Mercury Marine MerCruiser Service Manual #18 MARINE ENGINES - GM V-6 262 CID (4.3L)

Balance Shaft Including Gen+ Engines 
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This Workshop Service Repair manual PDF download for the GM V-6 262 CID (4.3L) Balance Shaft Including Gen+ Engines MARINE ENGINES Mercury Marine MerCruiser has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

V-6 Models Covered in This Manual
Model - Serial Number - Model Year
MCM 4.3L Alpha - OF000615 - OF800000 - 1993 - 1996
MCM 4.3LX Alpha - OF001220 - OF800000 - 1993 - 1996
MCM 4.3LX Gen+ Alpha - OF803000 and Above - 1996 and Above
MCM 4.3LXH Gen+ Alpha - OF803114 and Above - 1996 and Above
MCM 262 Magnum EFI Gen + Alpha - OF803800 and Above - 1996 and Above
MCM 4.3LX Bravo - OF605305 - OF800000 - 1996
MCM 4.3LX Gen+ Bravo - OF831000 and Above - 1996 and Above
MCM 4.3LXH Gen+ Bravo - OF803400 and Above - 1996 and Above
MCM 262 Magnum EFI Gen+ Bravo - OF803802 and Above - 1996 and Above


TABLE OF CONTENTS :

SECTION 1 - Important Information
SECTION 2 - Removal and Installation
SECTION 3 - Engine
SECTION 4 - Electrical Systems
SECTION 5 - Fuel System
SECTION 6 - Cooling System
SECTION 7 - Exhaust System
SECTION 8 - Power Steering


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 90-823226--1 996
Total Pages : 638


All Official Mercury Marine Manuals for MerCruiser Sterndrives and Inboards include easy to follow, step-by-step illustrated procedures based on the complete dismantling, repair, and assembling of boat motors, from the simplest repair to complex procedures, this manuals give you everything you need to do the job with confidence.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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SECTION 1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
SECTION 2 - Removal and Installation
A - MCM Models - Alpha Drives
A - MCM Models - Bravo Drives
SECTION 3 - Engine
A - 262 CID / 4.3L
SECTION 4 - Electrical Systems
A - Starting System
B - Ignition System
C - Charging System
D - Instrumentation
E - Wiring Diagrams
SECTION 5 - Fuel System
A - Fuel Delivery System
B - MerCarb 2 Barrel Carburetor
C - Weber 4 Barrel Carburetor
D - Electronic Fuel Injection (Throttle Body)
A - BSO / SAV Emission
SECTION 6 - Cooling System
A - Seawater Cooled Models
B - Closed Cooled Models
SECTION 7 - Exhaust System
A - General
B - Manifold and Elbows
C - Risers
D - Collectors
SECTION 8 - Power Steering
A - Pump

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90-823226
Notice
Notice to Users of This Manual
Engine Mechanical Replacement Parts Components
V-6 Models Covered in This Manual
Service Manual Outline
1. IMPORTANT INFORMATION
1A. GENERAL INFORMATION
Table of Contents
Introduction How to Use This Manual
Page Numbering
How To Read Parts Manual
Directional References Engine Serial Number Locations
Propeller Information Engine Rotation
Water Testing New Engines
Boat and Engine Performance
Boat Bottom
Marine Fouling
Weight Distribution Elevation and Climate
Water in Boat
1B. MAINTENANCE
Table of Contents
Maintenance Schedules
Maintenance Intervals
Alpha Models
Bravo Models
Tune-Up Specifications
Tune-Up Specifications
Fluid Capacities
Hour Break-In Period
Fuel, Oil, Fluid, and Coolant Specifications
Fuel
Crankcase Oil
Maintaining Crankcase Oil Level
Overfilled Engine Crankcase
Power Steering Fluid
Coolant for Closed Cooling System
Maintaining Power Steering Pump Fluid Level
With Engine Warm
Changing Oil and Filter
With Engine Cold
Filling and Bleeding Power Steering System
Maintaining Closed Cooling Flushing Cooling System Coolant Level
Lubrication
Throttle Cable
Shift Cable
Engine Coupler/U-Joint Shaft Splines
Audio Warning System Cold Weather or Extended Storage
Maintenance Precautions
Layup
Draining Instructions
Draining Seawater (Raw-Water) Cooled Models
Draining Seawater Section of Closed Cooled (Coolant) Models
Recommissioning
1C. TROUBLESHOOTING
Table of Contents
Precautions
Used Spark Plug Analysis
Wet Fouling (Oil Deposits)
Spark Plug Analysis
Normal Condition
Cold Fouling
Chipped Insulator
Overheating Scavenger Deposits
Pre-Ignition Damage High Speed Glazing
Reversed Coil Polarity Mechanical Damage
Splashed Deposits
Poor Boat Performance and/or Poor Maneuverability
Improper Full Throttle Engine RPM
RPM Too High
RPM Too Low
Engine Cranks Over But Will Not Start Or Is Hard To Start
Important Information
Thunderbolt IV and V Ignition ( No Spark)
Testing Thunderbolt IV System
WARNING
Testing Thunderbolt V Ignition System
Fuel System Rich
Fuel System Lean
Miscellaneous
Engine Will Not Crank Over/Starter Inoperative
Charging System Inoperative
Noisy Alternator
Instrumentation Malfunction
Radio Noise
Poor Fuel Efficiency
Carburetor Malfunction
Carburetor Malfunction (continued)
Engine Runs Poorly At Idle
Engine Acceleration Is Poor
Engine Runs Poorly At High RPM
Troubleshooting With Vacuum Gauge
Engine Noise
Important Information
Valve Cover Area
Cylinder Area
Camshaft Area
Crankshaft Area
Miscellaneous
Oil Pressure
Low Oil Pressure
High Oil Pressure
Excessive Oil Consumption
Water in Engine
Important Information
Water In Crankcase
Water On Top Pistons
Engine Overheats (Mechanical)
Engine Overheats (Cooling System)
Insufficient Water Flow From Belt Driven Seawater Pump
Power Steering
Poor, Erratic, or No Assist
Noisy Pump
Fluid Leaks
2. REMOVAL ANDINSTALLATION
2A. MCM MODELS - ALPHA ONE DRIVES
Table of Contents
Torque Specification
Tools/Lubricants/Adhesives/Sealants
Removal
Engine Removal
Installation
Engine Installation/Alignment
Engine Connections
2B. MCM MODELS - BRAVO DRIVES
Table of Contents
Torque Specifications
Tools/Lubricants/Adhesives/Sealants
Removal
Installation
Engine Installation/Alignment
Engine Connections
Throttle Connections
3. ENGINE
3A. 262 CID (4.3L)
Table of Contents
Torque Specifications 4.3L/4.3LX Engines
Torque Specifications 4.3L/4.3LX Engines (continued)
Tools/Lubricants/Sealants
Engine Specifications
CID / 4.3L Engine Specifications (Does Not Include Gen +)
CID / 4.3L Engine Specifications (Does Not Include Gen +)
CID / 4.3L Engine Specifications (Does Not Include Gen +)
CID / 4.3L Engine Specifications (Does Not Include Gen +)
CID / 4.3L Gen + Engine Specifications
CID / 4.3L Engine Gen + Specifications
CID / 4.3L Gen + Engine Specifications
CID / 4.3L Gen + Engine Specifications
CID / 4.3L Gen + Engine Specifications
Cylinder Head Identification
General
Engine Identification
Engine Rotation
Crankshaft Cylinder Head
Valve Train Piston and Connecting Rods
Camshaft and Drive
Intake Manifold
Balance Shaft
Lubrication System
Bearing Failures
Piston Failures
Pre-Ignition
Detonation
Engine Mounts Rocker Arm Cover
Removal
Installation
Installation
Intake Manifold
Removal
Cleaning and Inspection
Rocker Arm/Push Rod Hydraulic Roller Valve Lifters
Removal
Cleaning and Inspection
Installation
Locating Noisy Lifters Removal
Cleaning and Inspection
Installation
Valve Stem Oil Seal/Valve Spring
Removal - Head Installed
Valve Assembly (Exploded View)
Installation - Head Installed
Cylinder Head
Removal
Cleaning and Inspection
Installation
Cylinder Head and Valve Conditioning
Disassembly
Cleaning Inspection
Valve Springs - Checking Tension
Valve Guide Bore Repair
Valve Seat Repair Valve Grinding
Reassembly
Dipstick Specifications
All Engines
Oil Pan
Removal
Installation
Oil Pump
Removal Cleaning and Inspection
Reassembly
Disassembly
Installation Installation
Torsional Damper
Removal
Crankcase Front Cover/Oil Seal
Oil Seal Replacement (Without Removing Front Cover)
Crankcase Front Cover
Removal
Cleaning and Inspection
Flywheel
Removal
Inspection
Installation
Cleaning and Inspection
Rear Main Oil Seal
Removal
Installation Cleaning and Inspection
Installation
Rear Main Oil Seal Retainer
Removal
Main Bearings
Inspection
Checking Clearances
Replacement
Connecting Rod Bearings
Inspection and Replacement
Connecting Rod/Piston Assembly
Removal
Disassembly
Cleaning and Inspection
Reassembly
Installation
Crankshaft
Removal
Cleaning and Inspection
Installation
Cleaning and Inspection
Timing Chain and Sprocket
Removal
Installation - Timing Chain
Checking Timing Chain Deflection
Crankshaft Sprocket
Removal
Installation
Balance Shaft/Gears
Removal
Cleaning and Inspection
Installation
Camshaft
Measuring Lobe Lift
Removal Installation
Camshaft Bearings
Removal
Inspection
Installation
Inspection
Cylinder Block
Cleaning and Inspection
Oil Filter By-Pass Valve
Inspection and/or Replacement
4. ELECTRICAL SYSTEMS
4A. STARTING SYSTEM
Table of Contents
Starters (PG260 And Delco-Remy)
Specifications
Torque Specifications
Lubricants, Sealers and Adhesives
Identification Battery Cable Recommendations
Starting System Components For PG260 (Typical Diagram)
Starting System Components for Delco-Remy Direct Drive Starter (Typical Diagram)
PG 260 Starter Motor (Exploded View)
Delco-Remy Starter Motor (Exploded View)
Replacement Parts Warning
Maintenance
Testing WARNING CAUTION
Storage
Description
Positive Current Flow
Solenoid Switch
Periodic Inspection
Starter Motor Repair
Removal
Disassembly
Cleaning and Inspection
Armature Tests
Armature Bearing (Commutator End)
Shaft Assembly Bearing
Gear Bearing
Drive End Housing Bearing
Brushes and Brush Holder
Reassembly
Clearances
Standard Starter Slave Solenoid
Testing/Replacement
Installation
Delco PG 260
Identification
Replacement Parts Warning Solenoid Switch
Periodic Inspection
Maintenance
Starter Motor Repair
Removal
Disassembly
Armature Tests
Cleaning and Inspection
Brushes and Brush Holder
Reassembly
Clearances
Installation
4B. IGNITION SYSTEM
Table of Contents
Thunderbolt IV (HEI) Ignition System
Special Tools
Torque Specifications
Lubricants, Sealers and Adhesives
Coil Specifications
Exploded View for Thunderbolt IV Distributor For V-6 Engines
MCM V-6 262 CID (4.3L) with Thunderbolt IV
Distributor Advance Curves
Replacement Parts Warning
Repair
Precautions
Spark Plugs
Firing Order
Distributor Cap Rotor/Sensor Wheel
Sensor
Spark Plugs
Ignition Module
Distributor Repair
Removal
Spark Plug Wires
Disassembly
Reassembly
Distributor Installation
Engine Not Disturbed
Engine Disturbed
Ignition Timing
Thunderbolt V Ignition System
Identification
General Description
Over-Speed Control
Idle Speed Spark Control
Knock Retard Spark Control
Acceleration Spark Advance
Mean-Best-Timing (MBT) Spark Advance
Thunderbolt V Spark Control Graph
Knock Control Module
Circuit Description
Ignition Control Module
Ignition Control System Timing Lead
Ignition System Wiring Diagram
Timing and Idle Adjustment Procedures For Thunderbolt V Ignition
Setting Base Ignition Timing
Adjusting Engine Idle Speed
Adjusting Idle Mixture
Troubleshooting Thunderbolt V Ignition
Ignition Control Module /Coil /Distributor
Knock Control Module
Spark Plugs
Spark Plug Wires
4C. CHARGING SYSTEM
Table of Contents
Identification Mando 55 and 65 Amp Alternator
Specifications
Tools/Sealants
Replacement Parts Warning
Torque Specifications
Description
Precautions
Periodic Maintenance
System Components
Drive Belt Tension Adjustment
V-Belt
Serpentine Belt
Troubleshooting Tests (Alternator on Engine)
Circuitry Test
Current Output Test
Voltage Output Test
Alternator Repair
Removal
Exploded View
Disassembly
Cleaning and Inspection
Component Testing
Reassembly
Battery Isolators
Dual Battery Charging Systems Using a Battery Isolator
Installation
Battery Isolator
4D. INSTRUMENTATION
Table of Contents
Identification Special Information
Lighting Options
Gauges
Oil, Fuel and Temperature
Battery Gauge
Cruiselog Meter Vacuum Gauge
Speedometer
Tachometer
Gauge Replacement
Senders
Oil Pressure
Water Temperature WARNING
Fuel Tank Sender
Switches
Ignition Key Switch
Lanyard Stop Switches
Start/Stop Switch Buzzer
Audio Warning System
Oil Pressure Switch
Water Temperature Switch
4E. WIRING DIAGRAMS
Table of Contents
Wiring Colors for MerCruiser
MCM V-6 Alpha Thunderbolt IV
MCM V-6 Gen + Alpha Thunderbolt V Without Knock Sensor
MCM V-6 Gen + Bravo Thunderbolt V Without Knock Sensor
MCM 262 Magnum EFI Gen + Alpha and Bravo Starting and Charging Harness
MCM 262 Magnum EFI Gen + Alpha (Vapor Separator Tank [VST]) EFI System Harness
MCM 262 Magnum EFI Gen + Bravo (Vapor Separator Tank [VST]) EFI System Harness
MCM 262 Magnum EFI Gen + Alpha (Cool Fuel System) EFI System Harness
MCM 262 Magnum EFI Gen + Bravo (Cool Fuel System) EFI System Harness
Quicksilver Instrumentation
Dual Station Wiring (Using a Neutral Safety Switch in Only One Remote Control)
Dual Station Wiring (Using A Neutral Safety Switch In Both Remote Controls)
Dual Station Wiring (Using a Neutral Safety Switch in Engine Wiring Harness)
EFI Wiring Diagram (Chart 1 Of 4)
EFI Wiring Diagram (Chart 2 Of 4)
EFI Wiring Diagram (Chart 3 Of 4)
EFI Wiring Diagram (Chart 4 Of 4)
5. FUEL SYSTEMS
5A. FUEL DELIVERY SYSTEM
Table of Contents
CID / 4.3L
Torque Specifications
Special Tools
Lubricants, Sealers and Adhesives
Specifications
Identification
Replacement Parts Warning Precautions
Fuel Supply Connections
Description
Fuel System Components (Carburetor) Fuel Delivery System
Recommendations
Water Separating Fuel Filter
Testing Fuel Pump
Replacement
Electric Fuel Pump For Carbureted and VST Equipped Engine
Replacement
Fuel System For Carbureted Engines
VST System for Throttle Body Cool Fuel System For Throttle Body Injection Injection
5B. MERCARB) 2 BARREL CARBURETOR
Table of Contents
MerCarb 2 BBL Carburetor
Torque Specifications
Tools
Specifications
Exploded View
Identification
Important Service Information
Flooding at Idle RPM
Needle/Seat Change
Adjustable Accelerator Pump Lever High Altitude Re-Jetting
Description
Precautions Maintenance
Flame Arrestor with Carburetor WARNING Cover
Fuel Inlet Filter
Choke Inspection
Adjustments
Pump Rod
Choke Setting
Preliminary Idle Speed and Mixture
Choke Unloader
Final Idle Speed and Mixture
Installation
Repair
Removal
Disassembly
Cleaning and Inspection
Reassembly
5C. WEBER 4 BARREL
CARBURETOR
Table of Contents
Identification Torque Specifications
Tools
Replacement Parts Warning
Specifications
Jet Changes for Altitude
Carburetor Adjustment Specifications
Description
Precautions
Hard Starting
Important Service Information
Weber Carburetor Adjustable Accelerator Pump
Carburetor Metering Rod And Jet Identification
Maintenance
Flame Arrestor
Fuel Filter
Adjustments
Accelerator Pump
Choke Pull-Off
Float Drop
Float Level
Idle Speed and Mixture Adjustments
Thunderbolt IV Equipped Engines
Thunderbolt V Equipped Engines
Repair
Removal
Installation
Exploded View
Disassembly
Cleaning and Inspection
Reassembly
5D. THROTTLE BODY FUEL INJECTION
Table of Contents
General Information
Basic Knowledge and Tools Required
Electrostatic Discharge Damage
Introduction
Diagnostic Information
Wiring Harness Service
Wiring Connector Service
Abbreviations
Changes In Terminology
Diagnostic Trouble Codes
ECM Self-Diagnostics
Reading Codes
Diagnostic Code Tool With Malfunction Indicator Lamp
Intermittent Malfunction Indicator Lamp
EFI Diagnostic Circuit Check
Scan Tool Use with Intermittents
Scan Tools
Non-Scan Diagnosis of Driveability Concerns (With No Codes Set)
Special Tools
Service Precautions
Electronic Control Module (ECM) and Sensors
General Description
Computers and Voltage Signals
Analog Signals
Digital Signals
Engine Control Module (ECM)
Speed Density System
ECM Input and Sensor Descriptions
INPUTS
OUTPUTS
Distributor Module Mode
Spark Management
High Energy Ignition with Ignition Control (IC)
ECM Control Mode
Modes Of Operation
Base Ignition Timing
Results of Incorrect Operation
Fuel Metering System
General Description
Modes of Operation
Cool Fuel System
Throttle Body Injection Components
ECM Connector and Symptom Charts
ECM Connector and EFI Symptoms Chart (J-1 Circuits)
ECM Connector and EFI Symptoms Chart (J-1 Circuits)
ECM Connector and EFI Symptoms Chart (J-2 Circuits)
ECM Connector and EFI Symptoms Chart (J-2 Circuits)
Throttle Body Injection Wiring Diagram (Chart 1 of 4)
Throttle Body Injection Wiring Diagram (Chart 2 Of 4)
Throttle Body Injection Wiring Diagram (Chart 3 Of 4)
Throttle Body Injection Wiring Diagram (Chart 4 Of 4)
Diagnostic Circuit Check
Scan Tool Normal Specifications (Idle /Warm Engine/Closed Throttle/Neutral)
No ïMalfunction Indicator Lampì (Marine Diagnostic Code Tool Installed) Chart A-1 (1 of 2)
No Malfunction Indicator Lamp Chart A-1: (2 of 2)
No DLC Data or Will Not Flash Code 12 Malfunction Indicator Lamp On Steady (Marine Diagnostic Code Tool Installed) Chart A-2 (1 of 2)
No DLC Data or Will Not Flash Code 12 Chart A-2: (2 of 2)
Engine Cranks but Will Not Run Chart A-3 (1 of 4)
Engine Cranks but Will Not Run (Continued) Chart A-3: (2 of 4)
Engine Cranks but Will Not Run (Continued) Chart A-3 (3 of 4)
Engine Cranks but Will Not Run (Continued) Chart A-3: (4 of 4)
Fuel System Diagnosis Chart A-7 (1 of 6)
Fuel System Diagnosis (Continued) Chart A-7: (2 of 6)
Fuel System Diagnosis (Continued) Chart A-7 (3 of 6)
Fuel System Diagnosis (Continued) Chart A-7: (4 of 6)
Fuel System Diagnosis (Continued) Chart A-7 (5 of 6)
Fuel System Diagnosis (Continued) Chart A-7: (6 of 6)
EFI System/Ignition Relay Check (1 of 2)
EFI System / Ignition Relay Check (Continued) (2 of 2)
Ignition System Check (1 of 2)
Ignition System Check(1 of 2)
Ignition System Check (2 of 2)
Ignition System Check (2 of 2)
Idle Air Control (IAC) Functional Test (1 of 2)
Idle Air Control Functional Test (2 of 2)
Lanyard Stop Circuit Check (Emergency Stop) Circuit Check (1 of 2)
Lanyard Stop (Emergency Stop) Circuit Check (2 of 2)
Audio Warning Buzzer Circuit Check (1 of 2)
Audio Warning Buzzer Circuit Check (2 of 2)
Diagnostics-Without Scan Tool
Code 14: Engine Coolant Temperature (ECT) Sensor Circuit (Non-Scan) (1 of 2)
Code 14: ECT Circuit (Non-Scan) (2 of 2)
Code 21: Throttle Position (TP) Sensor Circuit (Non-Scan) (1 Of 2)
Code 21: Throttle Position (TP) Sensor Circuit (Non Scan)
Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Non-Scan) (1 Of 2)
Code 33: MAP Circuit (Non-Scan) (2 of 2)
Code 42: Ignition Control (IC) Circuit (Non-Scan) (1 of 2)
Code 42: IC Circuit (Non-Scan) (2 of 2)
Code 43: Knock Sensor (KS) (Non-Scan) (1 of 2)
Code 43: Knock Sensor (KS) Circuit (Non-Scan) (2 of 2)
Code 51: Calibration Memory Failure Non-Scan Diagnostics (1 of 2)
Code 51: Calibration Memory Failure (Non-Scan) (2 of 2)
Diagnostics - Using Scan Tool (Scan)
Code 14 Engine Coolant Temperature (ECT) Sensor Circuit (Scan) (1 of 2)
Code 14: ECT Circuit (Scan) (2 of 2)
Code 21: Throttle Position (TP) Sensor Circuit (Scan) (1 of 2)
Code 21: TP Sensor Circuit (Scan) (2 of 2)
Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Scan) (1 of 2)
Code 33: MAP Circuit (Scan) (2 of 2)
Code 42: Ignition Control (IC) Circuit (Scan) (1 Of 2)
Code 43: Knock Sensor (KS) (Scan) (1 Of 2)
Code 43: KS Circuit (Scan) (2 of 2)
Code 51: Calibration Memory Failure (Scan) (1 Of 2)
Code 51: Calibration Memory Failure (Scan) (2 of 2
Troubleshooting
Changes In Terminology
Diagnostic Trouble Codes
Important Preliminary Checks
Troubleshooting Charts
Fuel Delivery Systems
Cool Fuel System Exploded View
Vapor Separator Tank (VST) Exploded View
Torque Sequence For VST
VST Fuel Pump (Exploded View)
Vapor Separator Tank (VST)
Float and Needle Assembly
Diaphragm Assembly
Repair Procedures Torque Specifications
Special Tools
Lubricants/Sealants/ Adhesives
Throttle Body Injection System Description
Service Precautions
Throttle Body Exploded Views
Induction System
Throttle Body
Fuel Pressure Relief Procedure
Fuel Meter Cover Assembly
Fuel Injectors
Throttle Body
Throttle Body Adapter Plate
Throttle Body Injection Sensor and Module Servicing
Precautions
Electronic Control Module (ECM)
Knock Sensor (KS) Module Engine Coolant Temperature (ECT) Sensor
Manifold Absolute Pressure (MAP) Sensor
Idle Air Control (IAC) Valve
Knock Sensor
Fuel Pump Relay
Ignition Control (IC) System Components
Precautions
Ignition Coil
Spark Plug Replacement
5E. BSO / SAV EMISSION FUEL SYSTEM
Table of Contents
Identification Torque Specifications
Special Tools
Replacement Parts Warning
Carburetor Specifications
Carburetor Adjustment Specifications
Engine Specifications
Description Special Notes
Carburetor Top Cover
Sealed Idle Mixture Screws
Metering Assembly
Precautions
Fuel Filter
Maintenance
Flame Arrestor
Positive Crankcase Ventilation (PCV)
Troubleshooting
Checking Ported Vacuum Switch and Carburetor Vacuum Circuit for Correct Operation
Service Procedures
Checking Positive Crankcase Ventilation (PCV) Valve
Removing Seals From Idle Mixture Screws
Installing New Seals
Carburetor Installation Ported Vacuum Switch Installation
Emissions System Connections
Propane Assisted Idle Set Procedure
Emissions Testing
Test Equipment
6. COOLING SYSTEM
6A. SEAWATER COOLING MODELS
Table of Contents
Seawater Inlet Recommendations
Transom Mounted or Thru-Hull Seawater Pickups and Hose
Sea Strainer
Transom Mounted
Seawater Pickups
Thru-Hull Mounted
Removal
Sea Strainer (Quicksilver)
Installation
Stern Drive Unit Seawater Pickup Pump Output Test
Cleaning and Inspection
Stern Drive Unit Seawater Pickup Pump Repairs
Installation
Water Circulating Pump Replacement
Removal
Flushing Seawater Cooling System
Engines with Stern Drive Seawater Pickup Pump Check/Clean Seawater Strainer
Thermostat
Removal
Testing
Installation
Draining Seawater Cooling System
Draining Precautions
Auxiliary Hot Water Heater Installation Information
6B. CLOSED COOLED MODELS
Table of Contents
Water Flow Diagrams
Engines With Coolant Flow Thru Exhaust Manifolds (Excluding Gen +)
Engines With Raw Water Flow Thru Exhaust Manifolds
Description Seawater Pickup Pump (If Equipped)
Maintenance
Stern Drive Unit Seawater Pickup Pump
Belt Driven Seawater Pickup Pump
Closed Cooling Systems With Coolant Flow Thru Exhaust Manifolds (Excluding Engines With Serpentine Belt)
Maintaining Coolant Level
Pressure Cap Maintenance
Heat Exchanger Repair
Testing Closed Cooling System
Testing Coolant for Alkalinity
Pressure Testing System
Testing for Cylinder Head Gasket Testing Heat Exchanger Leak
Testing Pressure Cap
Thermostat
Removal
Testing
Installation
Coolant Recommendations
Change Intervals
Draining Instructions CAUTION WARNING
Changing Coolant
Closed Cooling Section
Seawater Section
Cleaning System
Closed Cooling Section
of Closed Cooling System
Flushing Seawater Section
Draining Seawater Section of Closed Cooling System
Draining Precautions
Filling Closed Cooling Section
Closed Cooling System With Raw Water Flow Thru Exhaust Manifold (Engines With Serpentine Belt Only)
Maintaining Closed Cooling System WARNING Coolant
Checking Coolant for Alkalinity
Changing Coolant
Flushing Seawater Section CAUTION
Cleaning Seawater Section of Heat Exchanger and Fluid Coolers
Cleaning Closed Cooling Section
Cold Weather or Extended Storage
Seawater Section Draining Instructions
Serpentine Drive Belt Adjustment
Auxiliary Hot Water Heater Installation
7. EXHAUST SYSTEM
7A. GENERAL
Table of Contents
Exhaust System Requirements
All Engines
7B. MANIFOLD AND ELBOWS
Table of Contents
Torque Specifications
Sealants
Removal
Installation
Cleaning and Inspection
7C. RISERS
Table of Contents
Exhaust Riser (Kit) Replacement Information Identification
Engine Preparation and Parts Removal
Additional Kit
Riser Installation
Torque Specifications
Sealants
Installation Diagrams
7D. COLLECTORS
Table of Contents
Torque Specifications
Shutter Replacement
Component Replacement
8. POWER STEERING
8A. PUMP
Table of Contents
Torque Specifications Precautions
Tools/Sealants
Power Steering Pump and Components (Exploded View)
Serpentine Belt Routing
Important Service Information
Pump Pulley Replacement
Serpentine Belt Adjustment
Testing and Repair
Checking Pump Fluid Level
Filling and Air Bleeding System
Belt Adjustment
V-Belt
Pump Assembly
Mounting Bracket
Hydraulic Hoses and Fluid Cooler
High Pressure Hose (Pump-to-Control Valve)
Low Pressure Hose (Cooler-to-Pump)
Low Pressure Hose (Control Valve-to-Cooler)
Priority Valve Kit (79691A1) Information
Installing Reservoir
Installing Priority Valve
Filling System with Fluid Maintenance
System Flow Diagram

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