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Mercruiser marine engines mcm 454 mag mpi service repair manual sn0 l010029 and up

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This document provides an overview and introduction to Mercury Marine's service manual for GM V8 454 cid and 502 cid marine engines. It covers topics such as how to use the manual, page numbering conventions, reading parts manuals, directional references, engine rotation, serial number locations, propeller information, water testing new engines, factors that affect boat and engine performance, and more. The document is the first section of the service manual and aims to give technicians important background information before servicing the engines.

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Number 23 Printed in U.S.A. 90-861326--1 MARCH 1999©1999, Mercury Marine MARINE ENGINES SERVICE MANUAL GM V8 454 cid (7.4L) / 502 cid (8.2L) Book 1 of 2 Sections 1 thru 4
90-861326--1 MARCH 1999 Page i Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con- cerning 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. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. 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’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these prod- ucts, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. We could not possibly know of and advise the service trade 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 products 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 the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are 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. 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.
Page ii 90-861326--1 MARCH 1999 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual. 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 and, 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 automo- tive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor en- gine 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 parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replace- ment parts. Replacement Parts WARNING Electrical, ignition and fuel system components on MerCruiser 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 ig- nition component opening would permit sparks to ignite fuel vapors from fuel sys- tem leaks, if they existed.
90-861326--1 MARCH 1999 Page iii Models Covered in This Manual Gen. VI Engines Sterndrive (MCM) Model Serial Number MCM 454 Mag MPI 0L010029 & Up MCM 502 Mag MPI 0L017000 & Up Inboard (MIE) Model Serial Number MIE 454 Mag MPI Horizon 0L002200 & Up MIE 8.2L MPI 0L002450 & Up L-29 Engines Sterndrive (MCM) Model Serial Number MCM 7.4L MPI 0L010003 & Up Inboard (MIE) Model Serial Number MIE 7.4L MPI 0L002006 & Up
1 2 3 4 5 6 7 8 Important Information Removal And Installation Engine Electrical System Fuel System Cooling System Exhaust System Drives 9Power Steering 90-861326--1 MARCH 1999 Page v Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models - Bravo and Blackhawk Drives B - MCM Models - Bravo and Blackhawk Drives with Driveshaft Extension C - MIE Models - Velvet Drive Transmission D - MIE Models - Hurth Transmission Section 3 - Engine A - 454 cid (7.4L) / 502 cid (8.2L) Section 4 - Electrical System A - Starting System B - Ignition System C - Charging System D - Instrumentation E - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery System for Electronic Fuel Injection B - Multi-Port Fuel Injection Descriptions and System Operation C - Multi-Port Fuel Injection Disassembly and Reassembly D - Fuel Injection System Troubleshooting E - General System Diagnostics F - Trouble Code Diagnostics - 454/502 Mag MPI & 8.2L MPI G - Trouble Code Diagnostics - 7.4L MPI Section 6 - Cooling System A - Seawater Cooled Models B - Closed Cooled (Fresh Water) Models Section 7 - Exhaust System A - General B - Manifolds and Elbows C - Risers D - Collectors Section 8 - Drives A - Velvet Drive In-Line Transmission B - Velvet Drive 5000A Down Angle Transmission C - Velvet Drive 5000V V-Drive Transmission D - Hurth V-Drive Transmission E - Walter V-Drive Transmission F - Drive Shaft / Propeller Shaft Models Section 9 - Power Steering A - Pump
1 A GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-1 IMPORTANT INFORMATION Section 1A - General Information Table of Contents Introduction 1A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual 1A-2. . . . . . . . . . . . . . . Page Numbering 1A-2. . . . . . . . . . . . . . . . . . . How to Read a Parts Manual 1A-3. . . . . . . . . . . Directional References 1A-4. . . . . . . . . . . . . . . . . Engine Rotation 1A-4. . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number Locations 1A-5. . . . . . . . Propeller Information 1A-6. . . . . . . . . . . . . . . . . . Water Testing New Engines 1A-6. . . . . . . . . . . . Boat and Engine Performance 1A-7. . . . . . . . . . Boat Bottom 1A-7. . . . . . . . . . . . . . . . . . . . . . . Marine Fouling 1A-8. . . . . . . . . . . . . . . . . . . . . Weight Distribution 1A-9. . . . . . . . . . . . . . . . . . Water in Boat 1A-9. . . . . . . . . . . . . . . . . . . . . . Elevation and Climate 1A-9. . . . . . . . . . . . . . .
GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-2 90-861326--1 MARCH 1999 Introduction This comprehensive overhaul and repair manual is designed as a service guide for the models previously listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines. 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 warnings required for safety. 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. Sections and section parts are listed on the “Service Manual Outline” page following “V-8 Models Covered in This Manual” page. Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. a b c d e f g a - Section Number b - Section Part c - Page Number d - Manual Number e - Revision No. 4 f - Month Printed g - Year Printed
GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-3 How to Read a Parts Manual POWER STEERING PUMP ASSEMBLY 1 2 3 4 5 6 7 8 9 10 REF.REF. NO. PART NO. SYM. QTY. DESCRIPTION 1 90507A12 1 PUMP ASSEMBLY-Power Steering 2 36- 95805 1 CAP 3 73873A1 1 PULLEY 4 16- 41877 1 STUD 5 57- 65607T 1 V-BELT 6 32- 806684 1 HOSE-Pressure (FITTINGS ON BOTH ENDS) 7 25- 89879 1 O-RING 8 25- 806232 1 O-RING 9 13- 35048 1 LOCKWASHER (3/8 in.) 10 61990 1 CABLE TIE REF. NO. : Number shown next to part on exploded view PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM part number will be given in description column. QTY. : The quantity that must be ordered. DESCRIPTION : Description of part, what parts are included with a part (all indented items come with the main item above the indented parts), serial number information, and special information.
GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-4 90-861326--1 MARCH 1999 Directional References Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this service manual, all directional references are given as they appear when viewing boat from stern looking toward bow. 72000 STARBOARD (RIGHT) PORT (LEFT) FORE or BOW (FRONT) AFT or STERN (REAR) Engine Rotation Engine rotation is determined by observing flywheel rotation from the rear (stern or flywheel end) of the engine looking forward (toward 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. 72001 Standard Left-Hand Rotation
GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-5 Engine Serial Number Locations 72923 b a Stern Drive (MCM) a - Serial Number Plate b - Starter Motor 72924 b a Inboard (MIE) a - Serial Number Plate b - Starter Motor
GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-6 90-861326--1 MARCH 1999 Propeller Information Refer to the “Propeller” section in appropriate MerCruiser Sterndrive Service Manual, or order publication 90-86144-92, “Everything you need to know about propellers.” Changing diameter, pitch or coupling of a propeller will affect engine rpm and boat perfor- mance. The blade configuration also will affect performance. Two like propellers, same pitch and diameter, from two different manufacturers 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 is required. 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). Conversely, installing a propeller, allowing engine to run above the specified rpm limit, will cause excessive wear on internal engine parts which will lead to premature engine failure. 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.
GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-7 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 (1.5 m). 72002 a a - Critical Bottom Area For best speed and minimum spray, the corner between the bottom and the transom should be sharp. 72003 a bc a - Bottom b - Sharp Corner c - Transom (Stern) The bottom is referred to as having a “hook” if it is concave in the fore-and-aft direction. A hook causes more lift on the bottom near the transom and forces the bow to drop. This in- creases wetted surface and reduces boat speed. A hook, however, aids in planing and re- duces 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 sup- port directly under the transom. 72004 a b a - Hook b - Transom (Stern)
GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-8 90-861326--1 MARCH 1999 A “rocker” is the reverse of a hook. The bottom is convex or bulged in the fore-and-aft direc- tion. It can cause the boat to porpoise. 72005 a b a - Rocker b - Transom (Stern) Any hook, rocker or surface roughness on the bottom, particularly in the critical center-aft portion will have a negative effect on speed, often several miles per hour on a fast boat. Marine Fouling Fouling is an unwanted build-up (usually animal-vegetable-derived) occurring on the boat’s bottom and drive unit. Fouling adds up to drag, which reduces boat performance. In fresh water, fouling results from dirt, vegetable matter, algae or slime, chemicals, minerals and other pollutants. In salt water, barnacles, moss and other marine growth often produce dramatic build-up of material quickly. Therefore, it is important to keep the hull as clean as possible in all water conditions to maximize boat performance. Antifouling paint, if required, may be applied to boat hull observing the following precautions. IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors. CAUTION Avoid corrosion damage. Do not apply antifouling paint to MerCruiser drive unit or transom assembly. IMPORTANT: If antifouling protection is required, Tri-Butyl-Tin-Adipate (TBTA) base antifouling paints are recommended on MerCruiser boating applications. In areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law, copper base paints can be used on boat hull and boat transom. Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty. Observe the following: Avoid an electrical interconnection between the MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40mm) UNPAINTED area on transom of the boat around these items. 71176 a b a - Antifouling Paint b - MINIMUM 1-1/2 Inch (40 mm) UNPAINTED Area
GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-9 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 efficient angle (3 to 5 degrees). 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 suit his/her needs. Weight and passenger loading placed well forward increases the “wetted area” of the boat bottom and, in some cases, virtually destroys the good 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 perform- ance, 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. 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 apparent when an engine is propped out on a cool dry day in spring and later, on a hot, humid day in August, does not have the same performance. 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. A Quicksilver Propeller Repair Station or experienced marine dealer can determine how much diameter to remove from a lower-pitch propeller for specific high-elevation locations. In some cases, installing high altitude gears in the drive unit is possible and very beneficial. Weather conditions may effect the 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.
1 B MAINTENANCESERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1B-1 IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Lubricants / Sealants / Adhesives 1B-2. . . . . . . Maintenance Schedules 1B-3. . . . . . . . . . . . . . . . Maintenance Intervals 1B-3. . . . . . . . . . . . . . . Scheduled Maintenance That Can Be Performed By Owner/Operator 1B-3. . . . . . . Scheduled Maintenance That Should Be Done by Dealer 1B-4. . . . . . . . . . . . . . . . . . . . Scheduled Maintenance That Should Be Done by Dealer 1B-5. . . . . . . . . . . . . . . . . . . . Scheduled Maintenance That Can Be Performed By An Owner/Operator 1B-6. . . . Scheduled Maintenance That Should Be Done by Dealer 1B-6. . . . . . . . . . . . . . . . . . . . Tune-Up Specifications 1B-8. . . . . . . . . . . . . . . . MCM (Sterndrive) Models 1B-8. . . . . . . . . . . . MIE (Inboard) Models 1B-10. . . . . . . . . . . . . . Firing Order 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . Fluid Capacities 1B-11. . . . . . . . . . . . . . . . . . . . . . Engines 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . Transmissions 1B-12. . . . . . . . . . . . . . . . . . . . . Sterndrive Units 1B-12. . . . . . . . . . . . . . . . . . . 20-Hour Break-In Period 1B-12. . . . . . . . . . . . . . After Break-in Period 1B-13. . . . . . . . . . . . . . . . . End of First Season Checkup 1B-13. . . . . . . . . . Specifications 1B-14. . . . . . . . . . . . . . . . . . . . . . . . Fuel Recommendations 1B-14. . . . . . . . . . . . Test For Alcohol Content In Gasoline 1B-15. Power Steering Fluid 1B-15. . . . . . . . . . . . . . . . . Transmission Fluid 1B-15. . . . . . . . . . . . . . . . . . . Draining Instructions 1B-48. . . . . . . . . . . . . . . Recommissioning 1B-64. . . . . . . . . . . . . . . . . . Coolant for Closed Cooling System 1B-16. . . . . Crankcase Oil 1B-16. . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase 1B-17. . . . . . . . . . . . . . . Checking Engine Oil Level/Filling 1B-17. . . . Changing Oil and Filter 1B-18. . . . . . . . . . . . . . . . Changing Water Separating Fuel Filter 1B-19. . MCM (Sterndrive) Models 1B-19. . . . . . . . . . . MIE (Inboard) Models 1B-20. . . . . . . . . . . . . . Power Steering System 1B-21. . . . . . . . . . . . . . . Checking Fluid Level 1B-21. . . . . . . . . . . . . . . Filling and Bleeding 1B-22. . . . . . . . . . . . . . . . Closed Cooling System 1B-23. . . . . . . . . . . . . . . Checking Coolant Level 1B-23. . . . . . . . . . . . Flushing System MCM (Sterndrive) 1B-24. . Flushing System MIE (Inboard) - Except 454 Mag MPI Horizon 1B-26. . . . . . . Flushing System MIE (Inboard) 454 Mag MPI Horizon 1B-28. . . . . . . . . . . . . . Transmission Fluid 1B-32. . . . . . . . . . . . . . . . . . . Checking Fluid Level 1B-32. . . . . . . . . . . . . . . Lubrication 1B-33. . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable 1B-33. . . . . . . . . . . . . . . . . . . . . Shift Cable 1B-34. . . . . . . . . . . . . . . . . . . . . . . . Shift Cable and Transmission Linkage 1B-34. Engine Coupler / U-Joint Shaft Splines 1B-35. Drive Shaft Extension Models 1B-36. . . . . . . Starter Motor 1B-37. . . . . . . . . . . . . . . . . . . . . . Cleaning Flame Arrestor 1B-38. . . . . . . . . . . . . . Plastic Side Mounted Flame Arrestor 1B-38. Plastic Front Mounted Flame Arrestor 1B-39 Metal Side Mounted Flame Arrestor 1B-39. . Serpentine Drive Belt 1B-40. . . . . . . . . . . . . . . . . Component Location 1B-40. . . . . . . . . . . . . . . Inspecting 1B-42. . . . . . . . . . . . . . . . . . . . . . . . Replacing and/or Adjusting Tension 1B-42. . Ignition Timing 1B-43. . . . . . . . . . . . . . . . . . . . . . . Cold Weather or Extended Storage 1B-44. . . . . Precautions 1B-44. . . . . . . . . . . . . . . . . . . . . . . Power Package Layup 1B-45. . . . . . . . . . . . .
MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-2 90-861326--1 MARCH 1999 Lubricants / Sealants / Adhesives DESCRIPTION PART NUMBER Quicksilver Liquid Neoprene 92-25711--3 Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3 Loctite Pipe Sealant With Teflon Obtain Locally Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2
MAINTENANCESERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1B-3 Maintenance Schedules Maintenance Intervals Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a previously printed schedules, are generally based on an average boating application and environment. However, individual operating habits and personal mainte- nance preferences can have an impact on the suggested intervals. In consideration of these factors, MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed. In some cases, this may allow for more individual tasks to be performed in a single visit to the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner and servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, environment, and maintenance requirements. Always disconnect battery cables from battery BEFORE working around electrical systems components to prevent injury to yourself and damage to electrical system should a wire be accidentally shorted. Scheduled Maintenance That Can Be Performed By Owner/Operator NON-HORIZON MODELS NOTE: Only perform maintenance which applies to your particular power package. Task Interval Engine Crankcase Oil - Check Level Closed Cooling Coolant - Check Level Power Steering Fluid - Check Level Sterndrive Unit Oil - Check Level Battery - Check Level And Inspect For Damage Weekly Power Trim Pump Oil - Check level Anodes - Inspect For Erosion Gear Housing Water Pickups - Check For Marine Growth Or Debris Serpentine Drive Belt - Inspect Condition And Check Tension Every 100 Hours Of Operation Or 120 Days, Whichever Occurs First. Propeller Shaft - Lubricate Saltwater Use: Every 50 Hours Of Operation Or 60 Days, Whichever Occurs First. Power Package - Exterior Surfaces - Spray With Rust Preventative First. Freshwater Use: Every 100 Hours Of Operation Or 120 Days, Whichever Occurs First. Power Package Exterior Surfaces - Clean And Paint Once A Year Cooling System - Flush Seawater Section Saltwater Use: After Every Use.
MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-4 90-861326--1 MARCH 1999 Scheduled Maintenance That Should Be Done by Dealer NON-HORIZON MODELS NOTE: Only perform maintenance which applies to your particular power package. Task Interval Seawater Pickup Pump - Disassemble And Inspect Whenever Insufficient Seawater Flow Is Suspected. (If Operating Temperature Exceeds Normal Range.) Crankcase Oil and Filter - Change Ignition System - Clean And Inspect Condition Flame Arrestor and Crankcase Ventilation Hose - Clean and Inspect. Positive Crankcase Ventilation (PCV) Valve (If Equipped) - Change Sterndrive Unit Oil - Change Gimbal Ring Clamping Screws- Retorque to 50-55 lb-ft (67-74 Nm). Rear Engine Mounts - Check Torque To 38 lb-ft (52 Nm). Gimbal Bearing - Lubricate Cooling System - Clean And Inspect Engine Alignment - Check Engine Coupling Universal Joint Shaft Splines - Lubricate End Of First Boating Season and Steering System - Lubricate And Inspect For Loose, Damage Or Missing Parts End Of First Boating Season and Thereafter, Every 100 Hours Of Operation Or Once Yearly, Whichever Occurs First Electrical System - Check For Loose Or Damaged Wiring Cooling System Hoses And Clamps - Inspect For Damage And Deterioration. Check Clamps For Tightness Closed Cooling System Pressure Cap - Clean, Inspect And Test Continuity Circuit - Check Components For Loose Connections, Broken Or Frayed Wires Shift Cable, Throttle Cable And Linkage - Lubricate And Inspect For Loose, Damaged Or Missing Parts Engine Exhaust System - Inspect Externally For Damage, Deterioration And Restrictions. Check For Tightness Ignition System - Check Timing And Adjust As Needed
MAINTENANCESERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1B-5 Scheduled Maintenance That Should Be Done by Dealer NON-HORIZON MODELS NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering Head and Remote Control - Inspect And Lubricate End Of First Boating Season And Thereafter, Every 100 Hours Of Operation Throttle Body - Inspect , y Or Once Yearly, Whichever Occurs First Fuel Filter - Replace Quicksilver Mercathode System - Test Output Closed Cooling Coolant - Test for Alkalinity Once a Year Heat Exchanger - Clean Seawater Section Drive Unit Bellows and Clamps - Inspect Universal Joint Cross Bearings - Inspect End Of First Boating Season And Thereafter, Every 200 Hours Of Operation Or Once Yearly, Whichever Occurs First Closed Cooling Coolant - Replace Every 5 years or 1000 hours, whichever occurs first1 1Only if Extended Life 5/100 Ethylene Glycol Antifreeze/Coolant is used. If any non-compatible coolant is added to this coolant, coolant must be changed every 2 years or 400 hours, whichever occurs first. All coolants other than Extended Life 5/100 Ethylene Glycol Antifreeze/Coolant must be changed every 2 years or 400 hours, whichever occurs first.
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MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-6 90-861326--1 MARCH 1999 Scheduled Maintenance That Can Be Performed By An Owner/Operator HORIZON MODELS Recommended Maintenance Interval Engine Oil - Check Level Transmission Fluid - Check Level Before Every Use Closed Cooling - Check Level Power Package Surfaces - Spray with Quicksilver Corrosion Guard Saltwater Use: Yearly Scheduled Maintenance That Should Be Done by Dealer HORIZON MODELS Recommended Maintenance Interval Transmission Fluid - Change Crankcase Oil and Oil Filter - Change Flame Arrestor - Clean And Inspect Yearly Throttle and Shift Linkage - Lubricate Yearly Fuel Filter - Change Heat Exchanger - Clean Seawater Section Positive Crankcase Ventilation Valve - Replace Every Three Years Serpentine Belt - Check Tension y Closed Cooling Coolant - Replace Every Five Years or 1000 Hours of Operation,Whichever Occurs First 1 Power Package Surfaces - Spray with Quicksilver Corrosion Guard Yearly If Used In Saltwater Engine Alignment - Check Per Boat Builder Recommendations 1 Only if Extended Life Coolant is used. If any other coolant is added to the Extended Life Coolant, coolant must be changed every 2 years or 400 hours of operation, whichever occurs first. All coolants other than Extended Life Coolant must be changed every 2 years or 400 hours of operation, whichever occurs first.
MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-8 90-861326--1 MARCH 1999 Tune-Up Specifications MCM (Sterndrive) Models Model MCM 7.4L MPI MCM 454 Mag MPI MCM 502 Mag MPI Propshaft Horsepower (SAV1 Rating) 3101 (2752) 3851 4151 Propshaft Kilowatts (SAV1 Rating) 2311 (2052) 2871 3091 Number of Cylinders 8 Displacement 454 C.I.D (7.4L) 502 C.I.D. (8.2L) Bore/Stroke In. (mm) 4.25 x 4.00 (108 x 101.6) 4.47 x 4.00 (113.5 x 101.6) Compression Ratio 9.3:1 8.6:1 8.75:1 Compression Pressure Minimum 100 psi (690 kPa)6 Idle rpm (in Forward Gear)5 6003 Max. rpm (at W.O.T.) 4200-46003 4600-50003 Oil Pressure (at 2000 rpm) Minimum 30 psi (207 kPa) Min. Oil Pressure (at Idle) Minimum 4 psi (28 kPa) Electrical System 12 V Negative (–) Ground Fuel Pressure (Running) 43 psi (248 kPa) Min. Battery Requirements 650 cca / 825 mca / 150Ah Firing Order 1-8-4-3-6-5-7-2 Spark Plug Type AC MR43LTS Champion RV12YC NGK BPR6EFS AC MR43T Champion RV15YC4 NGK BR6FS Spark Plug Gap .045 in. (1.1 mm) .040 in. (1 mm) Timing (at Idle rpm) 8° BTDC4 Thermostat 160° F (71° C) 1 Power rated in accordance with NMMA (National Marine Manufacturer’s Association) rating procedures. 2 Power rated in accordance with SAV1 rating procedures. This rating procedure is used to certify that the engine complies with “Stage 1” Swiss Regulations. Horsepower differences shown result from differences in test rpm, allowable test tolerances, and/or installation of special kit components. 3 Measured using a accurate service tachometer with engine at normal operating temperature. 4 Timing must be set using a special procedure as outlined in the appropriate section of this manual. 5 Idle speed on EFI engines is not adjustable. 6 Minimum recorded compression in any one cylinder should not be less than 70 percent of the highest recorded cylinder.

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Mercruiser marine engines mcm 454 mag mpi service repair manual sn0 l010029 and up

  • 1. Number 23 Printed in U.S.A. 90-861326--1 MARCH 1999©1999, Mercury Marine MARINE ENGINES SERVICE MANUAL GM V8 454 cid (7.4L) / 502 cid (8.2L) Book 1 of 2 Sections 1 thru 4
  • 2. 90-861326--1 MARCH 1999 Page i Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con- cerning 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. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. 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’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these prod- ucts, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. We could not possibly know of and advise the service trade 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 products 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 the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are 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. 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.
  • 3. Page ii 90-861326--1 MARCH 1999 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual. 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 and, 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 automo- tive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor en- gine 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 parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replace- ment parts. Replacement Parts WARNING Electrical, ignition and fuel system components on MerCruiser 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 ig- nition component opening would permit sparks to ignite fuel vapors from fuel sys- tem leaks, if they existed.
  • 4. 90-861326--1 MARCH 1999 Page iii Models Covered in This Manual Gen. VI Engines Sterndrive (MCM) Model Serial Number MCM 454 Mag MPI 0L010029 & Up MCM 502 Mag MPI 0L017000 & Up Inboard (MIE) Model Serial Number MIE 454 Mag MPI Horizon 0L002200 & Up MIE 8.2L MPI 0L002450 & Up L-29 Engines Sterndrive (MCM) Model Serial Number MCM 7.4L MPI 0L010003 & Up Inboard (MIE) Model Serial Number MIE 7.4L MPI 0L002006 & Up
  • 5. 1 2 3 4 5 6 7 8 Important Information Removal And Installation Engine Electrical System Fuel System Cooling System Exhaust System Drives 9Power Steering 90-861326--1 MARCH 1999 Page v Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models - Bravo and Blackhawk Drives B - MCM Models - Bravo and Blackhawk Drives with Driveshaft Extension C - MIE Models - Velvet Drive Transmission D - MIE Models - Hurth Transmission Section 3 - Engine A - 454 cid (7.4L) / 502 cid (8.2L) Section 4 - Electrical System A - Starting System B - Ignition System C - Charging System D - Instrumentation E - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery System for Electronic Fuel Injection B - Multi-Port Fuel Injection Descriptions and System Operation C - Multi-Port Fuel Injection Disassembly and Reassembly D - Fuel Injection System Troubleshooting E - General System Diagnostics F - Trouble Code Diagnostics - 454/502 Mag MPI & 8.2L MPI G - Trouble Code Diagnostics - 7.4L MPI Section 6 - Cooling System A - Seawater Cooled Models B - Closed Cooled (Fresh Water) Models Section 7 - Exhaust System A - General B - Manifolds and Elbows C - Risers D - Collectors Section 8 - Drives A - Velvet Drive In-Line Transmission B - Velvet Drive 5000A Down Angle Transmission C - Velvet Drive 5000V V-Drive Transmission D - Hurth V-Drive Transmission E - Walter V-Drive Transmission F - Drive Shaft / Propeller Shaft Models Section 9 - Power Steering A - Pump
  • 6. 1 A GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-1 IMPORTANT INFORMATION Section 1A - General Information Table of Contents Introduction 1A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual 1A-2. . . . . . . . . . . . . . . Page Numbering 1A-2. . . . . . . . . . . . . . . . . . . How to Read a Parts Manual 1A-3. . . . . . . . . . . Directional References 1A-4. . . . . . . . . . . . . . . . . Engine Rotation 1A-4. . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number Locations 1A-5. . . . . . . . Propeller Information 1A-6. . . . . . . . . . . . . . . . . . Water Testing New Engines 1A-6. . . . . . . . . . . . Boat and Engine Performance 1A-7. . . . . . . . . . Boat Bottom 1A-7. . . . . . . . . . . . . . . . . . . . . . . Marine Fouling 1A-8. . . . . . . . . . . . . . . . . . . . . Weight Distribution 1A-9. . . . . . . . . . . . . . . . . . Water in Boat 1A-9. . . . . . . . . . . . . . . . . . . . . . Elevation and Climate 1A-9. . . . . . . . . . . . . . .
  • 7. GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-2 90-861326--1 MARCH 1999 Introduction This comprehensive overhaul and repair manual is designed as a service guide for the models previously listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines. 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 warnings required for safety. 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. Sections and section parts are listed on the “Service Manual Outline” page following “V-8 Models Covered in This Manual” page. Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. a b c d e f g a - Section Number b - Section Part c - Page Number d - Manual Number e - Revision No. 4 f - Month Printed g - Year Printed
  • 8. GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-3 How to Read a Parts Manual POWER STEERING PUMP ASSEMBLY 1 2 3 4 5 6 7 8 9 10 REF.REF. NO. PART NO. SYM. QTY. DESCRIPTION 1 90507A12 1 PUMP ASSEMBLY-Power Steering 2 36- 95805 1 CAP 3 73873A1 1 PULLEY 4 16- 41877 1 STUD 5 57- 65607T 1 V-BELT 6 32- 806684 1 HOSE-Pressure (FITTINGS ON BOTH ENDS) 7 25- 89879 1 O-RING 8 25- 806232 1 O-RING 9 13- 35048 1 LOCKWASHER (3/8 in.) 10 61990 1 CABLE TIE REF. NO. : Number shown next to part on exploded view PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM part number will be given in description column. QTY. : The quantity that must be ordered. DESCRIPTION : Description of part, what parts are included with a part (all indented items come with the main item above the indented parts), serial number information, and special information.
  • 9. GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-4 90-861326--1 MARCH 1999 Directional References Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this service manual, all directional references are given as they appear when viewing boat from stern looking toward bow. 72000 STARBOARD (RIGHT) PORT (LEFT) FORE or BOW (FRONT) AFT or STERN (REAR) Engine Rotation Engine rotation is determined by observing flywheel rotation from the rear (stern or flywheel end) of the engine looking forward (toward 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. 72001 Standard Left-Hand Rotation
  • 10. GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-5 Engine Serial Number Locations 72923 b a Stern Drive (MCM) a - Serial Number Plate b - Starter Motor 72924 b a Inboard (MIE) a - Serial Number Plate b - Starter Motor
  • 11. GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-6 90-861326--1 MARCH 1999 Propeller Information Refer to the “Propeller” section in appropriate MerCruiser Sterndrive Service Manual, or order publication 90-86144-92, “Everything you need to know about propellers.” Changing diameter, pitch or coupling of a propeller will affect engine rpm and boat perfor- mance. The blade configuration also will affect performance. Two like propellers, same pitch and diameter, from two different manufacturers 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 is required. 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). Conversely, installing a propeller, allowing engine to run above the specified rpm limit, will cause excessive wear on internal engine parts which will lead to premature engine failure. 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.
  • 12. GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-7 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 (1.5 m). 72002 a a - Critical Bottom Area For best speed and minimum spray, the corner between the bottom and the transom should be sharp. 72003 a bc a - Bottom b - Sharp Corner c - Transom (Stern) The bottom is referred to as having a “hook” if it is concave in the fore-and-aft direction. A hook causes more lift on the bottom near the transom and forces the bow to drop. This in- creases wetted surface and reduces boat speed. A hook, however, aids in planing and re- duces 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 sup- port directly under the transom. 72004 a b a - Hook b - Transom (Stern)
  • 13. GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A-8 90-861326--1 MARCH 1999 A “rocker” is the reverse of a hook. The bottom is convex or bulged in the fore-and-aft direc- tion. It can cause the boat to porpoise. 72005 a b a - Rocker b - Transom (Stern) Any hook, rocker or surface roughness on the bottom, particularly in the critical center-aft portion will have a negative effect on speed, often several miles per hour on a fast boat. Marine Fouling Fouling is an unwanted build-up (usually animal-vegetable-derived) occurring on the boat’s bottom and drive unit. Fouling adds up to drag, which reduces boat performance. In fresh water, fouling results from dirt, vegetable matter, algae or slime, chemicals, minerals and other pollutants. In salt water, barnacles, moss and other marine growth often produce dramatic build-up of material quickly. Therefore, it is important to keep the hull as clean as possible in all water conditions to maximize boat performance. Antifouling paint, if required, may be applied to boat hull observing the following precautions. IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors. CAUTION Avoid corrosion damage. Do not apply antifouling paint to MerCruiser drive unit or transom assembly. IMPORTANT: If antifouling protection is required, Tri-Butyl-Tin-Adipate (TBTA) base antifouling paints are recommended on MerCruiser boating applications. In areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law, copper base paints can be used on boat hull and boat transom. Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty. Observe the following: Avoid an electrical interconnection between the MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40mm) UNPAINTED area on transom of the boat around these items. 71176 a b a - Antifouling Paint b - MINIMUM 1-1/2 Inch (40 mm) UNPAINTED Area
  • 14. GENERAL INFORMATIONSERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1A-9 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 efficient angle (3 to 5 degrees). 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 suit his/her needs. Weight and passenger loading placed well forward increases the “wetted area” of the boat bottom and, in some cases, virtually destroys the good 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 perform- ance, 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. 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 apparent when an engine is propped out on a cool dry day in spring and later, on a hot, humid day in August, does not have the same performance. 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. A Quicksilver Propeller Repair Station or experienced marine dealer can determine how much diameter to remove from a lower-pitch propeller for specific high-elevation locations. In some cases, installing high altitude gears in the drive unit is possible and very beneficial. Weather conditions may effect the 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.
  • 15. 1 B MAINTENANCESERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1B-1 IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Lubricants / Sealants / Adhesives 1B-2. . . . . . . Maintenance Schedules 1B-3. . . . . . . . . . . . . . . . Maintenance Intervals 1B-3. . . . . . . . . . . . . . . Scheduled Maintenance That Can Be Performed By Owner/Operator 1B-3. . . . . . . Scheduled Maintenance That Should Be Done by Dealer 1B-4. . . . . . . . . . . . . . . . . . . . Scheduled Maintenance That Should Be Done by Dealer 1B-5. . . . . . . . . . . . . . . . . . . . Scheduled Maintenance That Can Be Performed By An Owner/Operator 1B-6. . . . Scheduled Maintenance That Should Be Done by Dealer 1B-6. . . . . . . . . . . . . . . . . . . . Tune-Up Specifications 1B-8. . . . . . . . . . . . . . . . MCM (Sterndrive) Models 1B-8. . . . . . . . . . . . MIE (Inboard) Models 1B-10. . . . . . . . . . . . . . Firing Order 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . Fluid Capacities 1B-11. . . . . . . . . . . . . . . . . . . . . . Engines 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . Transmissions 1B-12. . . . . . . . . . . . . . . . . . . . . Sterndrive Units 1B-12. . . . . . . . . . . . . . . . . . . 20-Hour Break-In Period 1B-12. . . . . . . . . . . . . . After Break-in Period 1B-13. . . . . . . . . . . . . . . . . End of First Season Checkup 1B-13. . . . . . . . . . Specifications 1B-14. . . . . . . . . . . . . . . . . . . . . . . . Fuel Recommendations 1B-14. . . . . . . . . . . . Test For Alcohol Content In Gasoline 1B-15. Power Steering Fluid 1B-15. . . . . . . . . . . . . . . . . Transmission Fluid 1B-15. . . . . . . . . . . . . . . . . . . Draining Instructions 1B-48. . . . . . . . . . . . . . . Recommissioning 1B-64. . . . . . . . . . . . . . . . . . Coolant for Closed Cooling System 1B-16. . . . . Crankcase Oil 1B-16. . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase 1B-17. . . . . . . . . . . . . . . Checking Engine Oil Level/Filling 1B-17. . . . Changing Oil and Filter 1B-18. . . . . . . . . . . . . . . . Changing Water Separating Fuel Filter 1B-19. . MCM (Sterndrive) Models 1B-19. . . . . . . . . . . MIE (Inboard) Models 1B-20. . . . . . . . . . . . . . Power Steering System 1B-21. . . . . . . . . . . . . . . Checking Fluid Level 1B-21. . . . . . . . . . . . . . . Filling and Bleeding 1B-22. . . . . . . . . . . . . . . . Closed Cooling System 1B-23. . . . . . . . . . . . . . . Checking Coolant Level 1B-23. . . . . . . . . . . . Flushing System MCM (Sterndrive) 1B-24. . Flushing System MIE (Inboard) - Except 454 Mag MPI Horizon 1B-26. . . . . . . Flushing System MIE (Inboard) 454 Mag MPI Horizon 1B-28. . . . . . . . . . . . . . Transmission Fluid 1B-32. . . . . . . . . . . . . . . . . . . Checking Fluid Level 1B-32. . . . . . . . . . . . . . . Lubrication 1B-33. . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable 1B-33. . . . . . . . . . . . . . . . . . . . . Shift Cable 1B-34. . . . . . . . . . . . . . . . . . . . . . . . Shift Cable and Transmission Linkage 1B-34. Engine Coupler / U-Joint Shaft Splines 1B-35. Drive Shaft Extension Models 1B-36. . . . . . . Starter Motor 1B-37. . . . . . . . . . . . . . . . . . . . . . Cleaning Flame Arrestor 1B-38. . . . . . . . . . . . . . Plastic Side Mounted Flame Arrestor 1B-38. Plastic Front Mounted Flame Arrestor 1B-39 Metal Side Mounted Flame Arrestor 1B-39. . Serpentine Drive Belt 1B-40. . . . . . . . . . . . . . . . . Component Location 1B-40. . . . . . . . . . . . . . . Inspecting 1B-42. . . . . . . . . . . . . . . . . . . . . . . . Replacing and/or Adjusting Tension 1B-42. . Ignition Timing 1B-43. . . . . . . . . . . . . . . . . . . . . . . Cold Weather or Extended Storage 1B-44. . . . . Precautions 1B-44. . . . . . . . . . . . . . . . . . . . . . . Power Package Layup 1B-45. . . . . . . . . . . . .
  • 16. MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-2 90-861326--1 MARCH 1999 Lubricants / Sealants / Adhesives DESCRIPTION PART NUMBER Quicksilver Liquid Neoprene 92-25711--3 Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3 Loctite Pipe Sealant With Teflon Obtain Locally Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2
  • 17. MAINTENANCESERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1B-3 Maintenance Schedules Maintenance Intervals Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a previously printed schedules, are generally based on an average boating application and environment. However, individual operating habits and personal mainte- nance preferences can have an impact on the suggested intervals. In consideration of these factors, MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed. In some cases, this may allow for more individual tasks to be performed in a single visit to the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner and servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, environment, and maintenance requirements. Always disconnect battery cables from battery BEFORE working around electrical systems components to prevent injury to yourself and damage to electrical system should a wire be accidentally shorted. Scheduled Maintenance That Can Be Performed By Owner/Operator NON-HORIZON MODELS NOTE: Only perform maintenance which applies to your particular power package. Task Interval Engine Crankcase Oil - Check Level Closed Cooling Coolant - Check Level Power Steering Fluid - Check Level Sterndrive Unit Oil - Check Level Battery - Check Level And Inspect For Damage Weekly Power Trim Pump Oil - Check level Anodes - Inspect For Erosion Gear Housing Water Pickups - Check For Marine Growth Or Debris Serpentine Drive Belt - Inspect Condition And Check Tension Every 100 Hours Of Operation Or 120 Days, Whichever Occurs First. Propeller Shaft - Lubricate Saltwater Use: Every 50 Hours Of Operation Or 60 Days, Whichever Occurs First. Power Package - Exterior Surfaces - Spray With Rust Preventative First. Freshwater Use: Every 100 Hours Of Operation Or 120 Days, Whichever Occurs First. Power Package Exterior Surfaces - Clean And Paint Once A Year Cooling System - Flush Seawater Section Saltwater Use: After Every Use.
  • 18. MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-4 90-861326--1 MARCH 1999 Scheduled Maintenance That Should Be Done by Dealer NON-HORIZON MODELS NOTE: Only perform maintenance which applies to your particular power package. Task Interval Seawater Pickup Pump - Disassemble And Inspect Whenever Insufficient Seawater Flow Is Suspected. (If Operating Temperature Exceeds Normal Range.) Crankcase Oil and Filter - Change Ignition System - Clean And Inspect Condition Flame Arrestor and Crankcase Ventilation Hose - Clean and Inspect. Positive Crankcase Ventilation (PCV) Valve (If Equipped) - Change Sterndrive Unit Oil - Change Gimbal Ring Clamping Screws- Retorque to 50-55 lb-ft (67-74 Nm). Rear Engine Mounts - Check Torque To 38 lb-ft (52 Nm). Gimbal Bearing - Lubricate Cooling System - Clean And Inspect Engine Alignment - Check Engine Coupling Universal Joint Shaft Splines - Lubricate End Of First Boating Season and Steering System - Lubricate And Inspect For Loose, Damage Or Missing Parts End Of First Boating Season and Thereafter, Every 100 Hours Of Operation Or Once Yearly, Whichever Occurs First Electrical System - Check For Loose Or Damaged Wiring Cooling System Hoses And Clamps - Inspect For Damage And Deterioration. Check Clamps For Tightness Closed Cooling System Pressure Cap - Clean, Inspect And Test Continuity Circuit - Check Components For Loose Connections, Broken Or Frayed Wires Shift Cable, Throttle Cable And Linkage - Lubricate And Inspect For Loose, Damaged Or Missing Parts Engine Exhaust System - Inspect Externally For Damage, Deterioration And Restrictions. Check For Tightness Ignition System - Check Timing And Adjust As Needed
  • 19. MAINTENANCESERVICE MANUAL NUMBER 23 90-861326--1 MARCH 1999 Page 1B-5 Scheduled Maintenance That Should Be Done by Dealer NON-HORIZON MODELS NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering Head and Remote Control - Inspect And Lubricate End Of First Boating Season And Thereafter, Every 100 Hours Of Operation Throttle Body - Inspect , y Or Once Yearly, Whichever Occurs First Fuel Filter - Replace Quicksilver Mercathode System - Test Output Closed Cooling Coolant - Test for Alkalinity Once a Year Heat Exchanger - Clean Seawater Section Drive Unit Bellows and Clamps - Inspect Universal Joint Cross Bearings - Inspect End Of First Boating Season And Thereafter, Every 200 Hours Of Operation Or Once Yearly, Whichever Occurs First Closed Cooling Coolant - Replace Every 5 years or 1000 hours, whichever occurs first1 1Only if Extended Life 5/100 Ethylene Glycol Antifreeze/Coolant is used. If any non-compatible coolant is added to this coolant, coolant must be changed every 2 years or 400 hours, whichever occurs first. All coolants other than Extended Life 5/100 Ethylene Glycol Antifreeze/Coolant must be changed every 2 years or 400 hours, whichever occurs first.
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  • 21. MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-6 90-861326--1 MARCH 1999 Scheduled Maintenance That Can Be Performed By An Owner/Operator HORIZON MODELS Recommended Maintenance Interval Engine Oil - Check Level Transmission Fluid - Check Level Before Every Use Closed Cooling - Check Level Power Package Surfaces - Spray with Quicksilver Corrosion Guard Saltwater Use: Yearly Scheduled Maintenance That Should Be Done by Dealer HORIZON MODELS Recommended Maintenance Interval Transmission Fluid - Change Crankcase Oil and Oil Filter - Change Flame Arrestor - Clean And Inspect Yearly Throttle and Shift Linkage - Lubricate Yearly Fuel Filter - Change Heat Exchanger - Clean Seawater Section Positive Crankcase Ventilation Valve - Replace Every Three Years Serpentine Belt - Check Tension y Closed Cooling Coolant - Replace Every Five Years or 1000 Hours of Operation,Whichever Occurs First 1 Power Package Surfaces - Spray with Quicksilver Corrosion Guard Yearly If Used In Saltwater Engine Alignment - Check Per Boat Builder Recommendations 1 Only if Extended Life Coolant is used. If any other coolant is added to the Extended Life Coolant, coolant must be changed every 2 years or 400 hours of operation, whichever occurs first. All coolants other than Extended Life Coolant must be changed every 2 years or 400 hours of operation, whichever occurs first.
  • 22. MAINTENANCE SERVICE MANUAL NUMBER 23 Page 1B-8 90-861326--1 MARCH 1999 Tune-Up Specifications MCM (Sterndrive) Models Model MCM 7.4L MPI MCM 454 Mag MPI MCM 502 Mag MPI Propshaft Horsepower (SAV1 Rating) 3101 (2752) 3851 4151 Propshaft Kilowatts (SAV1 Rating) 2311 (2052) 2871 3091 Number of Cylinders 8 Displacement 454 C.I.D (7.4L) 502 C.I.D. (8.2L) Bore/Stroke In. (mm) 4.25 x 4.00 (108 x 101.6) 4.47 x 4.00 (113.5 x 101.6) Compression Ratio 9.3:1 8.6:1 8.75:1 Compression Pressure Minimum 100 psi (690 kPa)6 Idle rpm (in Forward Gear)5 6003 Max. rpm (at W.O.T.) 4200-46003 4600-50003 Oil Pressure (at 2000 rpm) Minimum 30 psi (207 kPa) Min. Oil Pressure (at Idle) Minimum 4 psi (28 kPa) Electrical System 12 V Negative (–) Ground Fuel Pressure (Running) 43 psi (248 kPa) Min. Battery Requirements 650 cca / 825 mca / 150Ah Firing Order 1-8-4-3-6-5-7-2 Spark Plug Type AC MR43LTS Champion RV12YC NGK BPR6EFS AC MR43T Champion RV15YC4 NGK BR6FS Spark Plug Gap .045 in. (1.1 mm) .040 in. (1 mm) Timing (at Idle rpm) 8° BTDC4 Thermostat 160° F (71° C) 1 Power rated in accordance with NMMA (National Marine Manufacturer’s Association) rating procedures. 2 Power rated in accordance with SAV1 rating procedures. This rating procedure is used to certify that the engine complies with “Stage 1” Swiss Regulations. Horsepower differences shown result from differences in test rpm, allowable test tolerances, and/or installation of special kit components. 3 Measured using a accurate service tachometer with engine at normal operating temperature. 4 Timing must be set using a special procedure as outlined in the appropriate section of this manual. 5 Idle speed on EFI engines is not adjustable. 6 Minimum recorded compression in any one cylinder should not be less than 70 percent of the highest recorded cylinder.