3. Install power valve and new gasket in primary
metering body.
a-Primary Metering Body
b-Gasket
c -Power Valve
Installing Power Valve
4. Assembly metering bodies to carburetor body in
order shown.
IMPORTANT: On 440/460 Cyclone carburetors this
operation cannot be performed until fuel bowls are
assembled because the carburetor has through bolts in
place of the springs.
a -Attachmg Screws and Gasket
b-Gasket
c -Metering Body
Installing Metering Bodies
90-14499--1 887
21173
5. Install accelerator pump assembly as shown.
6. Install sight plug and gasket. Tighten screws securely.
t t&)0
a-Fuel Bowl
b-Gasket
c -Sight Plug
d-Spring
e-Diaphragm
f-Pump Housing
g-Screws
h -Check Valve
ll ll--0 21170
Installing Accelerator Pump
FUEL SYSTEM -SE-15
7. Assemble needle seat as shown.
a -Locking Screw
b-Gasket
c-Adjustment Nut
d-Gasket
e-Needle Seat Assembly
f-"0" Ring
Needle Seat Assembly
SE-16-FUEL SYSTEM
18596
8. Assemble float, spring, hinge, and hinge pin as
shown.
18592
a-Float
b-Hinge Pin
c-Hinge
d-Spring
Assembling Float
9. Install float, and float retaining screws. Tighten
screws securely. Install needle seat assembly. Adjust
float to specifications. See "Adjustments" in
this section.
a -Locking Screw
b -Adjustment Nut
c-Float Retaining Screws
d-Float
Installing Float and Needle Seat
90-14499--1 887
10.1nstall fuel bowls as shown. Tighten screws securely.
21172
a -Screw and Gaskets
b-Fuel Bowl
c -Fuel Bowl Gasket
Installing Fuel Bowls
11.1nstall fuel inlet filter components, fuel inlet gasket,
and nut as shown. Tighten nut securely.
17585
a-Spring
b-Filter (Open End Towards Nut)
c-Gasket
d-Fuel Inlet Nut
Installing Filter and Inlet Nut
12. 1nstall idle mixture screws and gaskets. Lightly seat
needles, then back out 1-1/4 turns.
IMPORTANT: Do not tighten idle mixture needles
against seats or damage to needle and/or seat may
result.
a-Gaskets
b-Needles
c-Idle Mixture Hole (Only One Shown)
Installing Idle Mixture Screws
90-14499--1 887 FUEL SYSTEM -5E-17
" FUEL SYSTEM
FUEL INJECTORS/FUEL RAILS
Index
Page
Identification ................................. 5F-1
Replacement Parts Warning ................... 5F-1
Torque Specifications ........................ 5F-1
Lubricants/Sealants .......................... 5F-1
Precautions .................................. 5F-2
Fuel Injector/Fuel Rail Removal ............... 5F-2
Fuel Injector/Fuel Rail Installation ............. 5F-2
,.-...
..
FUEL SYSTEM -SF-1 90-14499--1 887
Identification
20579
Fuel Injector
'
If '
20578
Fuel Rail
a-Fuel Rails, Injectors (Four Per Rail) Between Manifold and Rail
Fuel Rail/Injector Location on Engine
Replacement Parts Warning
A WARNING
Electrical, ignition and fuel system components on
your MerCruiser are designed and manufactured to
comply with U.S. Coast Guard Rules and Regulations
to minimize risks of fire and explosion.
Use of replacement electrical, ignition or fuel system
components, which do no comply with these rules and
regulations, could result in a fire or explosion hazard
and should be avoided.
Torque Specifications
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Fuel Fitting to Rail *10-18 (14-25)
Cross Over Fuel
Line to Fuel Fitting
Securely
Inlet Fuel Line to
Fuel Block
Securely
Return Fuel Lines Securely
Fuel Regulator Securely
Fuel Rail 30 (3)
·NoTE 1: Coat fuel line inlet and outlet fitting threads
with Loctite Pipe Sealant with Teflon, DO
NOT use Teflon tape. Torque to specifications.
Lubricants/Sealants
LUBRICANTS/SEALANTS
92-41669-1 Quicksilver Insulating Compound
92-13831 Quicksilver 4 Cycle Lubricant
SEALANTS OBTAINED LOCALLY
Loctite Pipe Sealant with Teflon
90-14499--1 887 FUEL SYSTEM -5F-1
Precautions
A WARNING
ALWAYS disconnect battery cables from battery BEFORE
working on fuel system to prevent fire or explosion.
A WARNING
Be careful when changing fuel system components;
gasoline is extremely flammable and highly explosive
under certain conditions. Be sure that ignition key is
"OFF". DO NOT smoke or allow sources of spark or
flame in the area while changing fuel filters. Wipe up
any spilled fuel immediately.
A WARNING
Make sure that no fuel leaks exist, before closing
engine hatch.
A CAUTION
DO NOT operate engine without cooling water being
supplied to seawater pickup pump or pump impeller
will be damaged, and subsequent overheating damage
may result.
Injector/Fuel Rail Removal
1.
Disconnect cross over fuel line from rear of fuel rail.
a-Crossover Fuel Line
b-Fuel Rail
c-Support
d -Screw and Washer
e-Inlet Fuel Line
f-Return Fuel Line
g -Fuel Injector
h-E-Ciip
i-0-Ring (Injector to Manifold)
2.
Disconnect return lines and fuel inlet hose from
front starboard fuel rail and/or fuel regulator from
front of port fuel rail.
3.
Remove fuel rail attaching screws (four per rail). .."''
4.
Lift fuel rail off injectors, try to lift supports (two per '--.tt/1 .
rail) with fuel rail.
5.
Disconnect injector lead.
a-Injector (Installed into Manifold)
b-Injector Lead
6.
Pull injector from manifold.
NOTE: If injector is being replaced, E-ring and 0-ring
(manifold base to injector base) must be reused.
Injector/Fuel Rail Installation
NOTE: Upper and lower injector o-rings must be lubricated
with engine oil to prevent o-rings from galling.
1.
Push injector into manifold bore. Check o-ring
alignment.
2.
Install injector leads. Use Insulating Compound 9241
669-1 .
3.
Align injector tops with fuel rail openings and push
rail onto injectors.
4.
Install fljel rail screws. Torque to 30 lb. in. (3 N.m).
5.
Install fuel lines and regulator, tighten securely.
NOTE: Run fuel pump approximately one minute to
bleed air from fuel system before starting.
SF-2 -FUEL SYSTEM
90-14499--1 887
" COOLING SYSTEM
SEAWATER COOLED MODELS
INDEX
Page
Torque Specifications .......•................6A-1
Tools/Lubricants/Sealants .................... 6A-2
Specifications ................................ 6A-2
Seawater Inlet Recommendations ............. 6A-2
Transom Mounted or Thru-Hull Seawater
Pickups and Hose ...................... 6A-2
Seawater Inlet Valve ....................... 6A-2
Sea Strainer ............................... 6A-2
Seawater Pickups ............................ 6A-3
Thru-Hull ................................. 6A-3
Transom Mounted ......................... 6A-3
Seawater Pickup Pump Output Test ........... 6A-4
Stern Drive Unit Seawater Pickup Pump ....... 6A-5
Belt Driven Seawater Pickup Pump ............ 6A-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Disassembly .............................. 6A-5
Cleaning and Inspection ................... 6A-6
Reassembly ............................... 6A-7
Installation ................................ 6A-8
Water Circulating Pump Replacement ......... 6A-9
Drive Belt Tension Adjustment ................ 6A-9
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9
Seawater Pickup Pump .................... 6A-9
Power Steering Pump ..................... 6A-1 0
Flushing Cooling System .................... 6A-11
Belt Drive Seawater Pickup Pump ......... 6A-11
Stern Drive Unit Seawater Pickup Pump ... 6A-1 1
Thermostat ................................. 6A-12
Removal ......•.......................... 6A-12
Testing ...............•.................. 6A-12
Installation ...•...........................6A-13
Out-of-Season Storage (Draining) ...... ...... 6A-14
Draining Precautions ..................... 6A-14
MCM 305-350 CID Models ................ 6A-14
MCM 300 Tempest/320 EFI
Alpha One/Bravo ..............•....... 6A-15
MCM 454 CID Models .................... 6A-16
MCM 454/482/540 CID
Production Performance Models ....... 6A-17
MCM 454 Magnum ....................... 6A-19
M IE Models .............................. 6A-20
Auxiliary Hot Water Heater Installation ........ 6A-21
MCM/MIE V-8 Engines (74567A1 Kit) ...... 6A-21
Cooling System Flow Diagrams .............. 6A-22
MCM 200/230/260/350 Magnum ........... 6A-23
5.0 Litre/5.0 Litre LX
5.7 Litre/350 Magnum .................. 6A-24
MCM 300 Tempest Alpha One ............. 6A-25
MCM 300 Tempest TRS ................... 6A-26
MCM 320 EFI Alpha One .................. 6A-27
MCM 320 EFI Bravo ...................... 6A-28
M IE 230/260 ............................. 6A-29
MIE 5.7 Ski ............................... 6A-30
MCM 454 Magnum (1987) ................. 6A-31
MCM 454 Magnum (1988) ................. 6A-32
MCM 330 B-W/MIE 340 7.4 Litre ........... 6A-33
MCM 370 TRS/400 Cyclone
S/N 6721527 and Below ................ 6A-34
MCM 370TRS/400 Cyclone
S/N 6721528 and Above ................ 6A-35
MCM 440/460 Cyclone .................... 6A-36
MCM 420 ................................ 6A-37
MCM 575 ................................ 6A-38
,#'''.. ' ·..
COOLING SYSTEM -6A 90-14499--1 887
Torque Specifications
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Alternator Brace to Alternator 192 (28)
Alternator Brace to Block 30 (41 )
Alternator to Mounting Bracket 35 (48)
Alternator Mounting Bracket 30 (41 )
Drain Plugs (Note 1) Securely
Petcocks Securely
Power Steering Pump Brace
to Block
30 (41 )
Power Steering Pump Bracket 30 (41 )
Pulleys Securely
Seawater Pump Brace 30 (41 )
Seawater Pump Bracket to Block 30 (41 )
Seawater Pump Clamping Screw
on Cast Bracket
20 (27)
Seawater Pump Cover 120 (14)
Seawater Pump Mounting Nuts
to Stamped Steel Bracket
120 (14)
Hose Clamps Securely
Thermostat Cover 30 (41 )
Thermostat Housing 30 (41 )
Thru-Hull Pickup Nut 35 (42)
Water Circulating Pump 30 (41 )
Water Temp. Sender 20 (27)
NOTE 1. Coat threads with Perfect Seal before installing.
90-1 4499--1 887
COOLING SYSTEM -6A-1
Tools/Lubricants/Sealants
TOOLS/LUBRICANTS/SEALANTS
91 -37241 Universal Puller Plate
92-32609-1 Quicksilver Loctite (A)
92-34227-1 Quicksilver Perfect Seal
92-86154A1 Quicksilver 2-4-C Marine Lubricant
92-79214A1 Quicksilver Special Lubricant 101
73971A2 Flush Device
LUBRICANT OBTAINED LOCALLY
Shell Alvania No. 2
Specifications
COOLING SYSTEM CAPACITY
Model Qts (litres) Approximately
MCM 200/230/260
MCM 300 Tempest
MCM 350 Magnum
MCM 5.7 Ski
MIE 230/260
15 (1 4.1 )
MCM 330 B-W
MCM 454 Magnum
MIE 340
MCM 370 MCM 400/
440/460 Cyclone
20 (1 8.9)
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 adversely 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 seawater
pickup pump inlet with 1-1/4" (32mm) ID wire reinforced
hose of adequate wall thickness to prevent it
from collapsing from pump suction. Be sure to secure
hose connections with hose clamps.
Seawater Inlet Valve
If a seawater inlet valve is being used, it must be
installed between water pickup and seawater pickup
pump (or sea strainer), to allow operator to shut off the
seawater in case of a leak or when boat is not in use.
This will allow the operator to flush or drain the engine,
or clean the sea strainer while boat is in the water. Valve
used must have an internal cross-sectional area equal
to or greater than hose to prevent restricting water
flow. Install valve in an area where it will be easily
accessible and support adequately to prevent hose
fatigue.
1-1/4" ID (32mm)
HOSE CONNECTION
TO WATER PUMP INLET
THERMOSTAT
All Models 143° F (62° C)
Seawater Inlet
Recommendations
Transom Mounted or Thru-Hull
Seawater Pickups and Hose
Water pickup must be large enough to permit sufficient
water flow to engine seawater pickup pump for adequate
engine cooling [30 gal. per min. (1 14 litres per
min.) minimum]. Pickup also must supply a positive
head while underway.
6A-2 -COOLING SYSTEM
Seawater Inlet Valve (Thru-Hull Pickup Shown)
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.
90-14499--1 887
Seawater Pickups
Thru-Hull
f"'
Thru-Hull
1. Install pickup through 1-3/4" (44mm) hole in hull.
The slots must be facing forward and parallel with
flow of water.
2. Fasten pickup with the four (4) mounting screws.
Apply Loctite to threads and install nut on pickup
on inside of boat and torque nut to specifications.
Transom Mounted
a-Diagonal Mount [Leading Edge Of Pickup 1/8" (3.2mm) from
Boat Bottom I
b -Vertical Mount [Corner of Leading Edge of Pickup 1/8" (3.2mm)
from Boat Bottom]
Water Pickup Installed on Transom
--0
a-Hose Nipple-Pipe Thread Sealer on Threads, Tighten Securely
b-Nuts (4) Tighten Securely
c -Gasket -Between Pickup and Transom
d -"0" Ring (4)
e-Washer (4)
f-Screw (4) -Coat Each Shaft With Silicone Sealant or Equivalant
g -Plastic Plug -Teflon Paste to Threads, Tighten Securely
h-Pickup
i-Screen
j -Screw (2) -Tighten Securely
Seawater Pickup Installation
90-14499--1 887 COOLING SYSTEM -6A-3
Seawater Pickup Pump
Output Test
If an overheating problem exists, use this test to determine
if a sufficient amount of water is being supplied to
cool engine.
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 a 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
results. To help ensure accurate results, a
shop tachometer with an error of less than 5%
should be used. The boat tachometer definitely
should not be used as its accuracy is questionable.
A stop watch should be used to time the duration of
the test to help ensure that the accuracy is maintained
within 1 second. A 8 quart (7.6 1itre) or larger
capacity container calibrated in 1/4 quart increments
should be used to measure water output.
•
Due to the manner in which this test is performed, it
may not be possible to detect a marginal condition
or a high-speed water pump output problem.
1.
Stern Drive Seawater Pickup Pump Models: Remove
water inlet hose, which runs between gimbal
housing water tube and engine, and replace with
another hose of same diameter, but approximately
3ft. (1m) longer. Hose should be wire reinforced or
of adequate wall thickness to prevent it from kinking
when performing test. Clamp hose at gimbal
housing water tube only. Do not clamp hose at
engine end.
Belt Driven Seawater Pickup Pump: Remove water
hose, which runs between pump outlet and engine
and replace with another hose of same diameter,
but approximately 3ft. (1m) longer. Hose should be
wire reinforced or of adequate wall thickness to
prevent it from kinking when performing test.
Clamp hose at pump outlet only. Do not clamp hose
at engine end.
2.
Place an 8 quart (7.61itres) or larger container near
unclamped end of hose.
A CAUTION
Do not run engine for more than 15 seconds with hose
disconnected, in next step, as internal damage to
engine and exhaust system may result.
··., '
a -Water Tube
b -Hose Clamp
c -Water Hose
Stern Drive Pump Models
a -Seawater Pickup Pump
b-Seawater Outlet Hose
Belt Driven Pump Models
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 water flow overboard,
return engine to idle and stop engine. Reconnect
hose to engine.
4.
Measure quantity of water discharged into container
and compare with specifications given in
chart below.
5. Repeat test 4 times to check repeatability of results.
('""·id
6A-4 -COOLING SYSTEM
90-14499--1 887
BELT DRIVEN PUMP OUTPUT FOR 15 SECOND
PERIOD
7.5 Qts. (7.1 litres) Minimum
STERN DRIVE PUMP OUTPUT FOR 15 SECOND
PERIOD
Drive Unit Gear Ratio Minimum Quantity
1.98:1
1.84:1
1.65:1
1.50:1
1.32:1
3.0 Qts. (2.8 litres)
3.3 Qts. (3.1 litres)
3.6 Qts. (3.4 litres)
4.0 Qts. (3.8 litres)
4.5 Qts. (4.3 litres)
5.
Remove attaching hardware which secures pump
brace to cylinder block, oil pan or Power Steering
pump (as applicable).
6.
Remove pump mounting bracket-to-cylinder block
attaching hardware and remove pump, mounting
bracket and brace as an assembly.
7.
Loosen clamping screw, then remove pump. It may
be necessary to spread clamping bosses.
Stern Drive Unit Seawater
Pickup Pump
NOTICE
MCM 200/230/260/300 Tempest TRS/350
Magnum/454 Magnum have a seawater pickup
pump mounted in stern drive unit. Refer to
"Stern Drive Service Manual" for repairs.
Belt Driven Seawater Pickup
Pump
Removal
A CAUTION
If boat is in the water, be sure to close water inlet valve
before removing inlet hose from pump to prevent water
from draining into boat. If boat is not fitted with a valve,
either plug inlet or raise it above water level after removing.
IMPORTANT: The following procedure describes removal
of both pump and mounting bracket from
engine. On some installations, however, it may be possible
to remove pump with mounting bracket left
installed on engine.
1.
Disconnect water inlet and outlet hoses from pump.
2.
If pump is to be disassembled, break loose 4 pump
pulley attaching screws. Do not remove screws at
this time.
3.
On Engines With Power Steering: Remove Power
Steering pump drive belt to allow removal of seawater
pickup pump drive belt. (Some models)
4.
Remove pulley attaching screws and clamping ring
(some models) then remove pulley.
a-Screw (5)
b -Washer (5)
c-Cover
d-Gasket
e -Wear Plate (Outer)
f-Gasket
g-Plug
h-Impeller
i-Key
j-Body
k-Gasket
I-Wear Plate (Inner)
m -"0" Ring or Quad Ring
n-Oil Seal
o-Housing
p-Ball Bearing
q-Shaft
r-Ball Bearing
s-Snap ring
t -Oil Seal
u-Hub
Pump Assembly
Disassembly
1.
Remove cover and body attaching screws and
washers. Remove cover, gasket, outer wear plate
and gasket. (Discard gaskets.)
2.
Slide pump body off shaft. Remove impeller from
pump body and rubber plug from impeller.
90-14499--1 887
COOLING SYSTEM -6A-5
3. Remove impeller drive key from pump shaft, then
remove gasket, inner wear plate and "0" ring (or
Quad Ring). Discard gasket and "0"ring (or Quad
Ring).
7. If bearings require replacement, remove bearings
from shaft with Universal Puller Plate and an arbor
press. Bearings must be replaced, if removed.
4. Press hub off shaft with Universal Puller Plate (91 -
37241 ) and an arbor press.
Removing Hub
5.
Puncture front oil seal with a tool and pry from
bearing housing.
Removing Front Oil Seal
6.
Remove snap ring from bearing housing bore and
press shaft and bearings out pulley end of housing.
Bearings have a slip fit in housing, do not use
excessive force.
6A-6 -COOLING SYSTEM
Removing Bearings from Pump Shaft
8.
If rear seals require replacement, press seals from
bearing housing with an appropriate tool.
Cleaning and Inspection
1.
Clean metal parts in solvent and blow dry with compressed
air.
IMPORTANT: Do not spin bearings at high speed 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.
4.
Inspect bearing housing. Examine surfaces (where
bearings contact housing) for evidence of bearing
outer races turning in housing.
5.
Inspect seals in bearing housing.
6.
Inspect pump shaft bearings.
7.
Inspect pump shaft for grooves in surface where
seals contact shaft. Inspect keyway in shaft. Also,
inspect surface, where bearings contact shaft, for
evidence of inner races turning on shaft.
8.
Inspect impeller drive key.
.e
9. Inspect pump body.
10.1nspect inner and outer wear plate.
90-1 4499--1 887
y·· .
11. 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).
('
l\lo.._ 12.1nspect pump pulley.
13. Check drive belt for excessive wear.
Reassembly
Refer to Figure 1 also.
1.
Apply a thin coat of Loctite Type 'A" to outside
diameter of 2 new bearing housing rear seals, then
install seals in housing with seal lips facing impeller
end. (Press first seal in until it bottoms-out and
second seal in until flush with housing.)
IMPORTANT: It is recommended that Shell Alvanina
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 permissable to use 2-4-C Marine
Lubricant. However, 2-4-C Marine Lubricant is not
recommended for applications where continuous high
speed heavy-duty operation will be encountered.
2.
Pack cavity between seals with Shell Alvania No.2
Grease or substitute.
3.
Using an arbor press and suitable tool, press ball
bearings onto shaft until they seat. Press on inner r race of bearing only.
"-"'
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.
5.
Apply a thin coat of Loctite "A" to outside diameter
of new bearing housing front oil seal and press seal
into housing (with seal lip facing inward) until it
bottoms out.
IMPORTANT: Be sure to support impeller end of pump
shaft, when installing pulley hub, in next step, to prevent
placing a load on bearings.
90-1 4499--1 887
6.
Apply Special Lubricant 101 to pump shaft. Using
an arbor press and appropriate tool, press pulley
hub onto pump shaft to dimension shown.
a -.260" (6.6mm)
Pulley Hub Dimension
IMPORTANT: Pulley hub must be pressed onto shaft to
exact dimension on pumps with stamped steel mounting
bracket as this establishes proper drive belt alignment.
7.
Clamp bearing housing in a soft jawed vise with
flange end up.
8.
Coat "0" ring (or Quad ring) with 2-4-C Marine
Lubricant and install into groove in housing.
9.
Place inner wear plate on housing and align holes.
Coat both sides of a new wear plate gasket with a
thin film of Perfect Seal and position on wear plate.
10. 1nstall impeller into pump body by turning impeller
in direction that it will be turning in operation, while
simultaneously pushing inward. All impeller blades
must face in same direction.
11. Apply a small amount of grease to back side of
impeller drive key (to hold it in place) and position
key in keyway on shaft. Align groove in impeller hub
with drive key and slide impeller and pump body
assembly onto shaft. Position pump body so that
holes align with holes in wear plate, gasket and
bearing housing. Install rubber plug into end of
impeller.
12. Coat both sides of new cover gasket and wear plate
gasket with a thin film of Perfect Seal. Install outer
wear plate with new gaskets on each side, aligning
holes in plate and gaskets with holes in pump body.
13. 1nstall pump cover and secure with 5 screws and
washers. Torque screws to specifications.
COOLING SYSTEM -6A-7
Installation
1.
Position pump in mounting bracket so that outlet
connection will be directly above inlet connection
when pump is installed.
IMPORTANT: Pump must be positioned correctly or
overheating of engine may occur.
Cast Bracket
448-H
a-L.H. Out -At Top
b-Brass Plug -At Top
MCM and MIE L.H. {Standard) Rotation Engines
' t
6A-8 -COOLING SYSTEM
448-H
a-R.H. Out -At Top (Some Pumps are Not Marked. In Those
Cases, "Out" is At Bottom)
b -Brass Plug -At Bottom
MIE R.H. {Opposite) Rotation Engines
1.
Install flatwasher (spacer) between mounting
bracket clamping bosses and install clamping
screw and lockwasher. Do not tighten screw at this
time.
IMPORTANT: Flat washer must be installed between
mount bracket clamping bosses or damage to pump
may result {if clamping screw is overtightened).
2.
Attach brace to pump mounting bracket with screw,
lockwasher and nut. Do not tighten at this time.
3.
Install pulley on pump and secure with 4 screws,
lockwashers and clamping ring (some models).
Tighten screws finger tight only at this time.
4.
Attach pump, mounting bracket and brace assembly
to engine. Do not tighten attaching screws at
this time.
5.
Slide pump fore or aft in mounting bracket, as
required, to properly align pump pulley with crankshaft
pulley. After pump has been properly positioned,
torque clamping screw to specifications.
6.
Torque pump pulley attaching screws.
7.
Position drive belt on pulleys and adjust belt tension
as outlined in "Drive Belt Tension Adjustment" (see
Index).
8.
Connect seawater inlet hose to lower fitting on
pump.
9.
Connect outlet hose to upper fitting on pump.
10. Tighten hose clamps securely.
11.Power Steering Models: If applicable, reinstall drive
belt. Adjust tension as outlined in "Drive Belt
Tension Adjustment" (see Index).
90-1 4499--1 887
Water Circulating Pump Drive Belt Tension
Replacement Adjustment
( Removal Alternator
1.
Drain water from cylinder block.
2.
Break loose circulating pump pulley attaching
bolts. Do not remove bolts at this time.
3.
Power Steering Models: Loosen power steering
pump brace and pump mounting bolts, then pivot
pump inward and remove drive belts (some
models).
4.
Loosen alternator brace attaching bolts and alternator
mounting bolt, then pivot alternator inward
and remove drive belt.
5.
Remove pump pulley attaching bolts, lockwashers,
clamping ring (if so equipped) and pulley.
6.
Disconnect hose(s) from pump.
7.
Remove bolts, which secure pump to cylinder
block, and remove pump and old gaskets. (Discard
gaskets.)
Cleaning and Inspection
1.
Clean gasket surfaces on water pump and cylinder
block.
(
2. Inspect water pump for blockage, cracks, sand
holes, corrosion or other damage. Inspect pump
·
: .. impeller
for cracks and erosion. Replace complete
pump, if any damage exists.
3.
Check impeller shaft and bearings for excessive
side play. If play can be felt, replace complete
pump.
4.
Inspect pump pulley for bends, cracks, corrosion or
other physical damage. lnspect pulley for rotational
trueness. Replace pulley if damaged or untrue.
Installation
1.
Coat both sides of new circulating pump gasket
with Perfect Seal, then position gaskets and circulating
pump on cylinder block. Coat threads of circulating
pump attaching bolts with Perfect Seal and
install bolts and alternator brace (if applicable).
Torque bolts to specifications.
2.
Reconnect hoses to pump.
3.
Install pump pulley and clamping ring (if used) on
pump hub and secure with bolts and lockwashers.
Tighten bolts securely.
4.
Install drive belts and adjust tension as outlined in.
"Drive Belt Tension Adjustment" (see Index).
5.
If engine is equipped with Closed Cooling, fill
closed cooling section with coolant in accordance
with Section 6, Part B "Filling Instructions".
6.
Start engine and check for leaks.
90-14499--1 887
1.
Install drive belt on pulleys and adjust tension as
follows
a.
Pivot alternator away from engine, as required,
until correct tension is obtained as shown.
b.
After obtaining correct tension, securely retighten
alternator brace attaching bolts and
alternator mounting bolt.
a-Belt Should Depress 1/2" (13mm)
Alternator Drive Belt Tension
2.
If a new drive belt has been installed, recheck belt
tension after running for 5 minutes.
Seawater Pickup Pump
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 retighten
pump brace and pump mounting bolts.
a-Belt Should Depress 1/4" (6mm)
Seawater Pump Drive Belt Tension
2.
If a new drive belt has been installed, recheck belt
tension after running for 5 minutes.
COOLING SYSTEM -6A-9
Power Steering Pump
IMPORTANT: Do not pry on pump with pry bar or
screwdriver.
1.
Install drive belt on pulleys and adjust tension as
shown in the following photos.
a.
Pivot pump away from engine, as required, until
correct tension is obtained as shown.
b.
After obtaining correct tension, securely retighten
pump brace and pump mounting bolts.
2.
If a new drive belt has been installed, recheck belt
tension after running for 5 minutes.
a-Belt Should Depress 1/4" (6mm)
305/350 CID Models with Low Mounted Pump
a-Belt Should Depress 1/4" (6mm)
305/350 CID Models with High Mounted Pump
6A-10-COOLING SYSTEM
a-Belt Should Depress 1/2" (13mm)
454 CID Models with High Mounted Pump
a-Belt Should Depress 1/4" (6mm)
454/482/540 CID Production Performance Models
Flushing Cooling System
If engine is operated in salty, polluted or mineral-laden
waters, cooling system should be flushed periodically
(preferably after each use) to reduce corrosion and
prevent the accumulation of deposits in the system.
Cooling system also should be thoroughly flushed
prior to storage.
A WARNING
When flushing cooling system with boat out of water,
be certain that area in vicinity of propeller is clear and
that no person is standing nearby.
IMPORTANT: Do not run engine above 1500 RPM, as
suction created by seawater pickup pump may collapse
water supply hose and cause engine to overheat.
IMPORTANT: If cooling system is to be flushed with
boat in the water, water inlet valve (if so equipped)
must be closed, or water inlet hose must be disconnected
and plugged to prevent water from flowing into
boat.
90-1 4499--1 887
IMPORTANT: If boats 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.
A CAUTION
Watch temperature gauge at dash to ensure the engine
does not overheat.
Belt Driven Seawater Pickup Pump
1.
Loosen hose clamp and remove water inlet hose at
location shown.
a -Seawater Pickup Pump
b-Seawater Inlet Hose
Models with Belt Driven Seawater Pump
a-Disconnect Hose -Cooling Water Must Flow Thru Cooler(s) if
Engine is so Equipped
Production Performance Models
2.
Partially open water tap (approx. 1/2 maximum
capacity) and allow cooling system to fill completely.
Cooling system is full when water is discharged
thru the exhaust. Do not use full water tap
pressure.
3.
Place the remote control lever in neutral position
and start the engine. Operate engine at idle speed in
neutral gear for 10 minutes or until discharge water
is clear, then stop engine.
4.
Shut off water tap. Remove flushing connector from
pump inlet and reconnect water inlet hose. Be sure
to tighten clamp securely.
Stern Drive Unit Seawater Pickup
Pump
IMPORTANT: MCM 200/230/260 Engines: if engine
has a Closed Cooling system or is a Drive Shaft Extension
model refer to Figure below also, if cooling system
is going to be flushed with boat out of water. Two
independent water connects are required on these
models.
1.
Install Flush Device and connect garden hose
between it and water tap.
a-Flush Device
b -Garden Hose
Models with Stern Drive Seawater Pump
2.
Salt water areas and boat in the water:
a. Raise stern drive unit to full trailer position.
b. Install flush device over water intake holes.
c. Lower stern drive unit to full down position. ,
a -Minimum Water Level
b-Water Intake Holes
Minimum Water Level
3.
Partially open water tap (approx. 1/2 maximum
capacity) and allow cooling system to fill completely.
Cooling system is full when water is discharged
thru the propeller. Do not use full water tap
pressure.
COOLING SYSTEM -6A-1 1
90-1 4499--1 887
4.
Place remote control in neutral position and start
engine. Watch temperature gauge on instrument
panel to ensure that engine does not overheat.
5.
Stop engine, turn off water tap and remove Flush
Device.
Thermostat
Removal
1.
Drain water from cylinder block and exhaust manifolds.
2.
Disconnect hoses from thermostat cover.
3.
Remove thermostat cover attaching bolts and lockwashers,
then remove cover and gasket.
4.
Remove thermostat from thermostat housing or
cover.
a-Thermostat Housing Cover
Models without "T" Fitting on Housing Cover
a-Thermostat Housing Cover
Models with "T" Fitting on Housing Cover
a-Cover
b-Gasket
c-Spacer
d -Thermostat
e-0-Ring
f-Housing
NOTE: Some 1988 Models will have redesigned thermostat
housing.
Testing
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 insufficient
engine temperature, check thermostat for leakage
by holding it up to a lighted background. Light
leakage around the thermostat valve indicates that
thermostat is not closing completely and should be
replaced. (A small amount of leakage at one or 2
points around the valve perimeter is acceptable.)
11363
a -Check for Light Leakage Around Perimeter of Valve
Checking Typical Thermostats for Leakage
6A-12 -COOLING SYSTEM
90-14499--1 887
4. Check opening and closing temperature of thermostat
(using a tester similar to the one shown as
follows:
a. Fill tester to within 1" (25mm) of top with tap
water. Do not use distilled water.
b. Open thermostat valve and insert nylon string.
Position thermostat on string so that it will be
just below water level when suspended, then
allow valve to close. Suspend thermostat in
water.
c. Place thermometer in container and position so
that bottom of thermometer is even with bottom
of thermostat. Do not allow thermometer to
touch container.
a-Thermometer
b-Nylon String
c -Thermostat
Thermostat Tester 08788
IMPORTANT: When performing Steps d-thru-f, water
must be agitated throughly to obtain 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.
f. Unplug tester and allow water to cool to a
temperature 10° F (5° C) below specified temperature
on thermostat. Thermostat must be completely
closed at this temperature.
g. Replace a thermostat that fails to meet all of the
preceding tests.
90-14499--1 887
Installation
1. Clean gasket surfaces on thermostat cover and
thermostat housing.
2. If thermostat housing was disturbed during removal
of thermostat, remove thermostat housing and
replace thermostat housing to intake manifold
gasket. Before installing, coat both sides of new
gasket (without continuity rivets) with Perfect Seal.
IMPORTANT: If gasket has continuity rivets, Do not
coat with Perfect Seal or Audio Warning temperature
switch may not work properly.
3. Place thermostat in thermostat housing with thermostatic
element end toward housing. Be sure to
position thermostat so that mounting flange fits into
recess in thermostat housing.
All Models (With or Without T Fitting)
COOLING SYSTEM -6A-13
4.
Coat both sides of new thermostat cover to thermostat
housing gasket with Perfect Seal and position
on thermostat housing. Reinstall thermostat
cover and torque bolts to specifications.
5.
Reconnect hose(s) to thermostat cover.
6.
Start engine and inspect for leaks.
a-Screws
b -Lockwashers
c-Cover
d -Upper Gaskets (Coat Both Sides with Perfect Seal)
e-Stainless Steel Separator Plate
f -Thermostat
g -Cork Gasket
h-Sleeve (Install with Turned-In Edge Up)
i -Thermostat Housing
j -Gasket (Coat With Perfect Seal)
IMPORTANT: If gasket has continuity rivets DO NOT
use Perfect Seal.
Out-Of-Season Storage
(Draining)
Draining Precautions
IMPORTANT: If the possibility of freezing exists, cooling
system must be drained to prevent freeze damage
to cooling system. Cooling system also should be
drained if boat is to be stored for an extended period of
time to prevent corrosion damage.
A CAUTION
Cooling system, must be completely drained for storage,
or trapped water may cause freeze and/or corrosion
damage to engine.
6A-14-COOLING SYSTEM
A CAUTION
If boat is in the water, water inlet valve (if so equipped)
must be left closed until engine is to 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 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 valve must be
opened or the water inlet hose reconnected prior to
starting the engine.
IMPORTANT: A wire should be inserted into drain
holes to ensure that foreign material is not obstructing
the drain holes. On later models with two piece petcocks,
removal of petcock may be required so that wire
can be inserted completely into drain hole.
IMPORTANT: To prevent threads in manifolds, elbows
and cylinder blocks from rusting out during storage,
reinstall plugs using Perfect Seal on threads. Never
leave drain plugs out during storage.
Note: If possible, place a container under drains to
prevent water from draining into boat.
MCM 305/350 CID Models
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1.
Engine must be level or front of engine slightly
higher to properly drain cooling system.
2.
Drain system as shown.
a -Drain Plug -Remove
3" or 6" Risers (If Equipped)
"""-.H..· . ""';',!; :t;t .
90-1 4499--1 887
MCM 300 Tempest/ Alpha One/TRS
1.
Engine must be level or front of engine slightly
higher to properly drain cooling system.
2.
Drain system as shown.
a -Petcocks -Remove
b -Remove hoses to Lower Drain
Engine Drain Locations
3.
MCM 200/230/260 Driveshaft Extension Models:
Remove seawater inlet hose.
a -Seawater Pickup Pump
b -Seawater Inlet Hose
Driveshaft Extension Models
a-Remove Drain Plug
b-Remove Hose (Lower to Drain)
MCM 300 Tempest TRS
a-Remove Drain Plug
b-Remove Hose (Lower to Drain)
MCM 300 Tempest Alpha One
a-Drain Plug -Remove
Risers (If Equipped)
90-14499--1 887
COOLING SYSTEM -SA-15
a-Remove Drain Plug
b-Remove Hose (Lower to Drain)
MCM 320 EFI Alpha I Drive
a-Remove Drain Plug
b-Remove Hose (Lower to Drain)
MCM 320 EFI Bravo Drive
a-Seawater Pickup Pump
b -Hose -Remove
Seawater Pickup Pump
3.
After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Reconnect all hoses. Tighten clamps securely.
4.
For additional assurance against freezing and rust,
fill cooling system with a solution of permanent
antifreeze and water (mixed to proportions recommended
by manufacturer for lowest temperature to
which engine will be exposed to during storage). ..
a-Remove Cover and Thermostat Housing. Fill with Coolant until
Block and Heads are Full. Using New Gasket, Install Thermostat
and Cover. Torque Screw to Specifications
b -Remove Hoses. Fill Manifolds with Coolant. Reinstall Hoses and
Tighten Clamps Securely.
Filling With Coolant
MCM 454 CID Models (7.4 Litre and
1988 454 Magnum Included)
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1.
Engine must be level or front of engine slightly
higher to properly drain cooling system.
2.
Drain system as shown.
a-Remove Drain Plug
b-Remove Petcock
c-Remove Hose (Lower to Drain)
Cooling System Drain Locations
NOTE: Some models fluid coolers may be in slightly
different locations.
6A-16-COOLING SYSTEM
90-14499--1 887
a-Seawater Pickup Pump
b -Hose Remove
Seawater Pickup Pump
a-Drain Plug -Remove
3" or 6" Riser (If Equipped)
3.
After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Close petcocks and reconnect all hoses.
Tighten clamps securely.
a-Remove Screws and Thermostat Housing. Fill with Coolant until
Block and Heads are Full. Using· New Gasket, with Continuity
Rivets (Do Not Use Perfect Seal). Install Housing. Torque
Screws to Specifications
b-Remove Hoses and Fill Manifolds with Coolant. Reinstall Hoses
and Tighten Clamps Securely.
Filling with Coolant
90-14499--1 887
4.
For additional assurance against freezing and rust,
fill cooling system with a solution of permanent
antifreeze and water (mixed to proportions recommended
by manufacturer for lowest temperature to
which engine will be exposed to during storage).
MCM 454/482/540 CID
Production Performance
Models
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1.
Engine must be level or front of engine higher to
properly drain cooling system.
2.
Drain cooling system as shown.
a-Remove Drain Plug
b-Remove Hose (Lower to Drain)
MCM 370TRS/400 Cyclone 5/N 6721528 and Above
a -Remove Drain Plug
b-Remove Hose (lower to Drain)
MCM 370TRS/400 Cyclone 5/N 6721527 and Below
COOLING SYSTEM -6A-17
a-Remove Drain Plug 51 9-H
b -Remove Hose (Lower to Drain)
MCM 440/460 Cyclone
a -Remove Drain Plug
b-Remove Hose (Lower to Drain)
MCM 420
a-Remove Drain Plug
b -Remove Hose (Lower to Drain)
MCM 575 6A-18 -COOLING SYSTEM
a -Drain Plug -Remove
Risers (If Equipped)
TRANSMISSION
FLUID COOLER
ENGINE
OIL COOLER
a-Drain Plug on Bottom of Flywheel Housing -Drains Both Coolers
Dual Cooler Flywheel Housing
a -Seawater Pickup Pump
b -Hose -Remove
Seawater Pickup Pump
90-14499--1 887
3. After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Reconnect all hoses. Tighten clamps securely.
4. For additional assurance against freezing and rust,
fill cooling system with a solution of permanent
antifreeze and water (mixed to proportions recommended
by manufacture for lowest temperature to
which engine will be exposed to during storage).
a-Remove Screws and Thermostat Housing. Fill with Coolant until
Block and Heads are Full. Using New Gasket, with
Continuity Screws to Specifications
b-Remove Hoses and Fill Manifolds with Coolant. Reinstall Hoses
and Tighten Clamps Securely.
Filling With Coolant
90-14499--1 887
MCM 454 Magnum
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1. Engine must be level or front of engine higher to
properly drain cooling system.
2. Drain cooling system as shown.
857-H
a -Remove Drain Plug
b-Remove Hose (Lower To Drain)
MCM 454 Magnum (1987)
a -Remove Drain Plug
3" or 6" Risers (If Equipped)
COOLING SYSTEM -GA-19
4. After cooling system has drained completely, coat
threads of drain plug(s) with Perfect Seal and reinstall.
Close petcock and reconnect all hoses.
Tighten clamps securely.
a-Remove Cover and Thermostat Housing. Fill with Coolant Until
Block and Heads are Full. Using New Gasket. Install Thermostat
and Cover. Torque Screw to Specifications
b-Remove Hoses. Fill Manifolds with Coolant. Reinstall Hoses and
Tighten Clamps Securely
Filling with Coolant
5. For additional assurance against freezing and rust,
fill the cooling system with a solution of permanent
antifreeze and water (mixed to proportions recommended
by manufacturer for lowest temperature to
which engine will be exposed to during storage).
MIE Models
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1. Engine must be level or front of engine slightly
higher to properly drain cooling system.
6A-20 -COOLING SYSTEM
2. Drain system as shown.
a -Remove Drain Plug
b -Remove Petcock
c-Remove Hose (Lower to Drain)
MIE 230/260
a-Remove Drain Plug
b-Remove Petcock
c -Remove Hose (Lower to Drain)
MIE 340
a -Seawater Pickup Pump
b-Seawater Inlet Hose
Seawater Pickup Pump
90-14499--1 887
a -Drain Plug -Remove
3" or 6" Risers {If Equipped)
3.
After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Close petcock and reconnect all hoses.
Tighten clamps securely.
4.
For additional assurance against freezing and rust,
fill the cooling system with a solution of permanent
antifreeze and water (mixed to proportions recommended
by manufacturer for lowest temperature to
which engine will be exposed to during storage).
a-Remove Screws and Thermostat Housing. Fill with Coolant until
Block and Heads are Full. Using New Gasket, Install Housing.
Torque Screws to Specifications
b-Remove Hoses and Fill Manifolds with Coolant. Reinstall Hoses
and Tighten Clamps Securely
Filling With Coolant
90-14499--1 887
Auxiliary Hot Water Heater
Installation
When connecting a cabin heater or hot water heater to
a MerCruiser engine, certain requirements must be
met.
•
Supply hose (from engine to heater) and return
hose (from heater to engine) must not exceed 5/8"
(16mm) (Inside Diameter).
•
MerCruiser Engines Equipped With a Closed Cooling
System: Heater must be lower than the fill cap
on the heat exchanger. 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.
Make heater connections to MerCruiser engines
only at locations shown.
Check complete system for leaks after heater is
connected into cooling system.
Check for overheating condition (of engine) after
heater is connected into cooling system.
MCM/MIE V-8 Engines (74567A1 Kit)
1.
Drain cooling system.
2.
Remove thermostat housing assembly from intake
manifold. Do not remove cover from thermostat
housing.
3.
Remove 3/8" NPT plug from aft port side of thermostat
housing.
4.
Install the appropriate type fittings(s) (obtain from
local source) in threaded hole from which pipe plug
was removed to allow connection of water heater
supply hose. Coat threads of fitting(s) with Perfect
Seal before installing.
5.
Reinstall thermostat housing using new gasket.
Torque bolts to specifications.
6.
Connect hot water heat supply hose to fitting and
secure with a clamp (not provided).
a-3/8" NPT Plug b-Thermostat Housing
Water Heater Supply Hose Conection
COOLING SYSTEM -6A-21
7.
Connect auxiliary hot water heater return hose into
cooling system with "T" fitting and hose clamps as
shown. Cut approximately 3/4" (19mm) out of hose
to maintain proper hose configuration.
8.
Tighten "T" fitting hose clamps securely.
9.
Support hoses, as required, to ensure that they do
not rub or chafe against engine components.
10. With boat in the water, start engine and check for:
a.
Leaks
b.
Overheating
Heater Connection on Typical MerCruiser
V-8 (GM) Engine with Standard Cooling
Heater Connection on Typical MerCruiser
V-8 (GM) Engine with Closed Cooling System
6A-22 -COOLING SYSTEM
Cooling System Flow
Diagrams
MerCruiserengines with standard cooling systems use
seawater (water in which the boat is being operated) to
remove the heat given off by the engine.
The seawater is pumped to the cooling system by
means of an impeller type pickup pump (located in the
vertical drive or belt driven at the front of engine) which
picks up seawater and delivers it to the centrifugal
pump (located over an opening on the front of the
cylinder block). On some models, seawater may be
pumped through an oil cooler before going to the circulating
pump. The centrifugal pump then circulates
the seawater through the block, heads and manifolds,
removing the heat given off by these parts as it passes.
After passing through the engine, the seawater is
pumped into the exhaust elbow, where it mixes with the
exhaust gases, and is expelled overboard.
A thermostatic heat control which controls circulation
of the seawater, also is incorporated into the system. It
provides fast engine warmup and controlled operating
temperature.
.. ..
90-1 4499--1 887
TO EXHAUST
ELBOWS
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDENI
90-14499--1 887
FROM WATER INLET
(VIA FLUID COOLER I
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
THE RMOSTAT
LEGEND
ENGINE BLOCK
INTAKE MANIFOLD
ANO CYLINDER HEAD ASSY
(305 & 350 CU IN I
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIODENI
FROM WATER INLET
(VIA flUID COOlERI
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
MCM 200/230/260/350 Magnum 167-HR
COOLING SYSTEM -6A-23
WATER INLET
!FROM STERN DRIVEl
RESTRICTOR
22382
5.0 Litre/5.0 Litre LX/5.7 Litre/350 Magnum
(With Redesigned Thermostat Housing)
6A-24 -COOLING SYSTEM
tJ;·,'{ ..ol ..··..' '.r.. tf.;Vf
90-1 4499--1 887
90-1 4499--1 887
THERMOSTAT
HOUSING
ISEE CUTAWAY
VIEW BELOWI
TO EXHAUST
ELBOWS
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDEN!
OVERBOARD
ENGINE BLOCK
INTAKE MANIFOLD
AND CYLINDER HEAD ASSY.
1350 C.U. I.N.I
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDENI
EXHAUST ELBOW
EXHAUST
ElBOW ADAPTOR
TO EXHAUST
MANIFOLDS
THERMOSTAT
LEGEND
COLD WARM
FROM WATER INLET FROM WATER INLET
IVIA FLUID COOLER! IVIA FLUID COOLERI
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
727-H
MCM 300 Tempest Alpha One
COOLING SYSTEM -6A-25
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDENI
POWER STEERING
FLUID COOLER
!STARBOARD ENGINE
ONLY ONDUAL
INSTALLA TIONSI
SEAWATER PICK-UP
PUMP
THERMOSTAT
COVER
FROM SEAWATER PICKUP PUMP
IVIA FLUID COOLERI
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
THERMOSTAT
LEGEND
COlO WARM
MCM 300 Tempest TRS
6A-26 -COOLING SYSTEM
TRANSMISSION
FLUID COOLER
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDENI
FROM SEAWATER PICKUP PUMP
IVIA FLUID COOLERI
EXHAUST
ELBOW ADAPTOR
EXHAUST
MANIFOLD
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
728-H
90-14499--1 887
D THERMOSTAT
HOUSING
(SEE CUTAWAY
VIEW BELOW) ..
ENGINE
· CIRCULATING PUMP
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN)
FROM WATER INLET
(VIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
ENGINE BLOCK
INTAKE AND CYLINDER WATER INLET
HEAD ASSY (FROM STERN DRIVEl
(350 CU. IN.)
EXHAUST ELBOW
.. GASKET
THERMOSTAT
LEGEND
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN)
FROM WATER INLET
(VIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
320 EFI Cooling System Flow
90-1 4499--1 887 COOLING SYSTEM -6A-27
ENGINE
CIRCULATING PUMP
SEAWATER INLET c;:::>
ENGINE OIL
AND POWER
STEERING FLUID
.. GASKET
TO ENGINE
THERMOSTAT
LEGEND
COLD
TO ENGINE
CIRCULATING PUMP CIRCULATING PUMP
(PASSAGE HIDDEN) (PASSAGE HIDDEN)
FROM WATER INLET
(VIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
320 EFI Bravo Cooling System Flow
FROM WATER INLET
(VIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
6A-28 -COOLING SYSTEM 90-1 4499--1 887 ,...':<..·-:::; ----
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDEN)
TO EXHAUST
ELBOWS
FROM SEAWATER PICKUP PUMP
IVIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
90-14499--1 887
THERMOSTAT
LEGEND COLO WAAM
MIE 230/260/5.0 Litre/5.7 Litre
FROM SEAWATER PICKUP PUMP
IVIA FLUID COOLER)
TO EXHAUST
MANIFOLDS
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
779-H3
COOLING SYSTEM -6A-29
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN)
TO EXHAUST
ELBOWS
OV ERBOARD
THE RMOSTAT
LEGEND c:::=::J COLO
EXHAUST ELBOW 10..
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN)
n.. RESTRICTOR
FROM SEAWATER PICKUP PUMP
(VIA FLUID COOLER)
FROM SEAWATER PICKUP PUMP
(VIA FLUID COOLER I
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
MIE 5.7 Ski
6A-30 -COOLING SYSTEM 90-1 4499--1 887
;..
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDEN!
TO EXHAUST
ELBOWS
ENGINE BLOCK,
INTAKE MANIFOLD
AND CYLINDER HEAD ASSY.
(454 CU. IN.)
THERMOSTAT
LEGEND ..COLD ..WARM TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN!
TO EXHAUST
MANIFOLDS
FROM SEAWATER PICKUP PUMP FROM SEAWATER PICKUP PUMP
!VIA OIL COOLER! (VIA OIL COOLER!
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
857-H
MCM 454 Magnum (1987)
90-1 4499--1 887
COOLING SYSTEM -6A-31
ENGINE
CIRCULATING
PUMP
TO EXHAUST MANIFOLDS
TO ENGINE
CIRCULATING
PUMP
ENGINE BLOCK
INTAKE MANIFOLD
ANO CYLINDER HEAO ASSY.
.. RESTRICTOR
FROM WATER INLET (VIA FLUID COOLER)
THERMOSTATLEGEND
WARM
Water Flow Diagram 454 Magnum 1988
6A-32 -COOLING SYSTEM 90-14499--1 887
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDOENI
TO EXHAUST
ELBOWS
TRANSMISSION
FLUID COOLER
THERMOSTAT
LEGEND
COLD
WARM
EXHAUST ELBOW
c;::::7 PLATE
TO ENGINE
CIRCULATING PUMP
!PASSAGE HIDDEN!
TO EXHAUST
MANIFOLDS
FROM SEAWATER PICKUP PUMP FROM SEAWATER PICKUP PUMP
IVIA OIL COOLER! !VIA OIL COOLER!
COOLANT FLOW THROUGH THERMOSTAT COOLANT FLOW THROUGH THERMOSTAT HOUSING WITH THERMOSTAT OPEN HOUSING WITH THERMOSTAT CLOSED
MCM 330 (8-W)/MIE 340/7.4 Litre
90-14499--1 887 COOLING SYSTEM -6A-33
SEAWATER
INLET c;:::>
TRANSMISSION
FI.UIO COOI.ER
ENGINE
Oil. COOLER
SEAWATER PICK-UP
PUMP
Q EXHAUST ELBOW
EXHAUST
ENGINE CIRCULATING MANIFOLD
PUMP
MANIFOLD END CAP
298-H
NOTE 1: Some models did not use the flywheel housing engine oil cooler. A stringer mounted oil cooler was
used in the seawater inlet hose. A hose was connected between the transmission fluid cooler and the
thermostat housing.
MCM 370TRS/400 Cyclone 5/N 6721527 and Below
6A-34 · COOLING SYSTEM 90-14499--1 887
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN)
TO EXHAUST
ELBOWS
THE RMOSTAT
LEGEND
COL 0 --WARM
TO ENGINE
CIRCULATING PUMP
(PASSAGE HIDDEN)
FROM SEAWATER PICKUP PUMP
FROM SEAWATER PICKUP PUMP
(VIA OIL COOLERI
(VIA OIL COOLERI
COOLANT FLOW THROUGH THERMOSTAT
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
HOUSING WITH THERMOSTAT CLOSED
760-H
MCM 370TRS/400 Cyclone S/N 6721528 and Above
COOLING SYSTEM -6A-35
90-1 4499--1 887
6A-36 -COOLING SYSTEM
-ENGINE CIRCUlATING PUMP
MCM 440 Cyclone/460 Cyclone
EXHAUSTMANIFOlD 519-H
90-14499--1 887
TO ENGINE
CIRCULATING PU
(PASSAGE HIDDEN)
FROM WATER INLET
(VIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT CLOSED
ENGINE BlOCK.
INTAKE MANIFOlD
AND CYliNDER HEAD ASSY.
(454 CU. IN.I
THERMOSTAT
LEGEND
c0LD
EXHAUST
.. GASKET
FROM WATER INLET
(VIA FLUID COOLER)
COOLANT FLOW THROUGH THERMOSTAT
HOUSING WITH THERMOSTAT OPEN
MCM 420 Cooling System Flow
90-14499--1 887 COOLING SYSTEM -6A-37
6A-38 -COOLING SYSTEM
ENGINE CIRCULATING
PUMP
ENGINE BLOCK &
CYLINDER HEAD
ASSY.t540 CU.IN.. POWER STEE.RING
FLUID COOLER
MCM 575 Cooling System Flow
OVERBOARD
90-14499--1 887
COOLING SYSTEM
CLOSED COOLED MODELS
m
Index
Page
Torque Specifications ......................... 68-1
Lubricants/Sealants ........................... 68-1
Specifications ................................. 68-1
Description ................................... 68-1
Maintaining Coolant Level ..................... 68-2
Testing System ................................ 68-2
Testing Coolant For Alkalinity ............... 68-2
Pressure Testing System .................... 68-2
Testing For Cylinder Head Gasket Leak ...... 68-3
Testing Heat Exchanger .................... 68-3
Testing Pressure Cap ....................... 68-4
Heat Exchanger Repair ........................ 68-5
Thermostat ................................... 68-5
Removal ................................... 68-5
Testing ....................................68-5
Installation ................................. 68-6
Changing Coolant ............................. 68-8
Coolant Recommendations ................. 68-8
Change Intervals ........................... 68-8
Draining Precautions ....................... 68-8
MCM/MIE 305/350 CID Models .............. 68-8
MCM 230/260TR ........................... 68-9
MCM 454 CID Models ...................... 68-9
Closed Cooling Section ....................... 68-9
Seawater Section .......................... 68-10
Filling Closed Cooling Section ................ 68-10
Out-of-Season Storage ....................... 68-11
Closed Cooling Section .................... 68-11
Seawater Section Draining Precautions ..... 68-11
MCM/MIE 305/350 CID Models ............. 68-12
MCM/MIE 454 CID Models ................. 68-13
MCM 230/260TR .......................... 68-13
Cooling System Flow Diagrams ............... 68-15
MCM 200/230/260/MIE 230/260
Front Mounted Tank .................... 68-15
MCM 200/230/260/MIE 230/260
Rear Mounted Tank .................... 68-16
MCM 230/260TR .......................... 68-17
MCM 330 8-W/MIE 340 .................... 68-18
NOTICE
Refer to Section 6, Part A for the following:
• Seawater Inlet Recommendations
• Seawater Pickups
• Seawater Pickup Pump Output Test
• Stern Drive Unit Seawater Pickup Pump
• Belt Driven Seawater Pickup Pump
• Water Circulating Pump Replacement
• Drive Belt Tension Adjustment
• Flushing Cooling System
• Auxiliary Hot Water Heater Installation
"'-.,/
;·>t -.
90-14499--1 887 COOLING SYSTEM -68
Torque Specifications
Fastener Location Lbs. Ft. (N.m} Lbs. ln. (N.m}
Drain Plugs Securely
Heat Exchanger End 36-72
Cap (4-8)
Heat Exchanger
Securely Mounting Brackets
Hose Clamps Securely
Thermostat Cover 30
(41 )
Lubricants/Sealants
LUBRICANTS/SEALANTS
92-86154A1 Quicksilver 2-4-C Marine Lubricant
92-34227--1 Quicksilver Perfect Seal
Specifications
CLOSED COOLING SYSTEM CAPACITY
Model Qts (litres) Approximately
MCM/MIE
20 (19)
305/350 CID
MCM/MIE
28 (26.5)
454/482
THERMOSTAT
All Models
PRESSURE CAP
All Models 14 PSI (97 kPa)
90-1 4499--1 887
Description
There are several configurations of this cooling system,
but the operation is essentially identical. Basically,
the system is composed of two separate subsystems;
the seawater system and the closed cooling
system. The seawater system is similar in function to
the fan used in an automobile because it absorbs heat
(from the closed cooling system) as it passes thru the
heat exchanger. The closed cooling system is similar in
function to the rest of the cooling system in an automobile.
The coolant recovery system keeps the reservoir full.
Normal coolant overflow into recovery bottle is approximately
1/2 pint during warm-up. The coolant recovery
system draws coolant back into the reservoir from the
recovery bottle as the engine cools. As long as there is
coolant in the recovery bottle, the reservoir should
remain completely full. If not, there's a vacuum leak,
usually at the hose leaving the reservoir, or the gasket
under the recovery filler cap. The gasket seals against
the outer rim of the filler neck.
IMPORTANT: The coolant (anti-freeze) flows around
the outside of the cooling tubes while seawater flows
thru the inside of the cooling tubes in the heat exchanger.
All V-8 engine exhaust manifolds are cooled by coolant
in the closed cooling system. All V-8 stern drive and
inboard engines use a belt driven pump to pump seawater
thru the heat exchanger. Water from the seawater
pickup pump in the stern drive is used to cool the
stern drive only and is then dumped overboard.
COOLING SYSTEM -68-1
Maintaining Coolant Level
A.WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly then, push down and turn cap all-theway
off.
1.
Coolant level in heat exchanger should be within 1"
(25mm) from bottom of filler neck.
IMPORTANT: When reinstalling pressure cap, be sure
to tighten it until it contacts stops on filler neck.
2.
Coolant level should be between the "Add" and
"Full" mark on coolant recovery reservoir with
engine at normal operating temperature.
a-Fill Cap
Coolant Recovery Bottle
Testing System
Testing Coolant for Alkalinity
A.WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly, then, push down and turn cap all-theway
off.
1.
Obtain pink litmus paper from a local supplier (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 alkaline
and need not be replaced.
4.
If pink litmus paper remains pink, coolant is not
alkaline and MUST BE REPLACED.
68-2 -COOLING SYSTEM
'
l ·.
Pressure Testing System
A.WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly, then, push down and turn cap all-theway
off.
If coolant section of Closed Cooling System is suspected
of leaking or not holding sufficient pressure,
and no visible signs of leakage can be found, perform
the following test:
1.
Remove pressure cap from heat exchanger or
reservoir.
2.
Clean, inspect and pressure test pressure cap, as
outlined under "Testing Pressure Cap" in this section,
to eliminate the possibility that cap is not maintaining
proper pressure in system and is causing
coolant to boil over.
Clean inside of filler neck to remove any deposits or
debris. Examine lower inside sealing surface for
nicks or other damage. Surface must be perfectly
smooth to achieve a good seal between it and
rubber seal on cap. Also, check locking cams on
sides of filler neck to be sure that they are not bent
or damaged. If locking cams are bent or damaged,
pressure cap will not hold the proper pressure.
4.
Adjust coolant level in fresh water section to 1"
(25mm) below filler neck.
5.
Attach an automotive-type cooling system pressure
tester to filler neck and pressurize closed cooling
section to 17 psi (117 kPa).
6.
Observe gauge reading for approximately 2 minutes;
pressure should not drop during this time. If
pressure drops, proceed with the following steps
until leakage is found.
7.
While maintaining a pressure of 17 psi on closed
cooling section, visually inspect external portion of
cooling system (hoses, gaskets, drain plugs, pet-
cocks, core plugs, circulating pump seal, etc.) for
leakage. Also listen closely for bubbling or hissing,
as they usually are a sure indication of a leak.
8.
Test Heat Exchanger, as outlined.
90-1 4499--1 887
·.
9.
If no leakage could be found in above steps, engine
is leaking internally, and it probably is due to one or
more of the following: 1) Loose cylinder head bolts
or damaged gasket, 2) loose intake manifold bolts
or damaged gasket, 3) loose exhaust elbow or distribution
block retaining nuts or damaged gasket, 4)
cracked or porous cylinder head or block, 5)
cracked or porous exhaust manifold. Proceed as
follows until location of internal leak is found-
a.
Start engine. Repressureize system to 17 psi and
observe pressure gauge on tester. If needle in
gauge vibrates, compression or combustion is
leaking into closed cooling section from a leak in
the combustion chamber. Exact cylinders,
where leakage is taking place, sometimes can be
found by removing spark plug wires (one at a
time) while observing pressure gauge. Vibration
will decrease or stop when plug wire is removed
from leaking cylinder. Stop engine.
b.
Remove spark plugs (one at a time) from cylinders
and examine for presence of coolant. A
spark plug, that is perfectly clean or milky
appearing, is a sure indication of a leak.
c.
Drain oil from engine and examine for presence
of coolant. Oil usually will be milky, if coolant is
present. If coolant is present, remove engine
from boat and drop the oil pan. With engine in
the upright position, repressurize closed cooling
section to 17 psi and examine internal surfaces
of engine to locate leak.
d.
If no leakage can be found in above steps, entire
engine must be disassembled and inspected for
leakage.
Testing for Cylinder Head Gasket Leak
A leaking head gasket will cause combustion gas to be
forced into the cooling system. The mixture of coolant
and tiny air bubbles is a poor heat conductor; and will
overheat an engine quickly. Compression tests or cooling
system pressure check normally will not detect the
leak because the test pressure is far below the combustion
pressures which cause the leak. An effective test is
as follows:
IMPORTANT: Run boat in lake for this test. It is best to
run the engine at or above cruising speed during this
test. Usually a failed head gasket will not cause the
engine to overheat below cruising speed.
1.
Install a clear plastic hose between the reservoir
and coolant recovery bottle. Use a 2-3ft. (61-91cm)
long hose for this test.
2.
Route this hose so a "U" is formed.
3.
Put enough coolant into hose to fill the center 4 or 5
inches (10-13cm) of the "U".
4.
Observe the "U" while the engine is running.
a.
During idle and warm-up: some coolant and/or
air will leave the reservoir.
b.
During cruising speed (2500-3500 RPM); coolant
and/or air leaving the reservoir should stop
after approximately 5 minutes running at a given
RPM. A leaking head gasket will produce air
bubbling through the "U", going to the coolant
recovery bottle. The frequency and size of the
bubbles will depend on the size of the leak.
c.
At higher speeds (4000 + RPM): Normal operation
is the same as described in "b" above. A
failed head gasket will cause the bubbles to
come faster and may be accompanied by violent,
intermittent bursts of coolant.
It is important not to confuse normal warm-up expansion
with a failed head gasket. Normal warm-up produces
an intermittent flow of coolant which will stop
within approximately 5 minutes at a given RPM. A head
gasket leak will not stop -the one thing that marks a
failed head gasket is the continued passage of air, that
may be accompanied by violent, intermittent bursts of
coolant leaving the reservoir. If coolant continues to
flow (not in violent, intermittent bursts) from the reservoir
at cruising speed, something else besides the head
gasket is causing the engine to overheat.
Testing Heat Exchanger
For Internal Leak: An internalleak wi II cause coolant to
go into the seawater circuit when pressure is put on the
closed cooling circuit.
a.
Remove a seawater hose from the exchanger. Do
not drain the exchanger.
b.
Pressurize the closed cooling circuit to 14-20 PSI
(97-138 kPa) with a radiator tester.
c.
If seawater begins to flow from the nipple there is a
leak.
For Blockage:
IMPORTANT: Seawater flows THROUGH the tubes in
the exchanger. Closed cooling coolant flows AROUND
the tubes.
a.
Remove end caps and inspect for any blockage in
the seawater circuit (broken impeller blades, weeds,
etc.).
b.
Remove closed cooling circuit hoses and inspect
the tubes just inside the nipples. Because the complete
exchanger cannot be inspected, the heat
exchanger should be replaced if blockage is suspected.
COOLING SYSTEM -68-3
90-1 4499--1 887
Testing Pressure Cap
Pressure cap is designed to maintain a pressure of
approximately 14 psi (97 kPa) in closed cooling section
once engine has attained operating temperature. Cap
should be cleaned, inspected and pressure-tested at
regular tune-up intervals or whenever cap is suspected
of maintaining improper pressure, as follows;
A WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly, then, push down and turn cap all-theway
off.
1.
Carefully remove pressure cap from reservoir or
heat exchanger.
2.
Wash cap with clean water to remove any deposits
or debris from sealing surfaces.
3.
Inspect gasket (if used) and rubber seal on cap for
tears, cuts, cracks or other signs of deterioration.
Replace gasket, if damage, or entire cap, if rubber
seal is damaged.
a-Rubber Seal (Cap MUST BE Replaced if damaged)
b-Gasket (Look for Cracks under Gasket)
c-Locking Tabs (1 Hidden)
Pressure Cap
'r1(.",
4.
Check that locking tabs on cap are not bent or
damaged.
5.
Using a cooling system pressure tester (similar to
one shown). test cap to be sure that it releases at
proper pressure and does not leak. (Refer to instructions
which accompany tester for correct test procedure.)
Cap must relieve pressure at 14 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.
Pressure Testing Pressure Cap
IMPORTANT: Before reinstalling cap in next step,
examine lower inside sealing surface in filler neck to
ensure that it is perfectly smooth and free of debris.
Also, inspect cam lock flanges on sides of filler neck to
be sure that they are not bent.
6.
Reinstall cap on reservoir or heat exchanger.
a-Inspect for Damage
b -Clean Coolant Recovery Passage
Heat Exchanger
···"-..-/
68-4 -COOLING SYSTEM
90-14499--1 887
Heat Exchanger Repair
IMPORTANT: Braze with BCUP 2 rod or silver solder.
Care must be taken not to melt other joints during
repair.
1. Internal leaks can be repaired by brazing shut the
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 3
tubes. 2. Nipples and drains, that have been broken off the
heat exchanger, can be re-attached by brazing.
Thermostat
Removal
1. Drain coolant from cylinder block and exhaust
manifolds. 2. Disconnect hoses from thermostat cover.
3. Remove thermostat cover attaching bolts and lockwashers,
then remove cover and gasket.
4. Remove thermostat from thermostat housing.
a-Thermostat Cover
Models Without "T" Fitting in Cover
90-14499--1 887
a -Thermostat Cover
b -Circulating Pump
Models With "T" Fitting in Cover
Testing
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 insufficient
engine temperature, check thermostat for leakage
by holding it up to a lighted background. Light
leakage around the thermostat valve indicates that
thermostat is not closing completely and should be
replaced. (A small amount of leakage at one or 2
points around the valve perimeter is acceptable.)
a-Check for Light Leakage Around Perimeter of Valve
Checking Typical Thermostats for Leakage
11363
COOLING SYSTEM -68-5
4. Check opening and closing temperature of thermostat
(using a tester similar to the one shown, as
follows:
a. Fill tester to within 1" (25mm) of top with tap
water. Do not use distilled water.
b. Open thermostat valve and insert thread. Position
thermostat on nylon string so that it will be
just below water level when suspended, then
allow valve to close. Suspend thermostat in
water.
a-Thermometer b -Nylon String
Thermostat Tester
08788
c -Thermostat
c. Place thermometer in container and position so
that bottom of thermometer is even with bottom
of thermostat. Do not allow thermometer to
touch container.
IMPORTANT: When performing Steps d and e, water
must be agitated thoroughly to obtain accurate results.
d. Plug in tester and observe temperature at which
thermostat opens (thermostat drops off 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 temperature
on thermostat. Thermostat must be completely
closed at this temperature.
f. Replace a thermostat that fails to meet all of the
preceding tests.
68-6 -COOLING SYSTEM
Installation
11315
a-Install Thermostat with This End Toward Thermostat Housing
Typical Thermostat Installation A CAUTION Do not operate engine without cooling water being
supplied to seawater pickup pump, or pump impeller
will be damaged.
The thermostat housings and covers are made from the
same basic castings. However, the drilled holes, for
mounting the assemblies to the intake manifold, are in
different locations for the small block and large block
V-8 engines. Refer to figure below for correct location
of mounting holes in the different assemblies.
a-305/350 CID V-8 Engine b-454 CID V-8 Engine
Location of Mounting Holes in Thermostat Housing
and Cover Assemblies
1. Remove thermostat housing and gaskets. Discard
gaskets.
2. Clean gasket surfaces on thermostat cover, thermostat
housing and intake manifold.
3. Coat both sides of new thermostat housing to
intake manifold gasket (without continuity rivets),
with Perfect Seal, then position gasket and ther\
mostat housing on manifold.
IMPORTANT: If gasket has continuity rivets, do not
coat with Perfect Seal or Audio Warning temperature
switch may not work properly.
90-14499--1 887
('.
"-_./
4. Place thermostat, new cork gasket and retaining
sleeve in thermostat housing, as shown. 5. Coat both sides of new thermostat cover gasket
with Perfect Seal, then position gasket on thermostat
housing and reinstall thermostat cover. Torque
bolts to specifications.
6. Reconnect hoses to thermostat cover.
7. Refill Closed Cooling System with coolant, as outlined
in "Changing Coolant", see Index .
a-Bolts (Torque to Specifications)
b -Lockwashers
c-Cover
d-Gasket (Coat with Perfect Seal)
e-Sleeve (Install with Turned-In Edge Down}
f-Cork Gasket (Do Not Use Perfect Seal)
g -Thermostat
h-Housing
i-Plugs
j-Gasket (Coat with Perfect Seal)
305/350 CID Engines
90-14499--1 887
15138
a-Bolts {Torque to Specifications)
b -Lockwashers
c-Cover
d-Gasket (Coat with Perfect Seal)
e -Thermostat
f -Cork Gasket (Do Not Use Perfect Seal)
g -Sleeve (Turned-In Edge Up)
h-Housing
i -Gasket with Continuity Rivets (Do Not Use Perfect Seal)
454 CID Engines A CAUTION
14932
Do not operate engine without cooling water being
supplied to seawater pickup pump, or pump impeller
will be damaged.
8. Start engine and inspect for leaks.
COOLING SYSTEM -6B-7
Changing Coolant
Coolant Recommendations
A CAUTION
Alcohol or Methanol base anti-freeze or plain water,
are not recommended for use in fresh water section of
cooling system at any time.
It is recommended that the coolant section of Closed
Cooling System be filled with a 50/50 mixture of ethylene
glycol anti-freeze and water. In areas where the
possibility of freezing Does not exist, it is permissible
to use a solution of rust inhibitor and water (mixed to
manufacturers recommendations).
Change Intervals
The old coolant should be drained and flushed from
the closed cooling system at least every two (2) years
or whenever exhaust gases have entered into the system.
Draining Precautions
A WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly, then, push down and turn cap all-theway
off.
IMPORTANT: A wire should be inserted into drain
holes to ensure that foreign material is not obstructing
the drain holes. On later models with two piece petcocks,
removal of petcock may be required so that wire
can be inserted completely into drain hole.
NOTE: If possible, place a container under drains to
prevent coolant from draining into boat.
MCM/MIE 305/350 CID Models
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1. Engine must be level to properly drain cooling
system.
2. Remove pressure cap from reservoir.
68-8 -COOLING SYSTEM
fj,z; •t1..w1't ·· t1
90-14499--1 887
3. Drain coolant as shown.
a -Remove Petcock
b-Remove Hose (Lower to Drain)
Rear Mounted Tank
a -Remove Petcock
b-Remove Hose (Lower to Drain)
Front Mounted Tank
4.
After coolant has drained completely, reinstall petcocks
and hoses. Tighten clamps and petcocks
securely.
5.
Remove coolant recovery bottle from mounting
bracket and pour out coolant.
6.
Clean system as outlined in "Filling Closed Cooling
Section".
tion, BEFORE proceeding.
MCM 230/260TR
NOTICE
Refer to "Draining Precautions", in this sec
1.
Engine must be level to properly drain cooling
system.
2.
Remove pressure cap from reservoir.
3.
Drain coolant as shown.
4.
After coolant has drained completely, reinstall petcocks
and hoses. Tighten clamps and petcocks
securely.
5.
Remove coolant recovery bottle from mounting
bracket and pour out coolant.
6.
Clean system as outlined in "Cleaning System".
7.
Fill system as outlined in "Filling Closed Cooling
Section".
a -Remove Petcock
b-Remove Hose (Lower to Drain)
MCM/MIE 454 CID Models
NOTICE
Refer to "Draining Precaution", in this section,
BEFORE proceeding.
1.
Engine must be level to properly drain cooling
system.
2.
Remove pressure cap.
3. Drain coolant as shown.
a -Remove Petcock
b -Remove Hose (Lower to Drain)
4.
After coolant has drained completely, reinstall petcocks
and hoses. Tighten clamps and petcocks
securely.
5.
Remove coolant recovery bottle from mounting
bracket and pour out coolant.
6.
Clean system as outlined in "Cleaning System".
7.
Fill system as outlined in "Filling Closed Cooling
Section".
Closed Cooling Section
Closed cooling section of Closed Cooling System
should be cleaned at least once every 2 years or whenever
decreased cooling efficiency is experienced.
A good grade automotive cooling system cleaning
solution may be used to remove rust, scale or other
foreign material. Manufacturer's instructions, which
accompany particular cleaner, always should be followed.
If closed cooling section is extremely dirty, a pressure
flushing device may be used to flush out remaining
deposits. Flushing should be done in direction opposite
normal coolant flow to allow water to get behind
deposits and force them out. Refer to instructions
which accompany flushing device for proper hookup
and flushing procedure.
90-14499--1 887
COOLING SYSTEM -68-9
Seawater Section
Cooling efficiency of an engine with Closed Cooling is
greatly dependent upon heat transfer through the
tubes within the heat exchanger. During engine operation,
contaminants within the seawater (such as salt,
silt, lime, etc) collect on the inside of the tubes, thus
reducing heat transfer and greatly decreasing heat exchanger
efficiency. It is, therefore, recommended that
the seawater section of the heat exchanger be cleaned
at least once every 2 years or whenever decreased
cooling efficiency is suspected, as follows:
IMPORTANT: It may be necessary to remove heat
exchanger on some models. If heat exchanger is
removed, be sure to refill closed cooling section with
coolant.
1.
Remove seawater drain plug from bottom of heat
exchanger and allow water to drain. After water has
drained completely, coat threads of drain plug with
Perfect Seal and reinstall.
a -Bolt d -Gasket
b-End Cap e-Drain Plug (Refer to "Out-of-Season Storage"
c-Sealing Washer for Location on Model Being Worked On)
Typical V-8 Engine
2.
Remove bolts, which secure end plates to each end
of heat exchanger, then remove end plates, seal
washers and gaskets. Discard seal washers and
gaskets. Clean gasket material from end plates and
heat exchanger.
3.
Clean water passages in heat exchanger by inserting
a suitable size wire brush into each passage.
Use compressed air to blow loose particles out of
water passages.
4.
Apply Perfect Seal to both sides of new end plate
gaskets, then reinstall end plates, using new
gaskets and seal washers. (Be sure to install seal
washers between end plates and gaskets.) Torque
end plate bolts to specifications.
5.
Start engine and inspect cooling system for leaks.
6B-10-COOLING SYSTEM
Filling Closed Cooling
Section
NOTICE
See "Specifications" for appoximate closed
cooling system capacity and coolant recommendation.
1.
Fill closed cooling section with coolant as follows:
Front Mounted Tank
a.
Thru heat exchanger filler neck until coolant solution
is 1" (25mm) below filler neck.
Rear Mounted Tank
a.
Remove pipe plug (or heat switch) from thermostat
housing.
b.
Fill Closed Cooling section with coolant solution
thru heat exchanger filler neck until coolant
appears at hole in thermostat housing from which
pipe plug (or heat switch) was removed.
c.
Coat threads of pipe plug (or heat switch) with Perfect
Seal and reinstall.
d.
Continue filling Closed Cooling section until coolant
level is 1" (25mm) below filler neck.
a-Pipe Plug (or Heat Switch)
V-8 Thermostat Housing
90-1 4499--1 887
A CAUTION
•
DO NOT operate engine without water flowing thru
seawater pickup pumps, as pump impeller may be
damaged and subsequent overheating damage to
engine or stern drive unit may result.
•
Front of engine should be higher than rear to purge
trapped air out of the system during initial filling.
This will minimize the possibility of air being
trapped in the closed cooling section which can
cause engine to overheat.
•
Models with belt drive seawater pickup pump must
be in the water when running engine because
garden hose will not supply enough water to system
at higher RPM.
2.
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"
below filler neck.
3.
After engine has reached normal operating temperature
(themostat is fully open), and coolant level
remains constant, fill heat exchanger to bottom of
filler neck.
4.
Observe engine temperature gauge to make sure
that engine operating temperature is normal. If
gauge indicates excessive temperature, stop engine
immediately and examine for cause.
5.
Install pressure cap on heat exchanger.
6.
Remove cap from coolant recovery reservoir and fill
to "Full" mark wiht coolant solution. Reinstall cap.
7.
With engine still running, check hose connections,
fittings and gaskets for leaks. Repeat step 4.
IMPORTANT: Engine overheating is often due to air
being trapped in fresh water section. Purge air by running
engine at 2000 RPM for 10 minutes.
A WARNING
Allow engine to cool down before removing pressure
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 allow any pressure to
escape slowly, then, push down and turn cap all-theway
off.
8.
Recheck coolant level after first open-throttle boat
test and add coolant, if necessary.
9.
Maintain coolant level in coolant recovery reservoir
between "Add" and "Full" marks with engine at
normal operating temperature.
Out-of-Season Storage
Closed Cooling Section
Closed cooling section of Closed Cooling System
should be kept filled year around with recommended
coolant solution. Do not drain closed cooling section
for storage, as this will promote rusting of internal
surfaces. If engine will be exposed to freezing temperatures,
make sure that closed cooling section is filled
with an ethylene glycol anti-freeze and water solution,
mixed to manufacturer's recommended proportion, to
protect engine to lowest temperature to which it will be
exposed. If necessary, change coolant.
Seawater Section Draining
Precautions
A CAUTION
If the possibility of freezing exists, seawater section
must be drained to prevent freeze damage to cooling
system and engine. Seawater section also should be
drained if boat is to be stored for an extended period of
time, to prevent corrosion damage.
A CAUTION
If boat is in the water, water inlet valve (if so equipped)
must be left closed until engine is to 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 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 valve must be
opened or the water inlet hose reconnected prior to
starting the engine.
IMPORTANT: A wire should be inserted into drain
holes to ensure that foreign material is not obstructing
the drain holes.
IMPORTANT: To prevent threads in elbows from rusting
out during storage, reinstall plugs using Perfect
Seal on threads. Never leave drain plugs out during
storage.
NOTE: If possible, place a container under drains to
prevent water from draining into boat.
90-1 4499--1 887
COOLING SYSTEM -68-1 1
MCM/MIE 305/350 CID Models
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1. Drain system as shown. Engine must be level to
properly drain cooling system.
a-Remove Drain Plug
3" or 6" Risers (If Equipped)
a -Remove Drain Plug
b-Remove Hose (Lower to Drain)
Rear Mounted Tank
68-12 -COOLING SYSTEM
a-Remove Drain Plugs
b-Remove Hose (Lower to Drain)
Front Mounted Tank
a -Remove Drain Plug
b-Cooler Without Drain Plug -Remove Hoses. Lower to Drain
Power Steering Fluid Cooler (If Equipped)
2. Crank engine over slightly, with starter motor, to
purge any water trapped in seawater pickup pump.
Do not allow engine to start.
3. After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Reconnect hoses. Be sure to tighten hose
clamps and drain plugs securely.
90-14499--1 887
MCM/MIE 454 CID Models
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1.
Drain system as shown. Engine must be level to
properly drain cooling system.
a-Remove Drain Plug
3" or 6" Risers (If Equipped)
a-Remove Drain Plug
b -Cooler Without Drain Plug -Remove Hoses, Lower to Drain
Power Steering Fluid Cooler (If Equipped)
2.
Crank engine over slightly, with starter motor, to
purge any water trapped in seawater pickup pump.
Do not allow engine to start.
3.
After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Reconnect hoses. Be sure to tighten hose
clamps and drain plugs securely.
MCM 230/260TR
NOTICE
Refer to "Draining Precautions", in this section,
BEFORE proceeding.
1. Drain system as shown. Engine must be level to
properly drain cooling system.
a -Remove Drain Plug
3" or 6" Risers (If Equipped)
a -Remove Drain Plug
b -Remove Hose (Lower to Drain)
90-14499--1 887
COOLING SYSTEM -68-13
a-Remove Drain Plugs
b-Remove Hose (Lower to Drain}
a-Remove Drain Plug
b -Cooler Without Drain Plug -Remove Hoses, Lower to Drain
Power Steering Fluid Cooler (If Equipped)
69-14-COOLING SYSTEM
ENGINEOIL COOLER
a-Drain Plug on Bottom of Flywheel Housing -Drains Both Coolers
Dual Cooler Flywheel Housing
2. Crank engine over slightly, with starter motor, to
purge any water trapped in seawater pickup pump.
Do not allow engine to start.
3. After cooling system has drained completely, coat
threads of drain plugs with Perfect Seal and reinstall.
Reconnect hoses. Be sure to tighten hose
clamps and drain plugs securely.
90-14499--1 887
RECOVERY 80TTL£
TO EXHAUST
MANIFOLDS THERMOSTAT
HOUSING COVER
THERMOSTAT
HOUSING
COOLANT FLOW THROUGH THERMOSTAT HOUSING
WITH THERMOSTAT CLOSED !ENGINE COLD!
THERMOSTATLEGEND COlO..WARM
(..GIN£ BlOCK
fHJAK( MANIFOLD AND (VLINO(RHEAD A$$·v I)()S & 3$0 CU IN)
THERMOSTAT
THERMOSTAT
HOUSING
COOLANT FLOW THROUGH THERMOSTAT HOUSING
WITH THERMOSTAT OPEN !ENGINE WARM)
MCM 200/230/260/5.0 Litre/5.0 Litre LX/5.7 Litre MIE
230/260 Front Mounted Tank
779·H2
90-14499--1 887 COOLING SYSTEM -68-15
THERMOSTAT @
I tHOUSING }
CIRCULATING PUMP
TO EXHAUST
MANIFOLDS
THERMOSTAT
HOUSING COVER
THERMOSTAT
HOUSING
COOLANT FLOW THROUGH THERMOSTAT HOUSING
WITH THERMOSTAT CLOSED IENGINE COLD!
THERMOSTATLEGEND
COLO WARM
TO EXHAUST
MANIFOLDS
COOLANT RECOVERY
BOTTLE
EXHAUST ELBOW ..,
ENGINE BLOCK
LEGEND
THERMOSTAT
HOUSING COVER
HERMOSTAT
THERMOSTAT
HOUSING
COOLANT FLOW THROUGH THERMOSTAT HOUSING
WITH THERMOSTAT OPEN !ENGINE WARMI 779-HS
MCM 200/230/260/5.0 Litre/5.0 Litre LX/5.7 Litre MIE
230/260 Rear Mounted Tank
68-16 -COOLING SYSTEM 90-14499--1 887
HEAT
' err• . THERMOSTAT t HOUSING t t
EXCHANGER
ENGINE BLOCK
LEGEND .. FRESHWATER.. SEAWATER
EXHAUST
ELBOWtO&
HOUSING COVER
THERMOSTAT
HOUSING
COOLANT FLOW THROUGH THERMOSTAT HOUSING
WITH THERMOSTAT CLOSED !ENGINE COLDI
CIRCULATING
PUMP
THERMOSTAT
TO HEAT
THERMOSTATEXCHANGER
HOUSING COVER
THERMOSTAT
LEGEND
c== COLD
THERMOSTAT
HOUSING
COOLANT FLOW THROUGH THERMOSTAT HOUSING
WITH THERMOSTAT OPEN (ENGINE WARMI
749-H
MCM 230/260TR (Early)
90-14499--1 887 COOLING SYSTEM-68-17
PRESSURE
CAP COOLANT RECOVERY
EXHAUST El80W
•
HOUSING
ENGINE BLOCK
LEGEND
CIRCULATING PUMP
TO EXI;_ •
."' .·. ..' .
. . "'•'....:if.,.: -%..,·1,
Torque Specifications
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Battery Cables Securely
Hose Clamps Securely
Distribution Block 25 (34)
End Cap 96 (1 1)
Exhaust Elbow 25 (34)
Exhaust Manifold (Note) 25 (34)
NOTE: MCM 370TRS, 400TRS, 400/440/460 Cyclone:
Torque bolts to 35 lbs. ft. (47 N.m). Torque nuts to 25
lbs. ft. (34 N.m).
Quicksilver Sealants
Repair/replacement procedure(s), outlined in this section,
require the use of the following Quicksilver
sealants:
•
Loctite
•
Perfect Seal
Refer to the Quicksilver Accessories Guide for ordering
information.
r
'--"' Cleaning and Inspection
1.
Clean gasket material from all surfaces and wash
parts in solvent.
2.
Inspect all parts carefully. Machined surfaces must
be clean and free of all marks and deep scratches,
or water and exhaust leaks may result.
3.
Check water passages for foreign material. Passages
must be clean for efficient cooling.
4.
If more thorough inspection is desired, pipe plugs
may be removed from exhaust manifold and exhaust
elbow.
IMPORTANT: If plugs are removed, coat threads with
Perfect Seal before reinstalling.
5.
Check for cracks.
6.
To test manifold body for leaks, block off plates,
plugs, or short hoses with plugged ends must be
used. One block off plate must have a threaded 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.
Models with Alpha One Drive
Removal
1.
Disconnect battery cables from battery.
2.
Drain water from manifold and exhaust elbow.
3.
Disconnect exhaust bellows and cooling hoses.
4.
Starboard Manifold:
a.
Disconnect both shift cables.
b.
Disconnect instrument harness plug from engine
harness. Remove shift plate assembly from
exhaust elbow.
c.
Disconnect fuel lines and remove filter assembly.
d.
Remove circuit breaker/slave solenoid and
bracket.
Port Manifold:
a.
Remove ignition amplifier from exhaust elbow.
b.
Remove remote oil filter and bracket (If
equipped).
5.
Remove exhaust manifold fasteners; remove manifold
assembly and discard gaskets.
6.
Remove exhaust elbow.
7.
Refer to "Cleaning and Inspection". (See "Index")
Installation
1.
Using new gasket, install exhaust manifold to cylinder
head. Torque fasteners to 25 1bs. ft. (34 N.m).
IMPORTANT: See Section 7, Part 8 if exhaust risers
are used.
90-1 4499--1 887
EXHAUST SYSTEM -78-1
2. Install exhaust elbow. Torque fasteners to 251bs. ft.
(34 N.m).
'
OR ..
148-HR1
a -Stainless Steel Restrictor Plate
b-Gaskets
c-27-4181 3 Restrictor Gasket
Standard Seawater Cooled Models
a -Gasket 27-48042
b-Adaptor
c-Gasket 27-87105
MCM 300 Tempest Alpha One
OR ..
148-HR2
a-Stainless Steel Separator Plate
b-Gaskets
c-27-41811 Separator Gasket
Closed Cooling Models
3.
Starboard Manifold:
a.
Install circuit breaker/slave solenoid and
bracket.
b.
Install water separating fuel filter. Reconnect
fuel lines. Tighten securely.
c.
Install shift plate assembly. Plug in instrument
harness and tighten clamp securely.
d.
Install and adjust shift cables. Refer to appropriate
MerCruiser Stern Drive Service Manual.
Port Manifold:
a.
Install ignition amplifier to exhaust elbow.
Tighten bolts securely.
4.
Reconnect exhaust bellows and cooling hoses.
Tighten clamps securely.
5.
Reconnect battery cables to battery. Tighten
securely.
6.
Start engine and check for fuel, exhaust and water
leaks.
78-2 -EXHAUST SYSTEM
90-14499--1 887
-
.
.·
Models with Borg-Warner
Transmissions
Removal
1.
Disconnect battery cables from battery.
2.
Drain water from manifold and exhaust elbow.
3.
Disconnect exhaust and cooling hoses.
4.
Starboard Manifold:
a.
Disconnect fuel lines from water separating fuel
filter and remove filter assembly.
b.
Disconnect instrument harness plug from engine
harness.
c.
Remove circuit breaker/slave solenoid and
bracket.
Port Manifold:
a.
Remove ignition amplifier from exhaust elbow
(if equipped).
b.
Remove remote oil filter and bracket.
5.
Remove exhaust manifold fasteners; remove manifold
assembly and discard gaskets.
6.
Remove exhaust elbow.
7.
Refer to "Cleaning and Inspection. (See "Index".)
Installation
1.
Using new gasket, install exhaust manifold to cylinder
head. Torque fasteners to 25 1bs. ft. (34 N.m).
2.
IMPORTANT: See Section 7, Part B if exhaust risers
are used.
Install exhaust elbow. Torque fasteners to 25 1bs. ft. (34
N.m).
..
..
..
' OR..
148-HR1
a-Stainless Steel Restrictor Plate
b-Gaskets
c-27-41813 Restrictor Gasket
Standard Seawater Cooled Models (Except MCM 300
Tempest TRS and MCM 370 [S.N. 6721528 and Above])
a-Gasket 27-48042
b-Adaptor
c-Gasket 27-87105
MCM 300 Tempest TRS and MCM 370TRS (S.N.
6721528 and Above)
-
EXHAUST SYSTEM 78-3
90-1 4499--1 887
OR.
148-HR2
a-Stainless Steel Separator Plate
b-Gaskets
c-27-41 81 1 Separator Gasket
Closed Cooling Models
3.
Starboard Manifold:
a.
Install circuit breaker/slave solenoid and
bracket.
b.
Install water separating fuel filter. Reconnect
fuel lines. Tighten securely.
c.
Plug in instrument harness plug and tighten
clamp securely.
Port Manifold:
a.
Install ignition amplifier to exhaust elbow (if
equipped). Tighten bolts securely.
b.
Install remote oil filter and bracket. Tighten fasteners
securely.
5.
Reconnect battery cables to battery. Tighten securely.
6.
Start engine and check for fuel, exhaust and water
leaks.
MCM 370TRS (S.N. 6721527
and Below), 400TRS, 400
Cyclone
Removal
1.
Disconnect battery cables.
2.
Drain water from manifold and exhaust elbow.
3.
Disconnect exhaust hoses and cooling hoses.
4.
Starboard Manifold:
a.
Disconnect fuel lines from water separating fuel
filter and remove fuel filter assembly.
5.
Remove exhaust manifold fasteners; remove manifold
assembly and discard gaskets.
6.
Remove exhaust elbow.
7.
Remove end caps.
8.
Refer to "Cleaning and Inspection". (See "Index".)
Installation
1.
Install new gaskets and end caps on ends of manifold
body. Torque fasteners to 96 lbs. in (11 N.m).
2.
IMPORTANT: See Section 7, Part B if exhaust risers
are used.
Use a new gasket and install exhaust elbow to manifold
body. Torque fasteners to 25 lbs. in (34 N.m).
3.
Using a new gasket, install manifold. Torque bolts
to 35 lbs. ft. (47 N.m). Torque nuts to 25 lbs. ft. (34
N.m)
4.
Starboard Manifold:
a.
Install water separating fuel filter. Connect fuel
lines and tighten securely.
5.
Reconnect exhaust and water hoses. Tighten
clamps securely.
6.
Reconnect battery cables to battery. Tighten securely.
7.
Start engine and check for fuel, exhaust and water
leaks.
78-4 -EXHAUST SYSTEM
90-1 4499--1 887
MCM 440/460 Cyclone
440 and 460 cyclones have Gil Marine "header"
installed from the factory. From exhaust elbow to out
side of vessel is supplied by the boat manufacture.
Removal (Both Sides)
1.
Disconnect battery cables.
2.
Drain water from manifold and exhaust system.
3.
Disconnect exhaust hoses and cooling hoses.
4.
Remove exhaust manifold fasteners; remove manifold
assembly and discard gaskets.
5.
Refer to "Cleaning and Inspection". (See "Index".)
a -Gil Marine Exhaust "Header"
b-Gasket
Installation (Both Sides)
1.
Using a new gasket, install manifold. Torque bolts
to 35 lbs. ft. (47 N.m). Torque nuts to 25 lbs. ft. (34
N.m).
2.
Reconnect exhaust and water hoses. Tighten
clamps securely.
3.
Reconnect battery cables.
4.
Start engine and check for fuel, exhaust and water
leaks.
90-1 4499--1 887
MCM 420
Removal (Both Sides)
1.
Disconnect battery cables.
2.
Drain water from manifold and exhaust elbow.
3.
Disconnect exhaust hoses and cooling hoses.
4.
Remove exhaust manifold fasteners; remove manifold
assembly and discard gaskets.
5.
Remove exhaust elbow and exhaust pipe.
6.
Remove end caps.
7.
Refer to "Cleaning and Inspection". (See "Index'.)
a -Exhaust Manifold
b-Gasket
c -Exhaust Elbow
d -Metal Gasket
e-Exhaust Pipe
EXHAUST SYSTEM -78-5
Installation (Both Sides)
1. Use a new gasket and install exhaust elbow to manifold
body. Torque fasteners to 35 lbs. ft. (47 N.m).
2. Using a new gasket, install manifold. Torque bolts
to 35 lbs. ft. (47 N.m)
3. Install exhaust pipe with water discharge slot
towards the top of exhaust elbow.
a-Water D1scharge Slot at 12 O'Clock
b -Weld at 6 O'Clock
21167
4. Reconnect exhaust and water hoses. Tighten
clamps securely.
5. Reconnect battery cables.
6. Start engine and check for fuel, exhaust and water
leaks.
7B-6 -EXHAUST SYSTEM
MCM 575
MCM 575 models have manufacture installed stelling
"headers" made of stainless steel.
Removal
1. Disconnect battery cables.
2. Drain water from manifold.
3. Disconnect exhaust hoses and cooling hoses.
4. Remove exhaust manifold fasteners; remove manifold
assembly and discard gaskets.
5. Refer to "Cleaning and Inspection". (See "Index".)
Stelling Exhaust "Header"
Installation
1. Using a new gasket, install manifold. Torque bolts
to 30 lbs. ft. (41 N.m).
2. Reconnect exhaust and water hoses. Tighten
clamps securely.
3. Reconnect battery cables securely.
4. Start engine and check for fuel, exhaust and water
leaks.
90-14499--1 887
EXHAUST SYSTEM
----1
EXHAUST RISERS
Index
Page
Exhaust Riser Kit Identification ................7C-1
Torque Specifications 7C-1
........................
Sealants ..................................... 7C-1
53452A2 -6 ln. Exhaust Riser Kit
Replacement .............................. 7C-1
61811 A4 -3 ln. Exhaust Riser Kit
Replacement .............................. ?C-2
93320A3 -3 ln. Exhaust Riser Kit
Replacement ..............................7C-2
93322A3 -6 ln. Exhaust Riser Kit
Replacement ..............................7C-5
EXHAUST SYSTEM -7C 90-1 4499--1 887
Model
Production
Models
MCM 370TRS (S.N.
6721527 and Below),
400TRS, 400 Cyclone
MCM 440/460 Cyclone
MCM 420/575
3 ln. Riser 6 1n. Riser
Part No. Part No.
93320A3 93322A3
6181 1A4 53452A2
Not Not
Available Available
Exhaust Riser Kit
Identification
Torque Specifiations
Fastener Lcoation Lbs. Ft. (N.m)
Exhaust Elbow 20-25 (27-34)
Exhaust Riser 20-25 (27-34)
Sealants
SEALANTS
92-34227--1 Quicksilver Perfect Seal
90-14499--1 887
53452A2 6 ln. Exhaust Riser
Kit
Replacement
1. Drain exhaust elbow and exhaust manifold.
2. Remove fasteners. Remove elbow and riser.
3. Clean all gasket surfaces.
4. Using Perfect Seal on both sides of new gaskets,
install riser and elbow.
5. Torque fasteners to specifications.
6. Tighten hose clamps securely.
7. Check for leaks after starting engine.
a-Gasket
b-Lockwashers and Nuts (4)
c-Drain Plug -Down and Toward Front of Boat
d 6
ln.Riser
e-Gasket
f-Screws, Lockwashers and Nuts (4)
EXHAUST SYSTEM -7C-1
61811A4 3 ln. Exhaust Riser
Kit
Replacement
1.
Drain exhaust elbow and exhaust manifold.
2.
Remove fasteners, then elbow and riser.
3.
Clean all gasket surfaces.
4.
Using Perfect Seal on both sides of new gaskets,
install riser and elbow.
5.
Torque fasteners to specifications.
6.
Tighten hose clamps securely.
7.
Check for leaks after starting engine.
a-Gasket
b-Drain Plug -Down and Toward Front of Boat
c-3 ln. Riser
d-Gasket
e-Lockwashers and Nuts (4)
7C-2 -EXHAUST SYSTEM 90-1 4499--1 887
93320A3 3 ln. Exhaust Riser
Kit
Replacement
1.
Drain exhaust elbow and exhaust manifold.
2.
Remove ignition amplifier or shift plate (MCM only.)
3.
Remove fasteners, then elbow and riser.
4.
Clean all gasket surfaces.
5.
Using Perfect Seal on both sides of new gaskets,
install riser and elbow.
IMPORTANT: Gaskets, restrictor plate (or separator
plate and riser must be installed as shown.
IMPORTANT: If engine is equipped with closed cooling,
stainless steel separator plate must be installed
below 3 in. risers. If plate is installed above 3 in. riser, a
steam pocket will form in exhaust manifolds during
operation.
6.
Torque fasteners to specifications.
7.
Elbow with ignition amplifier: Reinstall ignition
amplifier and wiring harness mounting bracket
onto exhaust elbow using original attaching hardware.
Be sure to reconnect amplifier and wiring
harness ground wires to one of the attaching screws
and that amplifier spacers are installed between
amplifier and exhaust elbow. Tighten screws securely.
8.
Elbow with shift plate (MCM only): Reinstall shift
plate. Tighten fasteners securely. Readjust shift
cables as outlined in "Stern Drive Service Manual".
9.
Tighten hose clamps securely.
10. Closed Cooling System: Refill cooling system.
11. Check for leaks after starting engine.
._./
a-Gasket (27-87105)
Cb-Stainless Steel Separator
or
OR ..
148-HR4
c-Separator Gasket (27-4181 1) -DO NOT Use Perfect Seal on
Gasket
d-Gasket (27-871 05)
a-Gasket (27-87105) or cb-Stainless Steel Restrictor
148-HR3
c-Restrictor Gasket (27-41 81 3) -DO NOT Use Perfect Seal on
Gasket
d-Gasket (27-87105)
e -Drain Plug -Down and Toward Rear of Boat
f-Stud (2), Port Manifold with Remote Oil Filter -6-1/2 ln.
(165mm)
3 ln. Exhaust Elbow Standard Cooling
e -Drain Plug -Down and Toward Rear of Boat
f-Stud (2), Port Manifold with Remote Oil Filter -6-1/2 ln.
(165mm)
3 ln. Exhaust Elbow Closed Cooling
90-1 4499--1 887 EXHAUST SYSTEM -7C-3
a-Gasket 27-87105 b-Separator Gasket 27-41 81 1
a-Restrictor Gasket 27-41813
b-Gasket 27-87105
c-Stud (4), 9-9/16 ln. (243mm)
d-Stud (2), Remote Oil Filter Bracket -10-9/16 ln. (268mm)
4 ln. Exhaust Elbow Standard Cooling
c-Stud (4). 9-9/16 ln. (243mm)
d-Stud (2), Remote Oil Filter Bracket -10-9/16 ln. (268mm)
4 ln. Exhaust Elbow Closed Cooling
90-1 4499--1 887
7C-4 -EXHAUST SYSTEM
below 6 in. risers. If plate is installed above 6 in. riser, a
steam pocket will form in exhaust manifolds during
OR
a-Gasket (27-87105) cb-Stainless Steel Restrictor Plate
or
148-HRS
c-Restrictor Gasket (27-41813) -DO NOT Use Perfect Seal on
Gasket
d-Gasket (27-87105)
e-Drain Plug -Down and Toward Rear of Boat
f-Screw (2), Starboard Riser with Wiring Harness Bracket -1-1/8
ln. (29mm) 3 ln. Exhaust Elbow Standard Cooling
EXHAUST SYSTEM -7C-5
93322A3 6 ln. Exhaust Riser
Kit
\..._,/
Replacement
1.
Drain exhaust elbow and exhaust manifold.
2. Remove ignition amplifier or shift plate (MCM only).
3. Remove fasteners, then elbow and riser.
4. Clean all gasket surfaces.
5.
Using Perfect Seal on both sides of new gaskets,
install riser and elbow.
IMPORTANT: Gaskets, restrictor plate (or separator
plate) and riser must be installed as shown.
IMPORTANT: If engine is equipped with closed cooling,
stainless steel separator plate must be installed
operation.
90-1 4499--1 887
6.
Torque fasteners to specifications.
7.
Elbow with ignition amplifier: Reinstall ignition
amplifier and wiring harness mounting bracket
onto exhaust elbow using original attaching hardware.
Be sure to reconnect amplifier and wiring
harness ground wires to one of the attaching
screws and that amplifier spacers are installed
between amplifier and exhaust elbow. Tighten
screws securely.
8.
Elbow with shift plate (MCM only): Reinstall shift
plate. Tighten fasteners securely. Readjust shift
cables as outlined in "Stern Drive Service Manual".
9.
Tighten hose clamps securely.
1 0. Closed Cooling System: Refi II cooling system.
11. Check for leaks after starting engine.
OR
.... ..t..ket (27-87105) or Camless Steel S eparator c -Separator Gasket (27-41 81 1) -D0 NOT Use Perfect Seal Gasketd-G asket (27-87105)
w
:i
.
f-Screw (2ln. (29me-D R....r of BoatW1nng H arness Br
g-Down and To Starboard Riser
.
..
)
3 I n. Exhaust Elb ow CI osed Cooling
7C-6 -EXHAU ST SYSTEM 90-1 4499--1 887
a-Restrictor Gasket 27-41 813
b-Gasket 27-87105
c-Long Bolts (4) -Elbow to Riser
d-Short Bolts and Lockwashers (4) -Riser to Manifold
4 ln. Exhaust Elbow Standard Cooling
a-Gasket 27-87105
b -Separator Gasket 27-41811
c-Long Bolts (4) -Elbow to Riser
d-Short Bolts and Lockwashers (4) -Riser to Manifold
e-Plug
4 ln. Exhaust Elbow Closed Cooling
90-1 4499--1 887 EXHAUST SYSTEM -7C-7
EXHAUST SYSTEM
!L -.. --
EXHAUST COLLECTORS
I
Index
.
I:
I:
I
Page
Torque Specifications 70-1
................. .......
Sealants 70-1
.....................................
MCM 200, MCM 230, MCM 260 ................ 70-1
Shutter Replacement 70-1
.. ........... ......... Exhaust System Component
Replacement ..................... ......70-2
MCM 200, MCM 230, MCM 260 Oriveshaft
Extension Models 70-3
..... .............. ...... Shutter Replacement 70-3
......................
Exhaust System Component Replacement 70-3
..
MCM 330 8/W, MCM 230TR, MCM 260TR ...... 70-4
Exhaust System Component
Replacement .............. .............70-4
MCM 3 ln. Exhaust Hose Extension Kit
32-62364A 1 ............................... 70-5
MCM 6 ln. Exhaust Hose Extension Kit
32-59077 A 1 ............................... 70-6
Thru Transom Exhaust Flange ................70-6
Shutter Replacement 70-6
..................... .
Component Replacement 70-7
............ . ..... MIE 230, MIE 260, MIE 5.7 Ski
Single Exhaust Kit 48640A2 ................ 70-7
,.-.\'
EXHAUST SYSTEM -7D
.,
90-1 4499--1 887
305/350 CID with Alpha One
Drive
Shutter Replacement
IMPORTANT: Engine does not have to be removed to
change shutters.
1.
Loosen clamps and remove exhaust pipe elbow and
exhaust hose.
2.
Replace water shutter as shown.
3.
Reinstall pipe elbow and hose. Tighten clamps
securely.
a-Top of Pipe b -Shoulder Bushing
c-Water Shutter -Install as Shown
d -Shaft
EXHAUST SYSTEM -70-1
TORQUE SPECIFICATIONS
Fastener Location Lbs. Ft. (N.m)
Block Off Plate
20-25
(27-34)
Exhaust Pipe to 20-25
Gimbal Housing (27-34)
Exhaust Pipe to 20-25
Tee Pipe (27-34)
Hose Clamps Securely
Tee Pipe to Gimbal 20-25
Housing (27-34)
Upper Exhaust Pipe to 20-25
Lower Exhaust Pipe (27-34)
Water Shutter
Screw/Nut
Securely
SEALANTS
SEALANTS
92-861 66 Quicksilver Bellows Adhesive
92-34227 Quicksilver Perfect Seal
90-14499--1 887
Exhaust System Component
Replacement
1.
To replace any component(s) in either exhaust system
shown, the following must be adhered to:
•
All mating joint surfaces must be clean.
•
"0" ring must remain in groove to properly seal
joint to prevent leakage.
•
Torque all screws and lockwashers to specifications.
•
Tighten all clamps securely.
a-Mating Surface
b-"0" Ring
c-Clamps
d -Exhaust Bellows
e -Exhaust Pipe Elbow -Starboard: Casting No. 94443
Port: Casting No. 94444
f -Exhaust Hose
g -Water Shutters
h -Screws and Lockwashers -Torque to 20-25 Lbs. Ft. (27 -34 N.m)
i -Exhaust Pipe
3 ln. Exhaust System
70-2 -EXHAUST SYSTEM
a-Mating Surface
b-"0" Ring
c-Clamps
d-Exhaust Bellows
e-Exhaust Pipe Elbow
f -Exhaust Hose
g -Water Shutters
h-Screws and Lockwashers -Torque to 20-25 Lbs. Ft. (27-34 N.m)
i -Exhaust Pipe
4 ln. Exhaust System
90-1 4499--1 887
305/350 CID with Alpha One
Drive Driveshaft Extension
Models
Shutter Replacement
1.
Loosen hose clamps on exhaust hose and remove
screws and lockwashers.
2.
Remove exhaust pipe elbow.
3.
Remove water shutter, then retainer from tee pipe.
4.
Install retainer, and shutter as shown.
5.
Make sure mating surfaces are clean and "0" ring is
in groove.
6.
Reinstall exhaust pipe elbow with screws and lockwashers.
Torque screws to 20-25 lbs. ft. (27-34
N.m). Be certain that "0" ring remains seated in
groove, properly sealing joint to prevent leakage.
7.
Tighten clamps securely.
a-Screws and Lockwashers -Torque to 20-25 Lbs. Ft..(27-34 N.m)
b-Tee Pipe
c-"0" Ring
Exhaust System Component
Replacement
1.
To replace any componet(s) in exhaust system, the
following must be adhered to:
•
All mating joint surfaces must be clean.
•
"0" rings must remain in groove to properly seal
joints to prevent leakage.
•
Torque all screws and lockwashers to specifications.
•
Tighten all clamps securely.
a -Mating Surface
b-"0" Ring
. 0
0/
d -Retainer -Slots Facing Out
e-Water Shutter -Opens Toward Inside of Tee Pipe
f -Exhaust Pipe Elbow
g-Clamps
h -Exhaust Hose
0
a-Screws and Lockwashers-Torque to 20-25 Lbs. Ft. (27-34 N.m)
b-Tee Pipe
c-"0" Ring
d -Retainer -Slots Facing Out
e-Water Shutter -Opens Toward Inside of Tee Pipe
f-Exhaust Pipe Elbow
g-Clamps
h -Exhaust Hose
i -Exhaust Tube
j -Ground Strap
k -Exhaust Bellows
90-1 4499--1 887
EXHAUST SYSTEM -70-3
7.4 Litre
Exhaust System Component
Replacement
1.
To replace any componet(s) in exhaust system, the
following must be adhered to:
•
All mating joint surfaces must be clean.
• "0" rings must remain in groove to properly seal
joints to prevent leakage.
• Torque all screws and lockwashers to specifications.
•
Tighten all clamps securely.
a -Mating Surfaces -Must Be Clean
Inner Transom Plate
7D-4 -EXHAUST SYSTEM
MCM 330 8/W, MCM 230TR,
MCM 260TR, 5.7 Litre TR,
a-Retainer-Slots Toward Exhaust Pipe Elbow
b-Shutter -Opens Toward Transom Plate
c-"0" Ring
d -Exhaust Pipe Elbow
e -Screws and Lockwashers (3 Per Side) -Torque to 20-25 Lbs. Ft.
(27-34 N.m)
f-Clamps
g-Exhaust Hose
h-Exhaust Pipe -Casting No. 44141
i-Exhaust Bellows
Exhaust System Components 3 ln. Exhaust System
90-14499--1 887
a -Mating Surfaces -Must Be Clean
Inner Transom Plate
a-Retainer-Slots Toward Exhaust Pipe Elbow
b-Shutter -Opens Toward Transom Plate
c-"0" Rmg
d -Exhaust Pipe Elbow
e-Screws and Lock washers (3 Per Side)-Torque to 20-25 Lbs. Ft.
(27-34 N.m)
f-Clamps
g -Exhaust Hose
h -Exhaust Pipe -Casting No. 44391
i-Exhaust Bellows
Exhaust System Components 4 ln. Exhaust System
90-14499--1 887
3 ln. Exhaust Hose Extension
Kit 32-62364A 1
a -Original Exhaust Elbow or Exhaust Tube
b -Original Clamps
c-Original Exhaust Bellows
d -Original Exhaust Pipe
e -Clamps -From Kit
f-Exhaust Hose (3-1/4 ln. (83mm)) -From Kit
g-Exhaust Tube (3 ln. (76m)) -From Kit
EXHAUST SYSTEM -70-5
6 ln. Exhaust Hose Extension
Kit 32-59077 A 1
a-Original Exhaust Elbow or Exhaust Tube
b-Original Clamps
c-Original Exhaust Bellows
d -Original Exhaust Pipe
e-Clamps -From Kit
f-Exhaust Hose (4 ln. (102mm)) -From Kit
g-Exhaust Tube [4-13/16 ln. (148m)] -From Kit
4 ln. to 3 ln. Exhaust Reducer
Kit 44349A1
a-Reducer
b-Exhaust Tube
c -Hose Clamp
d -Exhaust Elbow
e -Exhaust Hose
70-6 -EXHAUST SYSTEM
Thru Transom Exhaust Flange
Shutter Replacement
1. Remove exhaust hose clamps, then hose. 2. Chisel rivets away from both support members.
3. Install new shutter as shown. Tighten screws and
nut securely.
4. Reinstall exhaust hose. Tighten clamps securely.
a -Shutter Hinge
b-Water Shutter -Opens Toward Outside of Boat
c -Support Member
d-Rivets (4)
05090
90-14499--1 887
Component Replacement
MIE 230, M IE 260, 5.0 Litre,
5.7 Litre, MIE 5.7 Ski Single
Exhaust Kit 48640A2
a-Screw and Nut (4)
b -Support Member
c-Water Shutter
d-Gasket
e -Exhaust Flange
f-Screws, Washers and Nuts (3)
g-Clamp
h -Cover ("Flapper"
)
IMPORTANT: If using a 2 into 1 collector system on an
MIE 340, collector outlet and related hose(s) and fitting(
s) must be a minimum of 5 in. I.D. to achieve
optimum performance.
AC0089
a -Hose -Cut to Fit
b-Hose -4 ln. (102mm) Long
c-Clamps -2 At Each Connection, Tighten Securely
d-Cut 2-3/8 ln. (60mm) From End of "Y" Pipe to Allow Use of 4 ln.
(102mm) Exhaust Hose
e -Connect to Thru Transom Exhaust Hose
90-14499--1 887
EXHAUST SYSTEM -70-7
DRIVE SYSTEMS
•
VELVET DRIVE®
{BORG-WARNER) TRANSMISSION
Index
Page
Torque Specifications ........................ 8A-1
Tools/Lubricants/Sealants .................... 8A-1
Specifications ................................ 8A-1
Transmission Fluid Specification ........... 8A-1
Transmission Fluid Capacity (Approximate) . 8A-2
Pressure Specification -Transmissions
Using White Spring
(Part No. 72N-242) ..................... 8A-2
Pressure Specification -Transmissions
'
Using Black Spring (Part No. 71-242) .... 8A-2
In-Line Transmission Output Shaft
Rolling Torque ......................... 8A-3
Identification ................................. 8A-3
MIE 230/260/5.7 Ski, MCM 370TRS (Forward
Mounted Engines S.N. 6721528 and
Above) Models with In-Line
Transmission .......................... 8A-3
MIE 230/260 Models with V-Drive
Transmission .......................... 8A-4
MIE 340, MCM 300 Tempest TRS/
MCM 320 EFI, 370TRS -S.N. 6721527
and Below/400TRS/400 Cyclone/
440 Cyclone/MCM 420/MCM 575/
460 Cyclone (Forward Mounted Engines
Models with In-Line Transmission ....... 8A-4
MIE 340 Models with V-Drive
Transmission .......................... 8A-5
Transom Mounted MCM and Production
Performance Models .................... 8A-5
In-Line Transmissions ..................... 8A-6
White Pressure Regulator Valve
Spring (Part Number 72N-242)
Identification ........................ 8A-6
V-Drive Transmissions ..................... 8A-6
White Pressure Regulator Valve
Spring (Part Number 72N-242)
Identification ........................ 8A-6
Important Information ........................ 8A-7
Shift Control and Cables ................... 8A-7
Engine ....................................8A-7
Transmission ............................. 8A-7
Propeller ..................... ............. 8A-7
Special Replacement Part Information ......... 8A-8
MCM 330 8-W, MCM Production
Performance Models .................... BA-8
MCM Production Performance (Front
Mounted) Engines .............. ........ 8A-8
Transmission Shift Levers ............... 8A-9
Shift Cable Adjustment ....................... 8A-9
Checking Transmission Fluid Level ............ SA-9
Changing Transmission Fluid ................ SA-10
Draining MCM and MIE Models with
In-Line Transmissions ................. SA-10
Draining MIE Models with V-Drive
Transmissions ........................ 8A-10
Filling Transmission ......................... 8A-11
Removal and Installation ..................... 8A-11
Inboard and V-Drive ...................... 8A-11
Stern Drive Models (Transom Mounted
Engines) .............................. 8A-12
Production Performance Stern Drive
Models (Front Mounted Engines) ....... SA-12
Pump Indexing .............................. 8A-13
Transmission Repair ......................... 8A-14
In-Line and V-Drive ....................... 8A-14
Stern Drive Transmission (Transom
Mounted Engine) Coupling
Replacement .......................... 8A-14
Stern Drive Transmission (Forward
Mounted Engine) Yoke Replacement ... 8A-15
Shift Lever Installation .................... 8A-15
Pressure Test ............................... 8A-16
Pressure Regulator Valve Spring
Identification .......................... 8A-16
Tailstock Assembly Repair ................... 8A-17
Removal/Installation ...................... 8A-18
Disassembly ............................. 8A-18
Cleaning and Inspection .................. 8A-18
Reassembly .............................. 8A-18
Transmission Venting ........................ 8A-19
DRIVE SYSTEM -SA 90-14499--1 887
Torque Specifications
Fastener Location Lbs. Ft. (N.m) Lbs. ln. (N.m)
Drain Plug (Bushing) 25 (34)
Fluid Hose to Bushing 25 (34)
Pump Housing to Adaptor
204-264
(23-29)
Rear Mounts to
Transmission
45 (61 )
Shift Lever to Valve
96-1 32
(1 1-15)
Tailstock to Transmission
(MCM Models)
50 (68)
Transmission to Flywheel
Housing
50 (68)
Yoke to Output Shaft
(MCM Forward Mounted
Engine Only)
100-200
(1 36-271 )
Neutral Start Switch
8-1 1
(1 1-14)
0 Tools/Lubricants/Sealants
Part
Number
Description
91 -34569A1 Slide Hammer Puller
92-861 54A1 Quicksilver 2-4-C Marine Lubricant
92-34227 Quicksilver Perfect Seal
92-32609-1 Quicksilver Loctite
92-86166 Quicksilver Bellows Adhesive
92-91 601 -1 Quicksilver RTV Sealer
Specifications
TRANSMISSION FLUID SPECIFICATION
Use only 10 wt. tractor hydraulic fluid meeting the
C3/To-2 specification (preferably Mobil 423, Chevron,
or Citgo). NOTE: Citgo has two grades of fluid meeting
the C3/To-2 specification; Citgo tractor hydraulic fluid,
and Citgo multi-purpose Dexron II -both are acceptable
for use.
90-14499--1 887 DRIVE SYSTEM -8A-1
TRANSMISSION FLUID CAPACITY (APPROXIMATE}
Engine Model
MIE 230/260
340, 5.0 Litre,
5.7 Litre, 7.4 Litre
MCM 330 (8-W)/
7.4 Litre TR
Production
Performance Models
In-Line Transmission
Qts. (litres}
1:1 -2 (1.9)
1.5:1 to 2.91:1 -3 (2.8)
2 (1 .9)
V-Drive Transmission
Qts. (litres}
4-1/2 (4.3)
.,