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1. pe SS 75157 Bravo Two Standard Insert Location Bravo One Two Optional Insert Location 75158 Tilt Limit Spacer Kit 1C 32 STERNDRIVE INSTALLATION 90 883145 3 10 03 Bravo Drive Remote Control Drive Unit Shift Cables Adjustment NOTE Using Adjustment Tool 91 12427 shift cables can be adjusted without or with the sterndrive installed using the following procedure IMPORTANT Drive unit propeller rotation is determined by the shift cable installation in the remote control Bravo One Two If shift cable end guide moves in direction A when control lever is placed in Forward remote control is set up for RIGHT HAND RH propeller rotation Bravo One Two If shift cable end guide moves in direction B when control lever is placed in Forward remote control is set up for LEFT HAND LH propeller rotation 71656 Bravo One And Two Blackhawk and Bravo Three Front propeller on drive unit is always LH Rotation and rear propeller is always RH Rotation Shift cable end guide must move in direction A when control lever is placed in Forward gear position 71656 Bravo Three And Blackhawk IMPORTANT When installing shift cables be sure that cables are routed in such a way as to avoid sharp bends and or contact with moving parts DO NOT fasten any items to
2. BLACK BLUE BROWN GRAY GREEN o PINK 2 PURPLE S ug D RED o m TAN cfs WHITE 3 YELLOW LIGHT DARK 94 NX o av l IND CM KNOCK Lj CONTROL A MODULE CES JT 1 Knock Sensor Wire 2 Ground Wire For Knock Module Knock Module Signal Wire 4 Battery Positive Wire To Knock Module 5 Ground For Future Options 6 Audio Warning System Wire 7 Distributor Wire TO DISTRIBUTOR 9 Dum 91 9 Q3H LHM 91 1d 91 IGNITION CONTROL MODULE 8 Distributor Wire 9 Battery Positive Wire To Ignition Module 10 Ground Wire for Ignition Module 11 Tachometer Wire 12 Ignition control trigger wire Pin L 13 Timing Lead for setting timing and other tests IGNITION SYSTEMS 2D 13 Thunderbolt V 1998 and Newer
3. 2200000 Co Co Co Co Who To Call List Sed NO 4 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 90 883145 4 Applicable Service Bulletins 1990 2004 MerCruiser Service Bulletin Index 1990 MERCRUISER SERVICE BULLETIN INDEX 90 1 90 2 90 3 90 4 90 5 90 6 90 7 90 8 90 9 90 10 90 11 90 12 90 13 90 14 90 15 90 16 90 17 90 18 USA and Canada Gasoline Recommendation A MerCarbs Having Incorrect Choke Settings B Spark Plug Wire Kit P N 84 813720A9 A Alpha One Bell Housing Shift Shaft Bushing Kit P N 23 79373A1 B Bravo U Bolt and Aloha One Gimbal Ring Screw Torque Checking Process C MCM 5 0LX Gear Ratio Used on 1990 Sea Ray Boats A Borg Warner Velvet Drive Distributors USA amp Canada A Removal of Upper Swivel Pin Grease Fitting on Alpha and Bravo Transom Assemblies B Bravo Drive Unit Shift Yoke Change C Alpha One Transom Assembly Intermediate Shift Cable Shift Plate Inspection opark Plug Wire Terminal and Boot Change Rough Idle or Can t Adjust Idle Mixture Screws Diesel Engine Idle RPM Incorrect Engine Maximum RPM on Serial Number Plate Wrong Diameter Water Hose Being Connected to 1 1 4 in 32mm Nipple on Y Connection Use of Propylene Glycol Antifreeze Oil Leak at Front of Engine Possible Cause for Engine Overheating Delco EST Ignition System Timing and Maximum RPM Changes Replacement of Gimbal Housing Studs Just Bel
4. ROTOR a d X MECHANICAL ADVANCE WEIGHTS BREAKER POINTS DISTRIBUTOR Proper Lateral Alignment Spring Tension 19 23 Oz Correct Lateral Misalignment by Bending Fixed Contact Support NEVER Bend Breaker Lever Point Alignment IGNITION SYSTEMS 2D 1 Thunderbolt IV Ignition System Thunderbolt IV Distributor Identification 72722 a Ignition Module Distributor with Ignition Module Mounted on 71790 Distributor Body Distributor with Ignition Module Mounted on NOTE Repair procedures for both distributors ex Exhaust Elbow cept for ignition module replacement are the same Exploded View Typical Distributor Cap Vent Gasket Rotor Sensor Wheel Screws 3 E Clip Shaft Screws 2 10 Lockwashers 2 11 Sensor 12 Upper Bushing 13 Ignition Module If So Equipped Apply Thermalconductive Grease 14 Screws 2 15 Distributor Housing 16 Lockwasher 17 Nut 18 Lower Bushing 19 Gasket 20 Washer 21 Gear 22 Roll Pin 20 2 IGNITION SYSTEMS 90 883145 3 10 03 Thunderbolt Module Identification Exhaust Elbow Mounted Module Distributor Mounted Module JL THUNDERBOLT IV b BREAKLESS ELECTRONIC TIMING GNITION A mn 8 gt M a a Engine Type b Spark Advance Degrees a Engine Typ
5. 2A 10 Quicksilver Instrumentation Wiring lt 2 10 MCM Gasoline Engine 2A 10 5 LX 350 Magnum Alpha Engines Thunderbolt V Ignition With Knock 2A 13 SmartCraft Product Rigging Components 2A 14 Typical System Layouts Single Engine Product Configurations 2A 14 V 6 and Small Block V 8 Electric Fuel Pump Used on Carbureted Models 2A 15 Shift Switch Operation 2A 16 ECM 555 Gear Indicator Shift Interrupt 2 17 Service Bulletins 2A 19 2A i BATTERIES WIRING 90 883145 3 10 03 Battery Requirements for MerCruiser Products Battery Ratings There are two major rating systems used in the USA for marine engine cranking batteries The most common is cca cold cranking amps which rates the cranking amps at 0 F The second system mca marine cranking amps rates the cranking amps at 32 F The mca marine cranking amps rating of a given battery is always higher than the cca cold cranking amps rating There is a third rating system that some discount stores use which rates the cranking amps of a battery at 80 F The advertised cranking amps of these batteries is high while the actual cca of it is very low Cold Cranking Amps CCA This figure represents in amps the current flow the battery can deliver for 30 seconds at 0 Fahrenheit without dropping below 1 2 vol
6. 96 Manual is 2 50 supplement is 1 50 SB 97 17 Carbureted engines dieseling both for 3 50 SB 98 4 Electric fuel pump check ball sticking Recommended Training Videos 98 5 Fuel detergents causing sticking problems MerCruiser Carburetion 8 Point Checklist 90 823732 57 MU V55 MerCruiser Vapor Lock SB 2000 5 Electric fuel pump recall Theory and Prevention 90 823732 80 MU V78 PB 98 6 Parts Bulletin on replacement fuel system parts Anti siphon Valves EVM Inc 1009 Madison Street P O Box 153 Two Rivers WI 54521 800 457 2490 voice 920 793 1406 fax Large sizes available 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 9 MerCarb Two Barrel MerCruiser Carburetor Identification Figure 1 Carburetor Part Number Location a Part Number b Date Code An embossed tag stamped with the MerCarb Part Number also is attached to one of the air horn attaching screws Figure 2 Figure 2 Part Number Tag Location a Part Number Embossed Tag b Air Horn Attaching Screw Data Code Explanation Example 2301 First Figure is Year 2 1992 3 1993 etc Second Figure is Month 2 February 3 March etc X October Y November Z December Third and Fourth Figures are Day of Month 01 First day 02 Second day etc 3A 10 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Description Venturi Cluste
7. Engine Installation Gear Lube Monitor Trim Position Sender Harness SmartCraft Transoms Power Steering Hose Routing Exhaust Hose Routing Methods of Measuring Exhaust Elbow Height Straight Edge Method Clear Hose Method Priming Engine with Oil Tool 1B i ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 Engine Mounts 90 883145 3 10 03 Front engine mounts are adjustable and must rest on boat stringers 3 8 in lag screws or bolts depending upon stringer construction retain engine mount pedestal to stringer Grade and length of lag screws or bolts must be selected based on stringer material and anticipated loading forces Washers with locking tabs are employed to avoid mounts loosening Adjustment nut is turned counterclockwise to raise front of engine or clockwise to lower front of engine 71649 22054 Typical V 6 or V 8 Front Mount 3 0L 181 cid Front Mount a Nut And Lockwasher b Adjustment Nut c Adjustment Nut d Lag Screws Or Bolts e Tab Washer f Locknut g Jam Nut Rear engine mounts are provided to align with inner transom plate mounts 22032 Typical Rear Mount a Rear Engine Mount b Inner Transom Plate Mount Bolt d Washer e Spacer f Fiber Washer g Double
8. 3B 40 PCM 555 Charging 3B 44 PCM 555 Ignition Circuit 3B 45 P N 91 805747A2 Timing Tool for MerCruiser EFI Engines 3B 46 CODEMATE w Marine EFI Code Reader 3B 46 Scan Tools Older Software and Newer EFI Systems 3B 46 Test Tool Data Link Connector DLC eror i o p NND E 3B 47 Quicksilver DDT Scan Tool 3B 48 DDT MC Ver 2 0 Cartridge MEFI 3 Function Flowchart 3B 51 1 Data Log Sheet DDT 3B 56 MEFI 2 Data Log Sheet DDT 3B 57 3 Data Log Sheet DDT 3B 58 PCM 555 03 and ECM 555 Data Log Sheet CDD TJ 3B 60 MerCruiser Rinda Scan Tool 3B 61 MerCruiser Rinda Function Flowchart 3B 63 MEFI 1 Data Sheet Rinda 3B 65 2 Data Sheet Rinda 3B 66 MEFI 3 Data Sheet Rinda 3B 67 PCM ECM 555 Data Log Sheet Rinda 3B 68 Computer Diagnostic System 3B 69 MerCruiser EFI Tool List 3B 73 90 883145 4 0804 Speed Density Theory and Operation Speed Density Theory 90 883145 3 10 03 All MerCruiser engines operate on the fuel injection strategy called Speed Density This means that the ECM primarily looks at
9. Pressure Switch 3A 64 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 4 0804 Additional Coolant Temperature Switch A second switch has been added to the system and it is located in a new thermostat housing on the 3 0L models and in the intake manifold coolant passage on V6 and Small Block V8 models This switch is used to keep the TKS unit from opening when the engine is warm which prevents additional fuel from entering the engine under hot re start conditions One lead is wired to the circuit breaker i e battery power via an in line fuse and the other lead is wired to the TKS unit This switch is normally open and closes completing the circuit above 130 degrees F When the engine coolant temperature reaches 130 degrees F the coolant temperature switch closes and remains closed until the coolant or sea water on sea raw water cooled engines temperature drops below 110 degrees F When closed the switch sends 12Vdc to the TKS Module thus keeping the additional fuel flow path closed until the engine cools sufficiently to warrant the additional starting fuel Once the coolant temperature drops below 110 deg F the coolant temperature switch opens and the 12Vdc is no longer sent to the TKS module The TKS unit will cool allowing the needle to back off the seat and aid in the next starting event The wiring harness will be equipped with a diode to prevent power from this source running back on the purple lead whi
10. 2D 24 Delco EST Ignition Troubleshooting 2D 26 MCM 3 0L 3 0LX EST Models Engine Wiring Diagram 2D 28 EFI Engines with High Energy Ignition and Electronic Spark Timing EST 2D 29 EST Operation Cranking Distributor Module Mode 2D 30 Engines with Mercury Marine Thunderbolt V Distributor and MEFI 3 ECM 1999 V 6 and Small Block V 8 Engines 2D 32 P N 91 805747A2 Timing Tool for MerCruiser Engines 20 33 90 883145 3 10 03 Conventional Ignition System Delco Remy and Prestolite EN WE SAFETY SWITCH OR BATTERY METER IN REMOTE CONTROL GROUND CIRCUIT BREAKER CHROME PLATED BRASS TERMINALS 1 8 2 0 OHMS RESISTANCE WIRE PRIMARY WINDING GROUND STARTER SOLENOID BATTERY dia am Positive to Negative Negative to Positive Contact Point Material Transfer Breaker S Points Open Breaker Points Points Open ex Closed v Angle 5 Breaker Points Direction of Rotation Cam Angle 90 883145 3 10 03 BRASS TERMINALS TERMINAL k BOOT RESISTOR j SPARK PLUGS is TO 30 000 VOLTS SHIFT CUT OUT WIRE TACH WIRE SECONDARY WINDING IRON CORE Lateral Misalignment NOTES RFI SUPPRESSION WIRES CAP SOLID CARBON CONTACT jc rd AAA
11. DESCRIPTION The Weber Carburetor has an idle system to supply the correct air fuel mixture ratios to the engine during idle and low speed operation The idle system is necessary during this period because air flow through the carburetor venturi is not great enough to cause fuel to flow from the main discharge nozzles At idle speed the throttle valves 7 are held slightly open by the idle speed screw The small amount of air which passes between the throttle valves and bores is regulated by the screw to give the desired idle speed Since the engine requires very little air for idle and low speed fuel is added to the air by the application of vacuum low pressure from the intake manifold directly through the idle system to the fuel in the carburetor float bowl With the idle mixture screw 9 holes located in a high vacuum low pressure area below the throttle valves and fuel in the float bowl vented to atmosphere the idle system operated in the following manner cont 3A 36 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Fuel from the float bowl flows through the main metering jets 2 around the metering rods into the main fuel well 1 It is then picked up and metered by the calibrated orifice at the tip of the idle tubes 3 It then passes up the idle tubes and is mixed with air from the air bleeds 4 located on the top of the idle tubes and in the idle cross channels The mixture then passes
12. Exhaust leaks Ignition timing Idle Forward Neutral Reverse gear operation rpm within specifications Steering operation throughout range Acceleration from idle rpm WOT rpm within specifications in FORWARD gear Power trim operation Trim tab adjustment Boat handling AFTER ON WATER TEST Propeller nut torque Fuel oil coolant water and fluid leaks Cil and fluid levels Apply Quicksilver Corrosion Guard to engine package C A R B Hang Tag and Owners Manual in boat C A R B Decal properly affixed to boat hull 496 Mag Bravo Install Man Page 154 90 863021042 JUNE 2004 1F 10 PREDELIVERY PREPARATION 90 883145 4 0804 MERCRUISER PDI AND MAINTENANCE LEVEL I G WINTERIZATION AND RECOMMISSIONING Table of Contents Cold Weather or Extended Storage Precautions Power Package Layup Carbureted Models Draining Instructions Single Point Drain System Draining Seawater Raw Water Cooled Models Draining Seawater Section of Closed Cooled Coolant Models Draining Instructions for New Drain Systems Identification Boat In The Water Boat Out Of The Water All Models Recommissioning 1G i WINTERIZATION AND RECOMMI
13. Power Package Layup CARBURETED MODELS NOTE Refer to MC Service Bulletin 2001 15 for additional information on EFI MPI proce dures NOTICE Refer to Cold Weather or Extended Storage Precautions in this section BEFORE proceeding 1 Follow instructions or b depending on type fuel available during layup a If boat is to be placed in storage with fuel in fuel tanks that does not contain alcohol Fill fuel tank s with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on container b If boat is to be placed in storage with fuel in fuel tanks that does contain alcohol if fuel without alcohol is unavailable Fuel tanks should be drained as completely as possible and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Follow instructions on container IMPORTANT If boat is to be placed in storage with fuel containing alcohol in fuel tanks refer to Fuel in this section for additional information 2 Replace the water separating fuel filter as outlined in Fuel Delivery Systems Water Separating Fuel Filter of appropriate service manual 3 Supply water to the seawater pickup pump as outlined in Flushing Cooling System 4 Start the engine and check for fuel leaks If leaks exist stop the engine immediately filter installation
14. 3B 20 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 MerCruiser EFI System Electronic Components see previous page for component location see part numbers ENGINE CONTROL MODULE 11 The ECM is the control center for the fuel injection system It constantly monitors information from various sensors engine temperature throttle opening engine speed air temperature and pressure and controls the systems that affect engine performance engine timing and injector pulse width The ECM supplies 5 or 12 volts to power various sensors or switches The ECM can also perform a diagnostic function check of the system It can recognize operational problems and store a code or codes which identify the problem areas to aid the technician in making repairs The following sensors interact with the ECM MANIFOLD ABSOLUTE PRESSURE SENSOR MAP 6 The Manifold Absolute Pressure Sensor MAP is a three wire sensor and is mounted at the rear of the intake plenum It is a pressure transducer that measures the changes in intake manifold pressure caused by engine load and speed The MAP sensor also is used to measure barometric pressure under certain conditions which allows the ECM to automatically adjust for different altitudes DISTRIBUTOR REFERENCE SIGNAL DIST REF 2 A Distributor Reference Signal Dist Ref is sent to the ECM from the Ignition Module in the distributor housing This reference signal is the tim
15. Desir Ide RPM XXX ic Press MODE to exit Press Left or Right arrows to reset Other data is available but use caution as some data may be avec by being in m the IAC reset mode 0 Page 3 Note Check to see if IAC is functioning by hitting Reset and then feel case of IAC for vibration NOILONGOYLNI NOILOSPNI 13614 OINOYLOSA TA Cont from page 1 MARINE DIAGNOSTICS 1 GM Single 2 GM Twin 3 Thunderbolt V 4 Injector test GM Tool Setup RPM Key On RPM 0 000 999 1000 1999 2000 2999 3000 3999 4000 RPM Lim RPM Lim Time ECM Run Time Select Options 1 Read hours Scroll down MULTI PULSE TEST Cycles in test XXX lt 5 200 On Time Millsec rm 100 600 ENTER to start i INJECTOR TEST MENU 1 Multi Pulse Test 2 Single Pulse Test SINGLE PULSE TEST On Time MS XXX 10 1000 Adj Increment XXX 10 100 500 ENTER to start Go to page 5 97 688 06 7080 4 P090 971689 06 99 96 NOILOSFNI 1915 OINOYLOA 13 Cont from page 1 TOOL SETUP MENU 1 General 2 User List Setup LL 3 Save Setup 4 Restore Setup PRN BAUD otop Bits PC Communication or Printer setup User List 1 allows 1 system of units User Default changes only Setting Press Enter Enter User Number Save Current User Setup
16. OIL PRESSURE SWITCH GRY 2 PUR 5 BLK 1 YEL RED 7 LIT BLU 8 TAN 3 BRN WHT 10 RED PUR 6 TAN BLU E _ KNOCK 4 m SENSOR 9 e 5 X gt 8 we te M TRIM TEMPERATURE hey SENDER SLAVE ALTERNATOR 2 j AM WI 4 3 4 A STARTER RES AD 9 gue MOTOR NN 1 9 CIRCUIT ELECTRIC Ua BLK Black BLU Blue Brown GRY Gray GRN Green Lo GS Le J ORN Orange PNK Pink PUR Purple A Ignition C Audio Warning System RED Red B Starting Charging and Choke D Instrumentation TAN fan WHT White YEL Yellow LIT Light DRK Dark 90 883145 3 10 03 IGNITION SYSTEMS 2D 17 Knock Control Module The Knock Control Module contains solid state circuitry which monitors the knock sensor s AC voltage signal and then supplies an 8 10 volt signal if no spark knock is present to the Ignition Control Module If spark knock is present the Knock module will remove the 8 10 volt signal to the Ignition Control Module It is extremely important that the correct knock module and sensor be used for the engine ap plication Using an incorrect knock module or sensor will result in unrecognized spark knock and engine damage The Knock module terminal B is powered by 12 volts from the ignition switch I
17. Re PS 75198 a Shift Shaft Lever b Roller c Shift Shaft Slide Stabilizer Tool Tool Description Part Number Shift Shaft Slide Stabilizer Tool 91 809815A1 Description Checks alignment of shift shaft slide and sterndrive unit during installation 75199 STERNDRIVE INSTALLATION 1 3 12 Position drive unit shift shaft so that it is straight forward by turning shift shaft clockwise while simultaneously turning propeller shaft counterclockwise lt B N aX os 79912 a Drive Unit Shift Shaft IMPORTANT Be sure to install RH or LH drive unit on the appropriate transom assem bly when making dual engine installations The LH rotation drive unit can be identified by the decal on the back side of the upper drive shaft housing which states Alpha One Counter Rotation 13 Place gasket on bell housing 70010 a Gasket 1C 4 STERNDRIVE INSTALLATION 90 883145 3 10 03 14 Install sterndrive unit as follows a Position trim cylinder straight back over top of acceleration plate Be careful not to scratch acceleration plate or trim cylinders b Guide U joint shaft through gimbal bearing and into engine coupler while simulta neously guiding shift slide into drive shaft housing Make sure shift slide remains upright and engaged with bell housing shift shaft lever c Remove Shift Slide Stabilizer Tool d Slide drive unit all the way into bell housing IMPORTANT If drive uni
18. IMPORTANT On Bravo drives the Trim In Limit Pin must be properly positioned be fore installing the trim cylinder anchor pin in the following steps 13 Ensure that the Trim In Limit Pin is positioned as shown for Bravo 1 2 and 3 models i 0M 75157 b 75158 a Spacer Positioned Forward Bravo One and Two b Spacer Positioned Aft Bravo Three 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 29 IMPORTANT To aid in installing rubber bushings use a water and soap solution DO NOT use oil or grease 14 Install trim cylinders on aft end of drive unit with hardware as shown Coat anchor pin threads with 2 4 C W Teflon Marine Lubricant and tighten nuts until they bottom Install plastic caps and tighten hand tight only lt A Me Anchor Pin b Large D Washers 2 c Rubber Bushings 4 d Small 1 0 Flat Washers 2 e Locknuts 2 f Plastic Caps 2 15 Place drive unit serial number decal as described in General Information ATTACHING SPEEDOMETER WATER TUBE GIMBAL HOUSING TO STERN DRIVE 1 Raise drive to gain access to area between Gimbal Housing and Stern Drive immediately atop the transom end of the anti ventilation plate 2 Insert speedometer tube fitting into opening on top side of anti ventilation plate
19. LH Simultaneously rotate propeller shaft clockwise until shaft stops to ensure full clutch engagement a Propeller Shaft Rotate Clockwise 1C 14 STERNDRIVE INSTALLATION 90 883145 3 10 03 Ef 7 9 Perform or b as appropriate a On Models with Earlier Type Switch check shift cutout switch lever position Roller must be centered a Shift Cutout Switch Roller b On Models with Later Type Switch check shift cutout switch plunger position Pin must be centered a Shift Cutout Switch Plunger Pin 10 If roller or plunger pin is not centered a Ensure adjustable stud is at bottom of slot in shift lever b Check remote control for proper shift cable output 3 in 76mm 1 8 in 3mm Refer to Installation Requirements 7 c If a and b are correct ensure drive unit shift cable is not crushed or kinked If drive unit shift cable is binding the shift cutout switch roller or plunger pin will move off center when shifting into and out of forward and reverse NOTE If shift cable was damaged during installation install new shift cable assembly in ac cordance with instructions contained in sterndrive service manual then repeat shift cable ad justment procedure 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 15 11 After remote control shift cable has been properly adjusted reinstall cable and shift assist assembly if applicable and secure
20. with engine at normal operating temperature If idle soeed is incorrect proceed as follows 1 Ensure that throttle cable has been adjusted properly 2 If idle speed is still not correct it may be necessary to perform EFI System Diagnostic Tests on the idle circuit Refer to the appropriate Mercury MerCruiser Service Manual for procedures WIDE OPEN THROTTLE TEST IMPORTANT To run engine at full throttle before the break in period is complete follow this procedure Start engine and run at idle RPM until normal operating temperature is reached Run boat up on plane e Advance engine RPM in 200 RPM Increments until engine reaches its maximum rated RPM To test if the correct propeller has been installed operate boat with normal load on board at WOT and check RPM with an accurate tachometer Engine RPM should be near top of the specified range so that under a heavy load engine speed will not fall below specifications If engine speed is too high replace propeller with a higher pitch propeller Normally a 300 to 400 RPM change exists between propeller pitches COLD WEATHER OR EXTENDED STORAGE If Power Package will not be used for an extended period of time or will be exposed to freezing temperatures drain water from seawater circuit of cooling system as ex plained in owner s Operation Maintenance and Warranty Manual Water MUST BE drained to prevent corrosion and freeze damage to engine Sterndrive unit s
21. When Activated BtoC Always 10K O e Jumper Plug Bravo Models f ECM 555 BATTERIES WIRING 24 15 NOTES 2A 16 BATTERIES WIRING 90 883145 4 0804 LI merCruizer TO SERVICE MANAGER PARTS MANAGER O ac P Revised June 1999 Information underlined is new Multiple EFI Engine Battery Precautions Models MIE Engines with Electronic Fuel Injection Situation Alternators They are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on When batteries for two different engines are connected one alternator will supply all the charging current for both batteries Normally the other engine s alter nator will not be required to supply any charging current EFI Electronic Control Module ECM The ECM requires a stable voltage source During multiple engine boat operation an electrical onboard device may cause a sudden drain of voltage at the engine s battery The voltage may go below the ECM s minimum required voltage Also the idle alternator on the other engine may now start charging and this could cause a voltage spike in the engine s electrical system In either case the ECM could shut off When the voltage returns to the range that the ECM requires the ECM resets itself The engine will now run normally This ECM shut down usually happens so fast that the engine just appears to have an ignition miss Recommendations
22. 1F 1 Power Trim Pump 1F 1 Trim Position Sender Adjustment if applicable 1F 2 Small Block and V6 Transom with EC 555 equipped engines 1F 3 496 Mechanical with Smart transom 1 3 Power Steering 1F 3 Drive Unit Gear Lube Monitor 1F 5 Propeller Installation 1F 6 Fresh Water 1F 6 Salt Water 1F 6 Test Running Engine 1F 7 Boat In The Water Tests 1F 9 Engine Idle Speed Adjustment 1 9 Wide Open Throttle Test 1F 9 Cold Weather or Extended Storage 1 9 Predelivery Inspection 1F 10 1F i PREDELIVERY PREPARATION 90 883145 3 10 03 Predelivery Preparation NOTICE to INSTALLER Before starting Predelivery read General Information and Installation Requirements completely Battery Connection IMPORTANT Engine electrical system is negative ground 1 Connect engine positive battery cable usually red to positive battery terminal 2 Connect engine negative battery cable usually black to negative battery terminal 3 Connect Power Trim pump black battery cable to negative battery terminal and pump red battery cable to positive battery terminal 4 Make sure that all battery terminal connections are tight then spray terminals with a bat tery connect
23. 902 RED TO FUEL PUMP RELAY concert mal liad KNOCK SENSOR 1 KNOCK SAFETY SWITCH MIE ONLY SENSOR 2 L29 ONLY OIL PRESSURE ee SWITCH KNOCK SENSOR 1 L mM KNOCK SENSOR 2 129 ONLY _ _ 4 150 BLK ori 906 TAN WHT 12 24 GEAR LUBE BOTTLE MCM ONLY GEAR LUBE BOTTLE SWITCH MCM ONLY 2 150 BLK TRANSMISSION NEUTRAL LOAD ANTICIPATION SIGNAL 76081 3B 42 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 ECM Wiring Diagram MEFI 3 Big Block V8 4 of 4 BCYL Senn ECM 450 BLK J1 4 ECM GROUND 450 BLK J1 5 ECM GROUND 450 BLK J1 20 ECM n GROUND 423 WHT J1 10 IC MODULE IGNITION CONTROL DIST REFERENCE HIGH BYPASS 430 PUR WHT J2 10 aE 2 WAY COIL JUMPER 424 TAN BLK J1 24 HARNESS p s DIST REFERENCE 453 RED BLK J1 3 LOW 2 WAY BLACK 44 CONNECTOR SED 121 WHT FROM IGNITION N BELAY 2 WAY GRAY CONNECTOR 121 WHT 29 DK GRN muuum 1 26 AUDIO WARNING CIRCUIT TRANSMISSION OVERTEMP SWITCH 208 BRN mam J1 22 NOT USED TO IGNITION RELAY TERMINAL 86 lt lt Ne e 1 TEMP L SENDER TO TACH GRY 585 TAN WHT J2 8 CONNECTOR HALVES BLUTAN SWITCH TO AUDIO _a TAN BLU WAR
24. 96 9 Thermostat Housings No Longer Available 1997 MERCRUISER PARTS BULLETIN INDEX 97 1 MerCruiser Paper Parts Lists 97 2 Drive Unit to Bell Housing Gasket Kits 97 3 MCI Alpha One Alpha One Gen II Gear Case and Bearing Bore Differences 97 4 P N 15120T Circulating Pump Pulley No Longer Available 97 5 Vacuum Shift Assist Kit Availability For MerCruiser D3 6L 97 6 Gauge Package Instrument Harness and Extension Harness Part Numbers For MerCruiser Diesels 97 7 Mercury Marine 4 Cyl 224 cid Engine Replacement Parts 97 8 Gasoline Engine Exhaust Riser Kits 97 9 1997 1 2 Shift Changes for Bravo One Two Three and BlackHawk 97 10 Bravo Three BlackHawk Lower Pinion Gear Shimming Tool Position 1998 MERCRUISER PARTS BULLETIN INDEX 98 1 Serpentine Belts Pulleys and Kits 98 2 4 3L 5 0L and 5 7L Replacement Parts 98 3 Cylinder Head Gasket and Torque Change 98 4 Water Shutter Kit Service Replacement For MerCruiser Diesel 98 5 454 502 cid Replacement Parts 98 6 Fuel System Replacement Parts 98 7 Heat Exchanger Clamps For D Tronic D2 8L Diesels 1999 MERCRUISER PARTS BULLETIN INDEX 99 1 Converting From Stainless Steel Exhaust Elbows to Cast Iron Exhaust Elbows 99 2 P N 16413A 3 and P N 16413A 9 V6 and V8 Thermostat Housings Ordering Information 99 3 New Closed Cooling Kits and Serpentine Belts For V6 and V8 305 350 CID Engines With High Mounted Delco Alternator 2000 MERCRUISER PARTS BULLETIN INDEX 00 1 Inline Di
25. Fuel Meter Outlet Gasket 15 Screws 2 7 Fuel Injector 2 16 Seal 8 Fuel Filter 2 17 O Ring 9 Lower O Ring 18 Idle Air Control IAC Valve 10 Screw 19 Screws 2 20 Fuel Inlet 3B 14 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 3 10 03 7 4L 129 MPI Induction System 1 Starboard Engine Cover 2 Port Engine Cover 3 Engine Cover Screws 4 4 Plenum 5 Plenum Screws 8 6 Plenum Gaskets 2 7 Adapter Studs 3 8 Adapter Gasket 9 Fuel Injector Harness 10 Fuel Rail Screws e 11 Fuel Rail Stud 12 Fuel Rail 13 Fuel Injectors 8 CM 14 O Ring 15 Fuel Rail Plug 16 Intake Manifold Screws 12 17 Manifold Absolute Pressure Sensor NV 18 MAP Sensor Seal 19 Intake Manifold 20 Intake Manifold Gaskets 2 D 9 21 Vacuum Fitting Intake Manifold 22 Water By Pass Hose 23 Hose Clamps 2 24 Water By Pass Fitting 2 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 15 496 8 1L MPI Induction System Typical a Intake Manifold b Fuel Rail c Throttle Body d Schrader Valve Small Block V 8 Induction System V 6 Similiar a Fuel Rail Assembly b Intake Manifold c Throttle Body d Schrader Valve 3B 16 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 MEFI 1 2 ECM Input and Sensor Descriptions 3 Similiar The following lists the sensors s
26. Reference Line Seat Assembly Pressure C K Vapor Pressure Vapor Regulator Assembly Water Separating Fuel Filter Vent Line Fuel Fill to Intake Bs In Tank ort Fuel Pressure High Reference Line hi Pressure i Return E Fuel Vapor Pressure Electric Vapor Regulator Return Fuel Fuel Pump Pump Fuel Assembly Fuel Pump Vapor Separating Tank Fuel Pump Vapor Separating Tank Fuel Pressure Neds Fuel Pressure Fuel Pressure Service Tap Fuel Pressure Service egulator Regulator Injector Filter One Piece Fuel Rail Assembely Filter Injector Filter One Piece Fuel Rail Assembely Filter 5 eS Fuel Pressure gt T Fuel Pressure E B Regulator INM E B Regulator emn n ee a l4 _ LET Reference 5 Reference Line to Line to Typical Plenum ypica Fuel Injector Fuel Injector 72573 72573 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 27 Typical EFI MPI System with Cool Fuel Fuel Delivery Components see diagram on next page FUEL PUMP ELECTRICAL CIRCUIT When the ignition switch is turned to the RUN position the ECM will turn ON the fuel pump relay for two 2 seconds When the ignition switch is turned to the crank position the ECM turns th
27. colored water to one half its rated capacity and all fuel tank fittings except the tank vent are to be capped 24 18 5 4 5 rocker assembly shall be adjusted to produce a rocking motion of approximately 15 degrees to either side of a vertical reference line at a rate of 3 to 4 seconds per cycle 24 18 5 4 6 The axis of rotation of the rocker and fuel tank sample shall be parallel to the tank baffles and perpendicular to the centerline of the tank length at a level not more than 6 inches 152 4mm above or below the tank bottom 24 18 5 4 7 tank shall be tested to and meet the requirements of 24 18 5 1 24 18 5 5 Tank Pressure Tests Every tank shall be tested by its manufacturer prior to installation to the maximum test pressure indicated on the tank label without evidence of leakage The test pressure shali be not less than 3 psig 21 90 883145 3 10 03 TABLE I TYPES OF HOSE HOSE MARKING PERMEATION RATING TABLE MATING OF HOSE WITH SPUDS IF MINOR OD IS MAXIMUM DIFFERENCE IN DIAME ER IS TABLE III HOSE CLAMP WIDTHS MINIMUM NOMINAL CLAMP BAND WIDTH OUTSIDE HOSE DIAMETER MINIMUM CLAMP BAND WIDTH Inches Millimeters Inches Millimeters Less than 7 16 11 11 1 4 6 7 16 11 11 thru 13 16 20 64 Over 13 16 20 64 5 16 8 3 8 10 90 883145 3 10 03 2 1 2 MINUTE FIRE TEST H 24 12 96 O 1996 American Boat amp Ya
28. down solenoid where it activates the solenoid to supply current the large green white lead to operate the trim motor in a down direction The pump motor is protected from overheating by an internal circuit breaker in the field winding which interrupts the ground circuit to the solenoids if an overheating condition is sensed 2F 2 POWER TRIM ELECTRICAL 90 883145 3 10 03 Power Trim Wiring Diagram BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK GROUND BOLT FLOOR MOUNT RED PUR od GRN WHT DOWN 7 SOLENOID TO TRAILER SWITCH SCA Lp Eo OWN NEUTRAL SWITCH INSTRUMENT WIRING HARNESS 0a 4 SWITCH 23726 90 883145 3 10 03 POWER TRIM ELECTRICAL 2 3 Trim Pump Wiring Diagrams Model With Three Button Trim Trailer Panel 20 Amp Fuse b Ground Bolt Floor Mount c UP Solenoid d 110 Amp Fuse e DOWN Solenoid f Trim Limit Switch RED PUR DRK 22252 GRN WHT BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK 2F 4 POWER TRIM ELECTRICAL 90 883145 3 10 03 Model With Trim In Handle and Trailer Switch Separate a 20 Amp Fuse b Ground Bolt Floor Mount UP Solenoid 110 Amp Fuse DOWN Sole
29. tower and wipe off excess insulating compound 75634 a Wire Supports b Distributor Terminal c Distributor Coil Wire Terminal d Coil Tower NOTE Make sure boot does not come off of tower due to hydraulic air pressure inside boot caused during installation Distributor Cap Checking 90 883145 3 10 03 1 To remove distributor cap a Loosen the distributor cap retaining screws b Lift cap away from distributor 2 Check cap contacts for excessive burning or corrosion 3 Check center contact for deterioration worn down burning or corrosion 4 Visually check cap for cracks or carbon tracks Thin black lines Generally inside the cap near contacts 5 If cap is acceptable clean cap with warm soap and water and dry with compressed air Replace if defective 75629 a Cap Retaining Screws b Lift Cap Upward c Cap Contacts d Center Contact Inside IGNITION SECONDARY 2E 5 Spark Plugs Checking 1 Disconnect spark plug wires high tension leads from spark plugs 74073 a Spark Plug Boot NOTE Use care when removing spark plug wires and boots from spark plugs Twist the boot 1 2 turn before removing Firmly grasp and pull on the boot to remove the wire end 2 Remove spark plugs NOTE A thin walled spark plug socket may be required 3 Inspect each spark plug for manufacturer and spark plug number All plugs must be from the same manufacturer and have the
30. 11 Gasket 12 Nut Fuel Inlet 13 Choke Rod 14 Gasket 15 Clip Retainer 16 Washer 17 Pump Shaft and Lever Assembly 18 Accelerator Pump Assembly 19 Screw 20 Screw 21 Inlet Needle and Seat Spring Loaded 22 Baffle Plate 23 Float 24 Carburetor Body 12 FUEL DELIVERY SYSTEM AND CARBURETION 25 Cam ldle 34 26 Screw 27 Idle Mixture Adjusting Needle 28 Spring 29 Washer 30 Nut 31 Clip Pump Rod 32 Washer Locking 33 Nut 34 Throttle 35 Spring 36 Screw Idle Speed Adjustment 37 PCV Tube Connection Fitting 38 Check Ball 39 Spring 40 Retainer 75842 41 Screw 42 ever Assembly 43 Screw 44 Choke Housing 45 Gasket 46 Air Horn 47 Pin 48 Screw 49 Gasket 50 Screw 51 Screw 52 Lock Washer 53 Flat Washer 54 Gasket 55 Venturi Cluster 56 Power Valve Assembly 57 Gasket 58 Gasket 90 883145 3 10 03 Fuel Systems Carburetors MerCarb Vacuum and Fuel delivery Vacuum is the primary principle which is used to de liver fuel into the air stream The vacuum is a result of the engine drawing air fuel into the cylinders on the intake stroke The atmospheric pressure inside the float bowl will force the fuel into the low pressure area which is created by engine vacuum Venturi vacuum develops when air passes through a restricted area or venturi at high speed The air pres sure within the venturi drops as the air speed in crease
31. 13 8 kPa Max Resonator Placement 13 17 In 330 432 mm If Equipped f 18 in 457 mm Minimum Between Exhaust El bow and Muffler g 6 Downward Slope Minimum on Conventional Inboards And Skis 4 on VDrives 5 vs Ex haust Elbow Outlet on 8 1S Models h Muffler Should Be Self Draining i Minimum Slope 1 2 in 13 mm per Foot Approx 3 In this Region j Exhaust Outlets Above Waterline with Maximum Load Shutters and Flappers Required on Models Except 8 15 4 in 102 mm Drop Minimum NOTE Effective waterline is water line in muffler Follow muffler manufacturer s instructions Typical Exhaust System with Collector and Water Lift Muffler a Water Line b Siphon Break Vacuum Valve Must Be Installed in Cooling Water Circuit If Exhaust Elbows Are At or Below Water Level See Muffler Manufacturer s Recommendations 4 in 102 mm Exhaust Hose Minimum 5 in 127 mm Minimum Required for Single Hose Portion on 8 15 Models Exhaust Back Pressure Check Point 12 24 in 305 610 mm 2 psi 13 8 kPa Max Resonator Placement 13 17 In 330 432 mm If Equipped 18 in 457 mm Minimum Between Exhaust Elbow and Collector 6 Downward Slope Minimum on Conventional Inboards 4 on V Drives 5 vs Exhaust Elbow Outlet on 8 1S Models Minimum Slope 1 2 in 13 mm per Foot Approx 3 In this Region Collector See Information on
32. 3B 19 MerCruiser EFI System Electronic bt TEE E mines 3B 20 MEFI 3 Sterndrive 7 4L MPI Bravo and MIE Inboard 7 4L Inboard 3B 20 The different modes of engine operation 3B 24 EFI System Air Delivery Components 3B 25 Fuel Systems Electronic Fuel Injection 3B 26 Throttle Body Injection With Vapor Separator Tank VST 3B 26 EFI System Vapor Separator Tank VST 3B 27 Typical EFI MPI System with Cool Fuel Fuel Delivery Components 3B 28 Cool Fuel System Fuel Pressure 2119 3B 30 Testing Fuel System Pressure on EFI Throttle Body Injection Systems 3B 31 Testing Fuel System Pressure on Multi Port Injection MPI Systems 3B 31 Fuel Pressure Test Gauge Adaptor tec 3B 32 GM ECM Identification 3B 34 ECM 555 Identification 3B 35 PCM 555 Identification 3B 36 3B i ELECTRONIC FUEL INJECTION INTRODUCTION PCM 555 Engine Guardian Strategy 3B 37 Typical Starting and Charging System Harness Small Block MEFI 3 3B 38 EFI System Harness 454 502 8 2L Models except 129 3 3B 39 ECM Wiring Diagram MEFI 3 Big Block 8
33. 97 23 MerCruiser Gasoline Engine Oil Recommendation 97 24 Service Tools 97 25 Gasoline Engine Compression Test 1998 MERCRUISER SERVICE BULLETIN INDEX 98 1 MCM 3 0L Flame Arrestor Decal 98 2 Operating a Bravo One Performance Drive with Low Water Inlets in Shallow Water 98 3 Regulator Piston for Velvet Drive Transmissions 98 4 Electric Fuel Pump Check Valve Sticking 98 5 USA Gasoline 97 24 Service Tools 98 6 7 41 129 Exhaust Valve Inspection 98 7 MerCruiser Lower Unit Shift Shaft Tool 98 8 New One Piece Oil Seal Carrier for Aloha One Gen Il 98 9 Installation Issues With MCM D7 3L D Tronics 98 10 Injection Pump Timing Specifications 98 11 Required MIE 7 4L MPI L29 ECM Replacement 98 12 Gimbal Housing Oil Reservoir Bulkhead Fitting Material Change 98 13 Required 1 Injector Replacement 98 14 3 0L Engines with Blown Head Gasket 98 15 Shift Cable Measurement for Transmissions 98 16 Bravo Drive Shaft Housing Replacement 98 17 Modification of Tool Kit 91 806563A1 for D Tronic Diesels 98 18 Second Station Start Stop Kit Instruction Sheets 1999 MERCRUISER SERVICE BULLETIN INDEX 99 1 Delco Starter Motors See SB 2001 11 99 2 V6 and V8 305 350 cid Engines With MEFI 3 99 3 MEFI 8 Diagnostic Trouble Codes and Audio Warning System 99 4 Sensor Failures in MEFI 3 Mercury Distributors Used On V6 and V8 305 350 cid Engines 99 5 Proper Oil Fill Level On Velvet Drive Transmissions 99 6 Proper Shift Set up For
34. Fuel line shut off tool MPI injector noid light Bosch connector GM TBI injector noid light Fuel line disconnect tool set fuel supply at rail 9 46 fuel return plug at rail Portable 6 6 gal Fuel Tank Cole Parmer Digital PSIG Gage Stevens Instruments Gearcase Pressure Tester Fuel quality testing kit Fluke Pressure Vacuum Transducer Module Electrical System Tools DMT 2004 multi meter Set 10 Mega ohm impedance Clamp on ammeter probe for any standard DVOM DVA adaptor for any standard DVOM EFI 12v test light unpowered IAC noid light EFI test lead set GM style harness test leads Packard connector repair Kit Quicksilver Electrical Hardware Kit bullet connectors Quicksilver Crimping Pliers packard style Quicksilver Harness Seal Kit Snap on Terminal Tool Kit Hemote Starter Switch Rinda 94016 Ignition System Tools Kilo Volt meter Snap On Air gap spark tester single 1 2 inch gap Air gap spark tester 8 adjustable gaps Timing jumper plug jumps A amp B at DLC Continuity light 1 5v self powered Timing light 91 881833A2 91 803135 8 4814 8 4914 8 4614 91 806901 91 18078 91 805918 2 J 34730A2 OTC 7188 J 34730 400 OTC 7187 J37088 A J 41769 OT C 7660 J 37088 1A or J 41769 1 J 41769 2 See current MPP Acessories Guide for selection of tanks Model No 68920 10 5 34 J 39383A 0 T C 7670 PV 350 Fluke 91 892647A01 91 802650 91 89045 1 J 34142 B OTC 30535
35. If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol These Reformulated Gasolines are acceptable for use in your MerCruiser engine GASOLINES CONTAINING ALCOHOL 90 883145 3 10 03 If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank The fuel system components on your MerCruiser engine will withstand up to 1096 alcohol content in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specific recommendations on the boats fuel system components fuel tanks fuel lines and fittings Be aware that gasolines containing alcohol may cause increased e Corrosion of metal parts Deterioration of rubber or plastic parts e Fuel permeation through rubber fuel lines e Starting and operating difficulties FUEL DELIVERY SYSTEM AND CARBURETION 3A 1 FIRE AND EXPLOSION HAZARD Fuel leakage from any part of fuel system can be fire and explosion hazard which can
36. If you find that the engine s electrical system is not functioning check the fuse first Do not use a higher amperage fuse in place of the 55 Amp part This fuse is matched to the engine harness wire gauge 55 Amp Fuse P N 88 79023A56 90 883145 4 0804 a 55 Amp Fuse NOTE Current carbureted engines use a 55 amp BLACK fuse EFI engines use a 90 amp WHITE fuse Do not substitute wrong fuse STARTING SYSTEM 2B 3 Testing A strong battery must be maintained If battery shows less than 9 1 2 volts when under start ing load at 80 F or 27 C it should be recharged Check with DC voltmeter 74307 a Voltmeter b Battery 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 e Battery must be 60 to 100 F 16 to 38 C e Electrolyte level must be correct in all cells Battery must be at least half charged Noobvious defects 1 Check voltage per manufacturer s specifications 2 f readings are low recharge and retest 3 If readings remain low battery should be replaced 2B 4 STARTING SYSTEM 90 883145 4 0804 Slave Solenoid Identification Types There are two types of slave solenoids standard or switch used on MerCruiser engines These engines use a standard type solenoid do not substitute a switch type solenoid The other engines use a slave
37. Microscopic damage or holes will result in eventual water intrusion corrosion and or component or circuit failure Locate damaged wire 2 Remove insulation as required OSB 73048 3 Splice two wires together using splice clips and rosin core solder 73048 4 Cover splice with heat shrink sleeve to insulate from other wires 73048 2A 8 BATTERIES WIRING 90 883145 3 10 03 Wiring Connector Service 90 883145 3 10 03 Most connectors in the engine compartment are protected against moisture and dirt that could create oxidation and deposits on the terminals This protection is important because of the very low voltage and current levels found in the electronic system The connectors have a lock which secures the male and female terminals together A secondary lock holds the seal and terminal into the connector When diagnosing open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors Merely wiggling a connector on a sensor or in the wiring harness may locate the open circuit condition This should always be considered when an open circuit or failed sensor is indicated Intermittent problems may also be caused by oxidized or loose connections Before making a connector repair be certain of the type of connector Some connectors look similar but are serviced differently Replacement connectors and terminals are listed in the Parts Catalog Ensure that the con
38. RH Rotation Bravo One Two Three And Blackhawk 71663 LH Rotation Bravo One And Two a Adjustment Tool b Barrel Retainer c Shift Lever Stud d Shift Lever Adjustment Slot 10 Remove adjustment tool 11 Lubricate shift cable pivot points with 30W oil Troubleshooting Shift Problems NOTE See Troubleshooting information following Alpha Drive Unit Remote Control and Drive Unit Shift Cables Adjustment and Shift Cutout Switch Checking 1 36 STERNDRIVE INSTALLATION 90 883145 3 10 03 Calculating Overall Drive Ratios INPUT SHAFT DRIVE GEAR GEAR END YOKE E BN us DRIVE SHAFT HOUSING So ETTET 1 22 Tooth 3 2 20 Tooth 3 13 Tooth 4 21 Tooth M Overall Ratio Ro Ro Driven 2 Drive 1 x Driven 4 Drive 3 Ro 20 22 x 21 13 Ro 909 x 1 615 Ro 1 468 1 47 Ro 1 47 Turns of Input Shaft to 1 turn of Prop Shaft 90 883145 3 10 03 PROPELLER SHAFT DRIVEN GEAR DRIVEN GEAR DRIVE GEAR STERNDRIVE INSTALLATION 1C 37 NOTES 10 38 STERNDRIVE INSTALLATION 90 883145 3 10 03 MERCRUISER PDI AND MAINTENANCE LEVEL I D POWER STEERING INSTALLATION Table of Contents Power Steering Installation 1D 1 1D i POWER STEERING INSTALLATION 90 883145 3 10 03 The flat surfaces on the cable guide tube of a DHB power steering valve assembly must be vertical as shown belo
39. Typical Alpha Drive V 8 Engines 50843 20 6 IGNITION SYSTEMS 90 883145 3 10 03 NOTES 90 883145 3 10 03 IGNITION SYSTEMS 2D 7 Thunderbolt V Ignition The Thunderbolt V ignition system uses the same distributor as the Thunderbolt IV system The system has a new Ignition Control Module with Digital Electronic Spark Advance D E S A There is also a Knock Control Module that is mounted with the ignition control module Ignition Control Module b Knock Control Module NOTE Earlier models have the modules mounted on the distributor Later models have the modules mounted on the exhaust elbow 2D 8 IGNITION SYSTEMS 90 883145 3 10 03 General Description The Thunderbolt V ignition system has several spark control features that will be described following e Idle Speed Spark Control e Acceleration Spark Advance e Mean Best Timing Spark Advance Over Speed Control Rev Limiter e Knock Retard Spark Control Idle Speed Spark Control The ignition module will control ignition timing to maintain a calibrated idle speed This is ac complished by making small spark advance adjustments This feature is only active within a certain RPM range This range may be slightly different from one engine model to another The approximate range is 400 700 RPM Acceleration Spark Advance This feature is active during acceleration only When accelerating the ignition module may add more spark advance to the Base
40. leave the engine running and switch voltmeter to the AC volt position and observe voltmeter reading a A reading of 0 25 AC volt or less while charging indicates the diodes are good b reading of more than 0 25 AC volt indicates that the alternator has defective diodes DC Volts W Engine Running 13 8 14 2v Gel Type 13 5 13 8v AC Volts or Ripple W Engine Running No more than 0 25V AC 2C 4 CHARGING SYSTEM 90 883145 3 10 03 6 If voltmeter reading stays above 15v the time the alternator is over charging the battery and alternator needs to be repaired 7 voltmeter reading is below 13 5v the alternator is not charging properly a Check for battery voltage at the RED PUR wire at the alternator b Check for battery voltage at the PUR wire at the alternator with the key switch ON NOTE Make sure engine wiring harness leads and the alternator leads are not reversed C If both wires have battery voltage go to step 8 8 If voltmeter reading is below 13 5v connect voltmeter lead to output terminal on the alternator and the voltmeter lead to the ground terminal on the alternator 9 Repeat step 4 If reading now is within range resistance in the charging circuit is the problem Check Alternator for DC Volts W Engine Running 13 8 14 2v 10 Test for resistance on the alternato
41. than 1 4 inch 6 4mm EXCEPTION Space required for expansion of new non metallic fuel tanks 24 10 6 All non integral tank supports chocks or hangers shall be separated from the metallic tank surface by a non metallic non moisture absorbent non abrasive material suitable for the purpose e g neoprene Teflon and high density plastics 24 10 6 1 Self wicking material such as carpet pile shall not be in contact with a metallic tank 24 10 7 Metallic fuel tanks installed above flat surfaces shall be separated from the surfaces by at least 1 4 inch air space when filled with fuel and the flat mounting surface shall be self draining 24 10 8 Each metallic tank must be installed to allow drainage of accumulated water from the tank s surfaces when the boat is in its static floating position 24 10 9 Metal tanks shall be installed where they cannot be reached by normal accumulation of bilge water in the static floating position 24 10 10 Aluminized steel tanks of less than 0785 inch 2mm thickness shall be installed above the cockpit floors or above deck if there is not a clearly defined cockpit 24 10 11 If a metallic fuel tank is encased in plastic 24 10 11 1 the tank material may not be a ferrous alloy and 24 10 11 2 the plastic must be attached to the metal surface of the tank so as to prevent moisture between the metal and the plastic and 24 10 11 3 the adhesive strength of the metal to plastic bond must e
42. 08 95 6 Oildyne Trim Pump Troubleshooting Chart 95 7 Reformulated Gasoline USA 95 8 MerCruiser Steering Recommendations 95 9 Diesel Fuel Filters and Fuel Additives 90 883145 3 10 03 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 4 3 95 10 MerCruiser D7 3L 270 Diesel Stern Drive Replacement 95 11 Ignition Advance Curves and Point Setting 95 12 Engine Compartment Temperature 95 13 Alpha One Generation Il Overheat 95 14 Cooling Systems Maintenance 95 15 MerCruiser D7 3L Diesel Overheat 95 16 Low Sulfur Diesel Fuels 95 17 3 0LX Engine Noise or Noisy Lifters 95 18 Hino Diesel Excessive Black Smoke 95 19 Turbo Charger Waste Gate 95 20 Delco Starter Motors See SB 2001 11 95 21 Bearing Cup Installation In The Bravo One Bearing Carrier 95 22 Shrink Wrapping Boats 95 23 Velvet Drive Distributors 95 24 Hurth Marine Gear Distributors See SB 2002 08 1996 MERCRUISER SERVICE BULLETIN INDEX 96 1 Bravo Transom Assemblies for the 1996 1 2 Model Year See SB 98 16 96 2 Water In Fuel Module WIF Warning Light 96 3 Serpentine Belt Adjustment 96 4 Quicksilver Digital Diagnostic Terminal DDT and Accessories See SB 2001 02 96 5 Troubleshooting Shift Problems 96 6 Modifying MerCruiser Engines To Increase Performance Or Horsepower 96 7 Modifying MerCruiser s Exhaust System 96 8 Brass Power Steering Hose Coupling 96 9 MerCruiser Scan Tool See SB 2001 01 96 10 Piston Ring End Gap 96 11 Hurth T
43. 13 Fuel Pressure Regulator 14 Fuel Block 15 Fuel Line From Fuel Block To VST 16 Fuel Injector 8 17 Intake Manifold 18 Engine Coolant Temperature ECT Sensor 19 Fuel Line From Front Of Starboard Fuel Rail To Rear Of Port Fuel Rail 20 Fuel Line From Rear Of Starboard Fuel Rail To Front Of Port Fuel Rail 21 Fuel Line From Cool Fuel System 22 Adapter Block 23 Schrader Valve a VST Equipped System b Cool Fuel System 3B 10 ELECTRONIC FUEL INJECTION INTRODUCTION 75068 90 883145 3 10 03 350 MPI Magnum Tournament Ski Black Scorpion Induction System 1 Flame Arrestor 2 Flame Arrestor Clamp 3 Throttle Body 4 Throttle Body Gasket 5 Manifold Absolute Pressure MAP Sensor 6 Plenum Fuel Rail Fitting 2 8 Fuel Line 9 Screw 2 10 Fuel Rail 2 11 Fuel Damper 12 Fuel Rail Fitting 2 13 Schrader Valve 14 Fuel Line 15 Fuel Injector 8 16 Manifold 17 Engine Coolant Temperature ECT Sensor 18 Inlet Fuel Fitting From Cool Fuel System 19 Fuel Line From Front Of Starboard Fuel Rail To Rear Of Port Fuel Rail 20 Fuel Line From Rear Of Starboard Fuel Rail To Front Of Port Fuel Rail a Earlier Fuel Hose System b Cool Fuel System 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 11 Later Model 350 Mag MPI Induction System MEFI 3 Model
44. 1F 3 4 When first starting engine be prepared to add fluid to pump a Fill Cap Dipstick 5 Cycle the steering full turns both port and starboard several times to help purge air from the system 1F 4 PREDELIVERY PREPARATION 90 883145 3 10 03 Drive Unit Gear Lube Monitor 90 883145 3 10 03 e Always check oil level when drive is cool and engine is shut down e level in reservoir bottle will rise and fall during drive operation a Drive Unit Gear Lube Monitor Mounted on Transom 1 With drive in full down position remove drive unit vent plug and sealing washer gt 8 9 70121 Vent Plug and Sealing Washer IMPORTANT Failure to fill drive unit to level of vent hole will result in a low drive oil level Oil Reservoir only MAINTAINS drive oil level and will not correct an improperly filled drive unit 2 Fill Oil Reservoir bottle with Quicksilver High Performance Gear Lube When oil starts to run out the drive unit vent hole after oil fills the entire length of hose between reservoir and drive unit re insert vent screw and sealing washer and tighten securely 3 Fill Oil Reservoir bottle to FILL mark Lubricate O ring in reservoir cap with sterndrive oil to insure ease of installing and removing cap and install cap Do not overtighten cap 4 Recheck oil level after first use PREDELIVERY PREPARATION 1F 5 Propeller Installation IMPORTANT Correct rotatio
45. 883145 3 10 03 CHARGING SYSTEM 2C 3 Testing Alternator Output with a Voltmeter NOTE Information from Service Bulletin 2001 12 August 2001 Models All MerCruiser engines No Trouble Found Alternators are returned for warranty that function properly when tested The first test that should be done on an engine with a charging problem is to check the condition and tightness of the alternator drive belt Next check the condition of the cranking battery If the fault is not with the belt or battery test the alternator as outlined in this bulletin NOTE Each time an engine is started the alternator has to reach about 1000 engine rom before it will put out charging current Testing the Charging System Perform this test before removing the alternator from the engine ike An analog or digital voltmeter can be used but the digital meter is best NOTE Be sure to 0 meter before making the test and that the boat s battery is fully charged 2 Connect voltmeter positive lead directly on the battery positive post not the battery cable ring terminal Connect voltmeter negative lead directly on the battery negative post not the bat tery cable ring terminal Start the engine increase rpm to 1300 and observe voltmeter reading a Most systems will give a reading of 13 8 to 14 2 volts Some gel cell batteries have a lower voltage setting of 13 5 to 13 8v If the voltmeter is within range
46. 9 Start the engine Operate at idle rpm until it reaches normal operating temperature and the fuel stabilizer has been circulated Shut off the engine 6 Change the engine oil and filter If boat has been operated in salty polluted or mineral laden waters flush cooling system as outlined in Flushing Cooling System 1G 2 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 90 883145 3 10 03 8 Prepare fuel system for extended storage as follows a Close the fuel shut off valve if equipped If no fuel shut off valve is present a suitable method must be employed to STOP the flow of fuel from the fuel tank to the engine before proceeding b Remove flame arrestor assembly and start engine c 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 20W engine oil into carburetor bores d Squirt the remaining 2 ounces 57 g of Storage Seal or oil rapidly into carburetor just as the engine begins to stall due to lack of fuel Allow engine to stop e Turn ignition key to OFF position f Refer to Flushing Cooling System and appropriately remove water supply to the sea water pickup pump 9 Clean flame arrestor and crankcase ventilation hoses and reinstall 10 Drain seawater section of cooling system as outlined in Draining Instructions 11 Closed Cooling Sy
47. Batteries Boats with multi engine EFI power packages require each engine to be connected to its own battery This ensures that the engine s Electronic Control Module ECM has a stable volt age source Battery Switches While engines are running battery switches should be positioned so each en gine is running off its own individual battery DO NOT run engines with battery switches in BOTH or ALL position In an emergency another engine s battery can be used to start an engine with a dead battery 90 883145 4 0804 BATTERIES WIRING 2 17 Battery Isolators Isolators can be used to charge an auxiliary battery used for powering accesso ries in the boat They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose NOTE Sure Power Industries Inc Model 32023A meets this design specification 1 The boat may have 2 engines connected to a single Model 32023A battery isolator The Model 32023A battery isolator is connected to 2 banks of batteries Each bank contains 2 batteries with the cranking battery for 1 engine in each bank The second battery in each bank is connected in parallel to the cranking battery oe amp I9 The Model 32023A battery isolator is designed for this type of use 2 battery banks 2 charging sources 120 amps maximum alternator output 6 When the engines are running either engine s alternator could be charging eithe
48. Battery 10 Amp ECM Injector 3 Coil Ignition Knock Module 4 Knock Sensor KS Module 14 Harness Connector To Starting Charging 5 Data Link Connector DLC Harness 6 Manifold Absolute Pressure MAP Sensor 15 2 Power Wire Engine Circuit 7 Air Control 8 Throttle Position TP Sensor 9 Engine Coolant Temperature ECT Sensor 10 Electronic Control Module ECM 11 Fuel Pump Relay 12 Ignition System Relay 16 Oil Pressure Audio Warning System 17 Load Anticipation Circuit 18 Water Temperature Sender 19 Gear Lube Bottle Not used on Inboard models 20 Intake Air Temperature IAT Sensor qu xe by Moan 5 a LHM NVL 1 76001 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 39 ECM Wiring Diagram MEFI 3 Big Block V8 1 of 4 INJECTORS 2 3 5 8 From INJ ECM 481 1 1 Lire EL 467 DK BLU INJECTOR DRIVER 10 AMP 439 PN INJECTORS 1 4 6 7 481 468 DK GRN 6 J1 17 BINJECTOR DRIVER a 1 17 From B 439 2 RED 465 DK J1 23 BFUEL PUMP RELAY FUEL PUMP RELAY FUSE 15A FUEL PUMP RELAY FUEL PUMP UE z 441 BLU WHT g J1 28 IAC COIL A HIGH CONTROL 442 BLU BLK 1 12 BIACCOIL A LOW IAC VALVE 443 GRN WHT IAC COIL HIGH 444 GRN BLK J1 27 COIL B LOW 461 ORN 41 32
49. Comments Reading Reading Engine Speed Des Idle Speed Coolant Temp Manifold Air Tmp TPS Volts Throttle Pct MAP Volts Manifold Pres Baro Volts Battery Volts Spark Advance Knock Retard IAC Position Base IAC Pos IAC Follower Injector ON Time Inj ON Time Crnk Fuel Flow Rate Engine Run Time Memcal Checksum Fault Switches Engine Overtemp Power Reduction E Stop Status Rinda Technologies Inc Chicago IL Tel 773 736 6633 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 65 MC RINDA MEFI II DATA SHEET Engine Data Worksheet Engine Type Year Serial No Contact Tel Date Spark Advance 115 Gasoline EFI MEFI Il ECM Scan tool requires adapter 94005 for this application n Data List 1 Data Item Current Normal Comments Reading Reading Engine Speed Des Idle Speed Coolant Temp Manifold Air Tmp TPS Volts Throttle Pct MAP Volts Manifold Pres Baro Volts Battery Volts Spark Advance Engine Knocking Knock Retard IAC Position Base IAC Pos IAC Follower Injector ON Time Fuel Flow Rate Engine Run Time Memcal Checksum Engine Overtemp Power Reduction Fault Switches Shift Interrupt E Stop Status Diagnostic Input Input J1 20 General Warn 1 General Warn 2 Fuel System Slave Input Fuel Pump Status Check Engine Lamp Rinda Technologies Inc Chicago IL Tel 773 736 6633 3B 66 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 MC RINDA MEFI 11 DATA SHEET Engine D
50. Control a RIGHT HAND RH propeller rotation drive unit Shift remote control into reverse gear wide open throttle position while simultaneously rotating propeller shaft clockwise Clutch should engage and cause propeller shaft to lock If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with reverse gear Retighten stud Shift remote control several times and stop in reverse to recheck shift cutout switch position Roller or plunger pin must be centered LEFT HAND LH propeller rotation drive unit Shift remote control into forward gear wide open throttle position while simultaneously rotating propeller shaft clockwise Clutch should engage and cause propeller shaft to lock If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with forward gear Retighten stud Shift remote control several times and stop in forward to recheck shift cutout switch position Roller or plunger pin must be centered 13 Two Lever Remote Control with Separate Shift and Throttle Levers 90 883145 3 10 03 a RIGHT HAND RH propeller rotation drive unit While turning propeller shaft clock wise move remote control shift handle into full reverse position Clutch should engage before shift lever comes to a stop If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with revers
51. Description The MerCruiser EFI Fuel System consists of a fuel supply water separating fuel filter me chanical fuel pump vapor separator tank VST electric fuel pump injector fuel filter fuel rail pressure regulator fuel injectors throttle body and throttle position TP sensor Fuel is drawn from the boat s fuel supply tank through a water separating fuel filter by a mechanical fuel pump mounted on and driven by a seawater pump and is delivered to the vapor separator tank VST The VST consists of a reservoir float needle and seat assembly fuel pump pickup screen electric fuel pump The electric fuel pump located in the VST pumps the fuel rail supplying pressurized fuel to the fuel injectors A pressure regulator located on the fuel rail maintains a constant fuel pressure in the fuel rail The fuel bled off from the pressure regulator is delivered back to the VST The throttle body is the component of the system which supplies the air required for optimum fuel combustion The throttle body consists of a housing two throttle plates throttle plate link age idle air control IAC valve and throttle position TP sensor Tech Tip See MC Parts Bulletin 98 6 for VST O Ring part number Sight Tube to Throttle New Style VST Body OLD Style VST SeafFuel Pump Tank Fuel Filter SeajFuel Pump Vent Line Fuel Fill to Intake EHE Needle 8 In Tank Fuel Pressure Needle amp Seat Assembly High
52. IGNITION SECONDARY 90 883145 3 10 03 Distributor Removal 1 Loosen four distributor cap retaining screws 2 Remove distributor cap Inspection 1 Clean cap with warm soap and water and blow off with compressed air 2 Check cap contact for excessive burning or corrosion Check center contact for deterioration 3 Check cap for cracks or carbon tracks using magneto analyzer 4 Check condition of distributor cap gasket Replace gasket if damaged or missing 5 If high tension leads are removed from cap refer to Spark Plug Wires in this section and the following illustrations for installation 72981 Wiring a Alignment Notch 72978 a Vent 90 883145 3 10 03 IGNITION SECONDARY 2E 1 Rotor Sensor Wheel Removal 1 Remove distributor rotor sensor wheel assembly from distributor shaft Rotor and sensor wheel are secured to the shaft with Loctite Use two flat blade screwdrivers The screwdrivers are positioned 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 off rotor sensor wheel assembly The use of torch lamp will also aid in the removal of the rotor sensor wheel assembly Wear protective gloves when handling heated rotor sensor wheel assembly to avoid severe burns 1 With the rot
53. Models with Exhaust Elbow Mounted Module Alpha and Bravo Models see Noite 1 Ignition System Wiring Diagram Se 515 w o 5 c a2 205 D 1 05265 do SRE n i Al Q JJ w Z comet J of IL oA GI KNOCK S CONTROL X MODULE SENS Z D TO ENGINE HARNESS U O O C W D E C J D J z m gt P lt m B e 3 o R oo 70 Q T TO DISTRIBUTOR IGNITION CONTROL MODULE 75456 NOTE Alpha Models Are Equipped With A Shift Cut Out Switch 305 and 350 cid Bravo Models Will Have Two BLACK Leads Connected Tog
54. Position Sensor is a 3 wire Hall Effect sensor and is mounted on the rear of the engine on the port side The sensor extends all of the way down to a timing wheel permanently attached to the crankshaft Windows and vanes of the timing wheel pass near the sensor causing it to turn on and off The result is a square wave 5 signal sent back to the PCM This signal informs the PCM of crankshaft position and engine RPM The sensor s position is fixed and cannot be adjusted There is also no air gap adjustment on this sensor A failure of the Crankshaft Position Sensor or its circuit will not set a fault 3B 22 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 CAMSHAFT POSITION SENSOR CMP The Camshaft Position Sensor is another 3 wire Hall Effect sensor and is mounted on the timing cover at the front of the engine The sensor extends close to the camshaft gear which is specially machined to provide a single window and single vane that passes near the sensor causing it to turn on and off The result is a square wave 5 Vdc signal sent back to the PCM This signal informs the PCM of camshaft position The camshaft position signal lets the PCM know whether a cylinder is on compression stroke or on exhaust stroke so the PCM can inject fuel and fire the ignition coil on the appropriate stroke A failure of the Camshaft Position Sensor or its circuit will set a fault and will result in the PCM firing the ignition coils each revolutio
55. Previous Drawing Muffler Must Be Positioned per Manufacturer s Specified Distance Below Exhaust Elbows Muffler Riser Must Extend Manufacturer s Specified Distance Above Water Line Drain Cock m Exhaust Outlets Above Waterline with Maximum Load Shutters and Flappers Required on All Models Except 8 1S O x 5 Q 90 883145 3 10 03 USE OF SERVICE LITERATURE 1A 9 Cooling System a Exhaust Elbow b Exhaust Manifold Seawater Pump d Water Circulating Pump e Thermostat Housing f Water Distribution Housing g Cool Fuel Box h Check Valve Power Steering Cooler See MC Service Bulletin 97 19 for pertinent information 1A 10 USE OF SERVICE LITERATURE 90 883145 3 10 03 Transom Assembly b i a 7 Inner Transom Plate wa 22 E b P grr 90 883145 3 10 03 USE OF SERVICE LITERATURE 1A 11 MerCruiser Drives Typical Bravo Il Bravo Ill 1A 12 USE OF SERVICE LITERATURE 90 883145 3 10 03 MERCRUISER EN PDI AND MAINTENANCE LEVEL I ENGINE INSTALLATION AND ALIGNMENT Table of Contents Engine lt New MerCruiser Sterndrive Rear Engine MOUNIS Gann Bee he Engine Alignment Checking Stringer Height Suspending The Engine Alignment Tool Requirements Final Engine Mount Height Adjustment
56. Rinda 94025 J 35616 A J 38125 B 86 813937A2 91 808696 91 881814A1 TT 600 91 52024A1 700 DIS KV 91 63998 1 91 850439T 1 91 805747A2 J 21008 A Locally available ELECTRONIC FUEL INJECTION INTRODUCTION 3B 73 General Diagnostic Tools Hand vacuum pump Mity Vac or equivalent J 23738 A OTC 7059 Rinda CodeMate winky blinky 94008 Rinda MerCruiser scan tool current software version 4 0 94050m Software update for scan tool version 4 0 94056 ECM PCM 555 adapter cable 64006 Update for scan tool software and cable 94056 Rinda Diacom PC software and cable Windows Version 94010m Quicksilver DDT digital diagnostic terminal 91 823686A2 MerCruiser DDT cartridge current software version 2 0 91 803999 SmartCraft DDT cartridge version 1 3 91 880118 003 MerCruiser DDT adaptor cable DLC and injector connectors 84 822560 2 ECM s SmartCraft MerCruiser DDT adaptor cable ECM PCM 555 ECM s 84 822560A13 or 84 822560A5 and 84 822560T12 OTC replacement boot for DDT 3305 30 OTC printer for DDT OTC 3285 OTC printer cable for DDT 25 pin serial port OTC 212536 OTC PC cable for DDT 9 pin serial port OTC 212535 Standard manifold vacuum gauge Locally available Mechanics stethoscope Locally available 3 of 5 32 I D clear vinyl hose with 5 32 Tee Locally available 5 16 or 3 8 clear vinyl hose with a hose barb on one end 9 Locally available Footnotes 1 2 Used
57. Settings User 1 Setup 1 5 this screen allows selection Press 1 Yes 2 No of English or Metric data values for complete data list Then press Enter The following screens allow user to customize the data list to be viewed what is viewed and order it is viewed and values to be displayed in English or Metric Save Current Tool Settings Are you sure Press 1 Yes 2 No Pressing this button will cause the tool to revert back to the previous setup Page 5 MERCURY MEFI 1 Data Log Sheet DDT Tech Service Education Engine Model Serial Number Customer RO Test RPM conditions Data english units Current Reading Comments Engine Speed Desired Engine Rom ECT Sensor F IAT Sensor F Map Sensor Hg Map Sensor V Baro Sensor Hg Baro Sensor V TP Sensor V TP Sensor Fuel Rate Gph Inj Pulse Width ms Spark Advance KS System Enabled KS Signal Knock Retard IAC Position Base IAC Position Trim Sensor V Not used by MC IAC Follower Vessel Speed MPH Not used by MC Battery V Fuel Pump Relay Power Reduction Overheat Detection Low Oil Pressure Switch Low Oil Level Switch Not used by MC Low Water Flow Switch Not used by MC Trans Temp Switch Not used by MC I O Fluid Level Not used by MC Gen Warn 1 Lamp Not used by MC Buzzer Lanyard Stop Overtrim Detection Not used by MC ECM Status Fuel System Not used b
58. Spark Timing Curve The amount of spark advance added is totally dependant on how fast RPM increases how fast the throttle is moved This feature is also active within a certain RPM range This range may be slightly different from one engine model to another The approximate RPM range for this feature is 1200 4000 RPM Within this range the module can add approximately 10 degrees of spark advance to the base spark timing curve Mean Best Timing MBT Spark Advance During light load cruising the ignition module searches for the optimal ignition timing This is also accomplished by small changes to the spark advance At a given RPM the module will try to add a small amount of advance and wait to see if there is an RPM change If RPM increases it will try to increase timing more The module will continue to advance timing until it no longer gets an increase in RPM Conversely if it senses an RPM drop it will start to retard some of the spark timing The approximate RPM range for this feature is 1200 4000 RPM Within this range the ignition module can add approximately 10 15 degrees of spark advance to the base spark timing curve NOTE The Audio Warning System is also connected into the ignition module circuit If the audio warning system becomes activated by the closing of one of the audio warning system switches the MBT feature is deactivated Over Speed Control The ignition module will prevent the engine speed from exceeding a preset
59. The reservoir shall be made leak proof and shall be capable of containing sufficient fuel to burn for a period of 2 5 minutes 24 18 4 6 7 The fuel tank sample and all connecting piping and fittings shall be checked for leakage and 3 psi aerostatic pressure applied to the tank vent Following the 90 883145 3 10 03 H 24 12 96 Corrected 7 98 Pressure Test the pressure shall be released and the tank vent left open to simulate a normal condition The size of the fuel tank sample vent shall be determined by the size of the vent fitting provided by the manufacturer 24 18 4 6 8 fuel tank sample is to be filled to one quarter rated capacity with gasoline and all openings capped or plugged except for the fuel tank vent that is to be extended without traps outside the Fire Test areas 24 18 4 6 9 N Heptane shall be poured into the reservoir in accordance with 24 18 4 5 7 24 18 4 6 10 The test method described in 24 18 4 7 shall be used 24 18 4 7 Test Method for Fuel Tank Fire Test 24 18 4 7 1 area in which the test is to be conducted is to be free from drafts but shall have provision for a free inflow of air during the test The test shall be conducted as follows 24 18 4 7 2 N Heptane in the hull section or the test enclosure shall be ignited and permitted to burn for a continuous period of 2 minutes The temperature within one inch of the component must be at least 1200 F 648 C some time w
60. Trim Indicator be marked to clearly indicate the maxi mum up out position where side support 15 still provided The drive unit should not be trimmed to a position beyond gimbal ring side support at engine speeds above 1200 RPM Avoid personal injury or damage to sterndrive unit Do not trim drive unit to an up out position where the drive unit receives no side support from the gimbal ring at engine speeds above 1200 RPM Refer to a properly marked mechanical Trim Position Indi cator 1 Install WARNING DECAL Contained in the transom assembly box at the operator station in a place where it will be clearly visible to the operator 2 mark the maximum Trim Up Out position on the mechanical trim indicator proceed as follows a Trim drive unit s to the Full Down In position b Check to ensure that the mechanical trim indicator indicates Full Down In position Adjust the indicator following the manufacturers recommendations c Slowly raise the drive unit s until the trim limit point is reached The trim limit point can be determined by measuring the amount of trim cylinder extension The dimen sion for the Bravo and Blackhawk drive units is 21 3 4 in 552 mm which is mea sured from front anchor point to rear anchor point centerlines as shown following Q nl 50464 a Trim Limit Dimension 21 3 4 in 554mm d With the trim cylinders at this position place a mark on the mechanical t
61. Wastegate to Exhaust Elbow Flex Tube 1993 MERCRUISER SERVICE BULLETIN INDEX 93 1 7 4L Bravo Three GM Gen V Engine Specifications 93 2 Vapor Separator Tank VST Recall B Electric Control Module ECM Recall 93 3 Universal Joint Cross amp Bearing Cup Seal 93 4 Required Flame Arrestor Replacement 93 5 Required Fuel Pump Push Rod Replacement 93 6 Add Water Inlet Hose Clamp 93 7 Alternate Gear Ratio Stern Drive Units for High Altitude 93 8 224 CID 3 7L Minimum Oil Pressure 93 9 New Reverse Gear 43 824109 and Thrust Spacer 23 824108 93 10 Bravo Shimming Procedure Change for the Gear Case Bearing Carrier 93 11 Required Starboard Engine Mount Bolt Replacement 4 2 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 90 883145 3 10 03 93 12 Required Fuel Inlet Fitting Replacement Weber Carburetor 93 13 MerCarb 2 BBL Carburetor See SB 97 8 93 14 Weber 4 BBL Carburetor See SB 97 9 93 15 Rochester 4 BBL Quadrajet Carburetor 93 16 Exhaust Bellows Falling Off 93 17 224 CID 3 7L Exhaust Elbow Reservoir Torque and Retorque 93 18 V6 and V8 Thermostat Housings 93 19 BlackHawk Drive Applications 93 20 Service Repair of Electrical Test Equipment 93 21 Possible Water Leakage Past Transom Mounting Studs on Alpha and Bravo Transom Assemblies 93 22 Sterndrive Setback System 93 23 MerCruiser Tester See SB 2001 01 93 24 Bravo Three Bearing Carrier Oil Seals 93 25 MCM 454 Magnum EFI MIE 454 EFI Ski GM Gen V Engine Speci
62. a voltage drop is not seen the knock sensor is faulty IGNITION SYSTEMS 2D 19 Troubleshooting Thunderbolt V Ignition IGNITION CONTROL MODULE COIL DISTRIBUTOR Check to ensure that tachometer GRY lead is not shorted to ground at the tachometer or within the harness No Spark Isolate shift cut out switch on Alpha models Check all Terminal Connections at Distributor Ignition Module and Ignition Coil Battery OK Distributor Clamping Screw Tight No Spark Check Engine and Instrument Wiring With Key in RUN Position Check for Battery Volts at Positive Terminal on Ignition Coil Less than battery volts Harness Battery Cables Key Switch Unplug WHT RED bullet connector from Voltage drop of Distributor 2 or more Check voltage on lead volts below bat coming from module tery voltage Typically 1 2 volts less than battery voltage 12 Volts 1 2 volts less than battery voltage Reconnect WHT RED bullet connectors Remove High Tension Lead from Dis tributor to Coil Insert a Spark Gap Tester from Coil Tower to Ground Dis Bond Replace Ignition connect WHT GRN Lead from Distrib oa Sensor in utor Place Ignition Key in RUN Posi Gol Distributor tion Rapidly strike the Terminal of the WHT GRN Lead that comes from mod ule against Ground See IMPORTANT below No Spark at Coil Substitute a New Ignition Coil Spark Install New Repeat Above Test at Coil Ignitio
63. air flow through the secondary venturi This air flow overcomes the counter weight and forces the auxiliary air valve 4 to rotate Increased air flow through the secondary boost venturi 3 creates a low pressure area around the secondary discharge tube Atmospheric pressure inside the float bowl forces fuel through the secondary jet 1 into the secondary fuel well Air entering the air bleed 2 mixes with fuel inside the well allowing an air fuel mixture to be pulled into the secondary discharge tube and out the secondary main discharge port Additional fuel is supplied thru the secondary Strut ports 5 for part throttle hard acceleration FUEL DELIVERY SYSTEM AND CARBURETION 3A 41 Weber Carburetor Accelerator Pump V Nec 5 KI Pi Ry DESCRIPTION During quick acceleration when the throttle is opened rapidly the air flow and manifold vacuum change almost instantaneously while the heavier fuel tends to lag behind causing a momentary leanness The accelerator pump is used to provide the fuel necessary for smooth operation during this time Fuel for acceleration is supplied by a double spring loaded pump plunger 3 operated by a pump shaft and lever assembly in the air horn connected directly to the throttle lever by a pump rod The top 1 and bottom 6 springs combine to move the plunger so that a smooth sustained charge of fuel is delivered for acceleration When the
64. anchor pin b Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud Ensure that backlash center mark is aligned with edge of control cable end guide ACAUTION DO NOT attempt to install or remove control cable barrel from stud without first re moving end guide anchor pin from shift lever and removing cable Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur c Remove control cable end guide from shift lever by removing anchor pin POM n 71660 a Control Cable End Guide b Anchor Pin c Backlash Center d Control Cable Barrel e Stud 7 install control cable 71661 a Lock Nut Tighten Until Bottomed Out b Washers Both Sides of Barrel c Anchor Pin d Cotter Pin Not Visible Spread Both Ends 8 Remove adjustment tool 9 Shift remote control lever into full forward position Place end of adjustment tool in barrel retainer HH ROTATION BRAVO ONE TWO THREE AND BLACKHAWK MODEL Rear slot in tool should fit over shift lever stud LH ROTATION BRAVO ONE AND TWO Forward slot in tool should fit over shift lever stud 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 35 If slot does not fit over stud loosen shift lever stud and slide stud up down until slot in tool fits over stud When adjustment is correct retighten stud 71662
65. and oystem View on all engines after and including the 2001 model year NOTE Additional products will be compatible with System Tachometer and System Speedometer Contact your Mercury Marine Sales Department for additional SmartCraft product compatibility and availability 2A 12 BATTERIES WIRING 90 883145 4 0804 V 6 and Small Block V 8 Electric Fuel Pump Used Carbureted Models For engine starting and running the electric fuel pump uses two electric circuits These two circuits are designed to prevent the fuel pump from running if the key is accidently left on A jumper wire connects one side of the oil pressure switch to the electrical harness The purple wires in the har ness are supplied current when the key switch is in the run position When the engine is running oil pressure 4 psi holds the contacts inside the oil pressure switch closed Current will pass through the closed contacts and on to the purple yellow wire connecting to the fuel pump During starting the oil pressure switch is open due to little or no oil pressure To engage the starter the starter solenoid is activated by current through the yellow red wire With the solenoid activated a metal disk inside the solenoid connects the positive battery terminal to the purple yellow wire This connection bypasses the oil pres sure switch and supplies current to the fuel pump Fuel Pressure 3 9 psi Electric Fuel Pump Filter Replacement S B 92 15 Stickin
66. and Figure 1 8 Clamp On Probe to Meter 2 Position rotary function knob to DC Voltage scale indicated 2004 mv 3 Read DC Voltage on DMT2000A Display 1 mV 1 amp Figure 1 7 Clamp On Probe AC DC CLAMP ADAPTER Figure 1 8 DMT2000A with Clamp On Current Probe 90 883145 4 0804 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 2G 9 NOTES 2G 10 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 90 883145 3 10 03 FUEL SYSTEMS LEVEL I FUEL DELIVERY SYSTEM AND CARBURETION Table of Contents Page Fuel Recommendations 1 FUEL 5 1 USING REFORMULATED OXYGENATED GASOLINES USA ONLY 3A 1 GASOLINES CONTAINING 1 Test For Alcohol Content In Gasoline 3A 2 Winter Storage 2 Warranty 2 Fuel Pump Identification and Test Fitting Fuel Delivery System 3A 4 General 3A 4 Special Information About Electric Fuel 5 Special Information For all Gasoline Engines 3A 5 Checking for Restrictions in Fuel Delivery SYSTEMS bona dE e dn 6 Testing Fuel System Pressure on Throttle Body Injection Systems 7
67. and lever assembly in the air horn connected directly to the throttle lever by a pump rod The top 2 and bottom 7 springs combine to move the plunger so that a smooth sustained charge of fuel is delivered for acceleration When the pump plunger moves upward as happens during throttle closing fuel enters the slotted pump well flows around the side of the pump plunger and into the bottom of the pump well When the throttle valves are opened the connecting linkage forces the pump plunger downward in the well The downward motion of the plunger forces fuel into the pump discharge passage 9 and unseats the pump discharge check ball 6 Fuel then passes on through the passage to the pump jets 3 in the cluster where it sprays into the venturi area The pump discharge check ball is used in the pump discharge passage to prevent air from being drawn into the passage during upward movement of the pump plunger to prevent a momentary delay in delivery of fuel The plunger uses a pump cup expander Garter spring 8 to maintain constant pump cup to pump wall contact FUEL DELIVERY SYSTEM AND CARBURETION 3A 17 Adjustable Accelerator Pump Lever This new 3 holed lever will allow you to change the amount of fuel delivered to the engine by the accelerator pump The hole closest to the lever s shaft will give the same amount of fuel as the single hole lever did The center hole gives approximately 0 5 cc less fuel and the hole farthest away w
68. at IDLE verify that timing did advance to Base Timing Idle Timing 2400 2800 rpm 1 BTDC 12 BTDC 23 BTDC 1 ATDC 10 BTDC 21 BTDC 2 ATDC 9 BTDC 20 BTDC 2D 24 IGNITION SYSTEMS 90 883145 3 10 03 3 0L 3 0LX models a filter is installed in the battery wire pink between the and ignition module inside the distributor This prevents an engine misfire if the trim motor is activated with the engine running ee cs 4 NN 7 DISTRIBUTOR m n TOUT SWITCH SHI cu e XS MUSS FEED IGNITION COIL ng LE ens FY on N TO IGNITION SWITCH 90 883145 3 10 03 IGNITION SYSTEMS 2D 25 Delco EST Ignition Troubleshooting Erratic Spark Symptoms 1 If the erratic spark occurs only when the engine is warm or is especially bad on warm days remove the ignition module and make sure that plenty of thermal transfer compound is present on the module s base The module will misfire if it is too hot 2 Verify that the purple power lead carbureted or red power lead EFI to the ignition coil is holding steady battery voltage during the erratic spark misfiring event If not check the key switch and safety lanyard switch for loose connections or internal failure a Try isolating the boat harness with a shop test harness the 3 foot MerCruiser harness part 84 812475A3 and MerCruiser
69. by a 110 amp fuse located on the solenoid and then on thru the red purple lead to a 20 amp circuit breaker on older pumps or a 20 amp fuse new pumps which serves to protect the trim control and harness from an overload Pushing the up out button in the control panel or the trim switch in the control handle upward connects the red purple jumper lead and the purple white lead which routes current to the trim limit switch which is normally a closed circuit The blue white lead then carries the current to the up solenoid where it activates the solenoid to supply current via the large blue white lead to operate the trim motor in an up direction The up out button in the control panel or the trim switch in the control handle allows approximately 17 of trim from full down position after which point the trim limit switch opens and current can no longer be supplied to the pump motor By pressing the up out and up button simultaneously or the trailer button on the control handle this will connect the purple white jumper lead to the blue white lead which bypasses the trim limit switch Current then proceeds to the up solenoid and allows the drive unit to travel to a full up position Pushing the in button in the control panel or the trim switch in the control handle downward connects the red purple jumper lead and the green white lead The green white lead then carries the current to the
70. can be capped and is or can be provided with graduations or a mark at about 1 3 full A pencil mark on a piece of 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 to 3 times as much fuel as water 3 Shake container vigorously and allow it to sit upright for 3 to 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 WINTER STORAGE WARRANTY 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 Performance problems and fuel system or other damage resulting from the use of gasoline alcohol blended fuels are not the responsibility of MerCruiser and will not be covered under our warranty 2 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Fuel Pump Identification and Test Fitting 76036 CARTER LOW VOLUME CARTER LOW VOLUME CARTER HIGH VOLUME NON SIGHT TUBE TYPE SIGHT TUBE TYPE 72677 DUAL DIAPHRAGM AIRTEX CARTER
71. cause serious bodily injury or death Careful peri odic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines fit tings fuel filters and carburetors fuel injection components should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deteriora tion requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required IMPORTANT When operating a MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of storage common to boats create unique problems In cars alcohol blend fuels nor mally 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 Test For Alcohol Content In Gasoline The following is an acceptable and widely used field procedure for the detection of alcohol in gasoline Use any small transparent bottle or tube that
72. entrance of moisture and dirt However periodic inspection is required as follows 1 Inspect terminals for corrosion and loose connections 2 Inspect wiring for frayed and worn insulation 3 Check starter mounting bolts for tightness 2B 6 STARTING SYSTEM 90 883145 3 10 03 Delco PG260 Starter Motor Starter Specifications Delco 1 0 Number MerCruiser Part Number 9000821 50 806964 No Load Test Brush Spring Tension Oz Grams 83 104 Engine Rotation Volts 101 160 in 025 4 06mm Bearing Depth Gear 014 038mm Maximum Bearing Depth Housing 017 0 4mm Maximum Torque Specification _ en cp All Other Fasteners Tighten Securely Lubricants Sealants Adhesives Part Number Quicksilver Liquid Neoprene 92 25711 3 NOTE The PG260 starter cannot be rebuilt The only replacement components available are the solenoid and drive housing Description The Delco PG260 starter motor features small permanent magnets mounted inside the field frame These magnets take the place of current carrying field coils mounted on iron pole pieces Internal gear reduction approximately 4 to 1 through planetary gears results in armature speeds in the 7000 rom range The armature and drive shaft are mounted on roller or ball bearings in place of bushings The starter motor is designed to operate under great overload and produce a high horsepower for its size It can do this only for a short t
73. have a single rail and others use two rails A fuel rail positions the fuel injectors in the intake manifold and supplies fuel evenly to each injector FUEL INJECTORS J The fuel injectors are eight electric solenoid operated devices that meter pressurized fuel to each engine cylinder The Fuel Injectors are controlled by the Electronic Control Module ECM which grounds the injector coil to open the injector nozzle and allow fuel to spray into the intake manifold next to the intake valve Fuel pressure to the injectors is controlled by the Fuel Pressure Regulator FUEL PRESSURE REGULATOR E The fuel pressure regulator is mounted to the top of the fuel cooler and is connected internally with the fuel passage that surrounds the fuel cooler water passage tube It is a diaphragm operated relief valve that maintains constant pressure differential across the injectors at all times An intake manifold vacuum line is attached to the regulator housing and a spring is mounted inside the housing pushing on the diaphragm Engine manifold vacuum and the spring counteract each other to apply the correct pressure in the regulator diaphragm under all engine operating conditions Fuel pressure varies from model to model 3B 28 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 3 10 03 When there is excess fuel in the cooler that cannot be used by the engine the fuel pressure regulator is forced open and the extra fuel is bled off and sent thr
74. idle mixture screws that prevent tampering with the idle mixture after the mixture has been properly adjusted EMISSIONS HIGH SPEED CIRCUIT The high speed circuits use staged step up rods in the main metering jets to control the amount of fuel admitted to the nozzles The position of the step up rod is controlled by manifold vacuum applied to the vacuum piston 3A 44 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 ANSI ABYC Standard 24 ANSI ABYC Standard H 24 GASOLINE FUEL SYSTEMS The following ABYC ANSI Standard H 24 Gasoline Fuel Systems Effective Date 12 96 has been reprinted with the permission of the American Boat and Yacht Council Inc For information on joining the ABYC or for more information on the Standards and Recommended Practices for Small Craft contact the organization at ABYC 3069 Solomons Island Road Edgewater MD 21037 1416 Phone 410 956 1050 Fax 410 956 2737 www abycinc org A membership application form is attached ABYC Cover Sheet for H 24 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 45 American Boat amp Yacht Council 3069 Solomons Island Road Edgewater MD 21037 1416 410 956 1050 410 956 2737 ABY Setting Standards for Safer Boating ABYC MEMBERSHIP APPLICATION Date Name Company Address city state Zip Business Phone Home Phone E
75. ignition switch assembly part 45421247 lf the problem disappears the problem is in the boat harness not the MerCruiser engine harness b There are several splices in the purple lead on almost all MerCruiser engines so it may be necessary to go into the engine harness to find the loose connection On an EFI engine ignition coil power comes from the system relay the purple or red power lead the coil holds steady voltage carefully flex the pink and brown harness between the coil and the ignition module while the engine is running If the engine runs better or quits replace the harness between the coil and ignition module This is usually because the filter in the pink lead has failed 4 ferratic spark is still present isolate the gray carbureted or white EFI tach lead at the negative side of the ignition coil Use a suitable jumper lead to jump the purple or red lead to the ignition coil and leave the tach lead disconnected Kent Moore Jumper Lead Kit J 35616 works well or you can cut the gray or white tach lead near the ignition coil and install a bullet connector from Quicksilver connector kit part 286 813937A2 If the en gine now runs better tach lead is partially shorted to ground in the engine harness boat harness or in the tach itself 5 If erratic spark is still present troubleshoot the secondary system with a Kv meter No Spark Troubleshooting 1 Visually check the ignition coil for melted p
76. in posi tion shown 3 With fitting fully seated turn handle to left to a tightly seated position as shown 22025 22025 a Tube Fitting b Opening c Handle 10 30 STERNDRIVE INSTALLATION 90 883145 3 10 03 Drive Shaft Housing Aft Trim Cylinder Anchor Pin Hole Modified There was a change made to Bravo drives S N 0K184626 and above and transom assem blies S N 0K139943 and above in late 1997 The Bravo drive shaft housing was changed in the aft trim cylinder anchor pin hole area It is now slotted to allow for two possible place ment positions for a new trim in limit spacer P N 808006 The trim in limit spacer is made of a composite material designed to withstand both the effects of thrust and corrosion It can be installed by hand This change replaced the A B trim in limit blocks that were mounted on the gimbal housing trim cylinder front anchor pin for most applications 808006 u ME 75158 Trim In Limit Spacer Positioning When installing a newer 1997 Bravo Three drive unit onto an older or newer transom assem bly you would place the trim in limit spacer in the aft most position of the rear anchor pin slot Do not use trim in limit blocks with this application You should also install a Trim Limit Spacer Kit in the trim cylinders P N 15768 3 This will prevent the drive from contacting the transom assembly when in the full trailer position When you are mounting a
77. is controlled by the calibrated restriction in the vacuum inlet diaphragm cover This gives the dashpot action required to delay air valve opening enough for efficient fuel flow from the secondary discharge nozzles 3A 30 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Rochester Quadrajet Accelerating Pump System 90 883145 3 10 03 During quick acceleration when the throttle is opened rapidly the air flow and manifold vacuum change almost instantaneously The fuel which is heavier tends to lag behind causing a momentary leanness The accelerator pump is used to provide the extra fuel necessary for smooth operation during this time The accelerating pump system is located in the primary side of the carburetor It consists of a spring loaded pump plunger and pump return spring operating in a fuel well The pump plunger is operated by a pump lever 1 on the air horn which is connected directly to the throttle lever by a pump rod When the pump plunger 11 moves upward in the pump well as happens during throttle closing fuel from the float bowl enters the pump well through a slot in the top of the pump well lt flows past the synthetic pump cup seal 7 into the bottom of the pump well The pump cup is a floating type the cup moves up and down on the pump plunger head When the pump plunger is moved upward the flat on the top of the cup unseats from the flat on the plunger head and allows free movement of fuel through
78. mail Address Your title position or occupation Products or business of company m INN No of Employees Membership Categories Check one Business Member 155 Silver Patron 1 000 Manufacturing Member 250 00 Sustaining Member 250 00 Participating 500 00 Silver Plus 1 500 Gold Patron 2 500 Platinum 5 000 I wish to purchase one Standards and Technical Information Reports for Small Craft in addition to the membership checked above for 219 plus 17 00 shipping and handling I wish to purchase one CD ROM containing Standards and Technical Information Reports for Small Craft in addition to the membership checked above for 219 plus 7 00 shipping and handling To guarantee delivery to countries outside the U S we must ship air mail and insured Because these costs vary depending on destination we can only guarantee delivery if you authorize air mail and provide credit card information Payment by Check or Money Order payment must be received before materials are shipped VISA Account ff Exp Date Master Card Account Exp Date American Express Account Exp Date If AMX ID Code Signature Date 3A 46 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 H 24 GASOLINE FUEL SYSTEMS Based on ABYC s assessment of the existing technology and the problems associated with achieving the goals of this standard ABYC recommends compliance with this standard for all boats associated equipment and systems m
79. mal operating temperature Refer to the Operation and Maintenance Manual for the correct idle speed 1 Disconnect the throttle cable from carburetor IMPORTANT In order to properly set idle speed the ignition module MUST BE locked in the Base Timing Mode This is necessary because of the Idle Speed Control fea ture that exists in the ignition module See information on the previous pages about this feature 2 Connect a shop tachometer to engine 3 Using a jumper wire connect the ignition system timing lead 13 PUR WHT wire to a good engine ground This locks the ignition module into the Base Timing Mode 4 Start engine and allow it to reach normal operating temperature Place the remote control lever in forward gear idle position 5 Adjust idle speed to recommended RPM 6 Stop engine Reagjust cable barrel and reinstall the throttle IMPORTANT Be sure to disconnect the jumper wire from the ignition system test ter minal before attempting to resume normal operations If the jumper wire is left in place the ignition module will operate in the Base Timing Mode This means that the addi tional timing advance features would not be functioning 7 Remove the jumper wire from the timing terminal 2D 16 IGNITION SYSTEMS 90 883145 3 10 03 Thunderbolt V Engine Wiring Harness Diagram WIRING O L HARNESS WATER DRIVE UNIT TEMPERATURE OIL LEVEL
80. maximum fuel flow into the float chamber yet prevents needle fal ling out of inlet seat 3 Initial idle mixture provides a base starting point for idle mixture 4 Accelerator pump adjustments a Linkage position in accelerator pump arm determines volume of fuel to be deliv ered per stroke b Pump rod measurement ensures maximum fuel delivery for the linkage position selected 5 Choke unloader determines choke plate opening at W O T on a COLD engine 6 Choke pull off vacuum break sets choke plate opening immediately after startup on a COLD engine a Not used on MerCarb 7 Choke spring electric choke divorced choke or stove pipe Determines the total time duration of choke operation 8 Final idle mixture and idle speed prevents stalling at low speeds amp shifting problems a Engine must be at normal operating temperature b Boat must be in the water with the correct propeller installed c Outdrive in specified gear check service manual d On Thunderbolt 5 ignition systems the purple white timing lead must be connected to ground before starting the engine This locks out the ignition s idle speed timing control Recommended fuel system literature Applicable Fuel System Service Bulletins Changes in Gasoline SB 97 8 MerCarb Adjustments amp 1996 Manual and 2000 supplement troubleshooting 1 800 378 9974 SB 97 9 Weber Adjustments 8 Fax 1 219 546 5845 troubleshooting
81. method IMPORTANT Be sure to disconnect the jumper wire from the ignition system test ter minal before attempting to resume normal operations If the jumper wire is left in place the ignition module will operate in the Base Timing Mode This means that the addi tional timing advance features would not function 7 Make sure that the distributor has been tightened Remove the jumper wire from the tim ing terminal 8 Stop engine and remove timing light Adjusting Idle Mixture 90 883145 3 10 03 The procedure for adjusting carburetor idle mixture can be found in the appropriate engine service manual This procedure also requires that the ignition module be locked in the Base Timing Mode IMPORTANT In order to properly set idle mixture the ignition module MUST BE locked in the Base Timing Mode This is necessary because of the Idle Speed Control fea ture that exists in the ignition module See information on the previous pages about this feature 1 Using a jumper wire connect the ignition system timing lead 13 PUR WHT wire to a good engine ground This locks the ignition module into the Base Timing Mode 2 Adjust idle mixture following the procedure in the appropriate engine service manual Remove the jumper wire from the timing terminal IGNITION SYSTEMS 2D 15 Adjusting Engine Idle Speed This procedure should be done with boat in the water drive unit in neutral and engine at nor
82. negative cable between engine and battery They measure 108 in 274 3 cm of positive cable between the engine and the battery switch and 120 in 804 8 cm between the battery switch and battery Add 36 in 91 4 cm 108 in 274 3 cm 120 in 804 8 cm 264 in 670 5 cm divide by 2 132 in 335 3 cm or 11 ft 3 4 So BOTH the negative AND positive battery cable use the 00 70mm gauge cable By using the same gauge battery cable 00 7Omm gauge in the example above for BOTH the negative and positive cable the longer length positive cable can use a smaller gauge cable than it would have if the negative and positive gauges were sized to their respective lengths Battery Testing Hydrometer Tests A fully charged battery will read between 1 225 and 1 280 at 80 Fahrenheit Readings of 1 225 and lower will require recharging amp retesting All cells should read within 30 points of each other You must correct the Hydrometer reading for Ambient Temperature CAPACITY TESTS The Specific Gravity must be 1 225 or higher before continuing Variable Load High Rate Discharge Tester Recommended Discharge the battery with a load bank carbon pile set to 1 2 the CCA Rating or 3 times the Amp Hour Rating for 15 Seconds at the end of the 15 second period the battery voltage must be 9 6 volts or higher Fixed Resistance This equipment has built in load for high rate discharge te
83. newer 1997 Bravo One or Two drive unit onto a newer transom assembly you should place the trim in limit spacer in the forward location of the rear anchor pin slot See Service Bulletin 98 16 for more information about these changes and trim component positioning 75157 b 75158 a Spacer Positioned Forward Bravo One and Two b Spacer Positioned Aft Bravo Three 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 31 New Replacement Bravo Drive Shaft Housing New replacement Bravo One Two or Three drive shaft housings have a modified aft anchor pin hole The original housing had a round anchor pin hole which has now been changed to an elongated or slotted hole This upgrade requires the use of an insert P N 808006 to posi tion the anchor pin correctly On Bravo One and Two models the insert should be placed in the forward most position in the slotted hole For Bravo Three units the insert should be placed in the aft most position in the slotted hole When using a newer drive shaft housing to replace an older Bravo Three housing the trim in limit blocks are no longer needed They should be removed A Tilt Limit Spacer Kit P N 15768A3 should also be installed to prevent the drive shaft housing and top cover from mak ing any contact with the gimbal ring U bolt f _ m NR C
84. open end of hose and siphon water until it starts to come out of the hose Put a finger over the hose and lift open end until it is at the top of the exhaust elbow Slowly take finger off end of hose to let the water level stabilize The water will seek the level of the water outside the boat Keep hose close to exhaust elbow and as vertical as possible The measurement between water in hose and top of exhaust elbow is the exhaust elbow height 76859 72700 Clear Hose Method For Measuring Exhaust Elbow Height a Waterline Outside Of Boat b Top Of Exhaust Elbow c 5 16 3 8 in 8 10 mm Clear Plastic Hose 15 ft 4 5 m Long d Weighted Hose End In Water e Waterline Level Equal To Waterline Level Outside Of Boat f Measurement Waterline Top Of Exhaust Elbow ENGINE INSTALLATION AND ALIGNMENT 1B 17 9 Refer to Measuring Procedure for measurement instructions NOTE Remember that moving weight and people around in the boat will change the water level in the hose 10 After measurement is taken lift weighted end of hose above water line and drain clear plastic hose Refer to Measuring Procedure and compare measurement to MerCruiser s specifications Priming Engine with Oil IMPORTANT This applies to all power packages that have not been run within 6 months replacement of partial engines or after rebuilding an engine Ground the ignition coil wire that goes to the distributor cap directly to engine gro
85. or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plug from the following locations a Aft rear drain plug from the heat exchanger 73581 a Heat Exchanger Drain Plug b Bottom of exhaust manifold 75177 a Exhaust Manifold Drain Plug 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 9 3 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NOTE It may be necessary to lift or bend hoses to allow water to drain completely 4 Make sure gear housing water vent and drain holes soeedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed 71216 a Vent Holes b Anode Cavity Drain Holes c Drain Hole d Speedometer Pitot Hole 5 Crank engine over slightly with starter motor to purge any water trapped in seawater pick up pump Do not allow engine to start 6 After cooling system has been drained completely install drain plugs reconnect hoses and tighten all hose clamps securely 1G 10 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 Draining Instructions for New Drain Systems Ensure that boat is out of the water or seacock is closed and bil
86. or of equivalent flammability to that used on the boat 24 18 4 5 3 qualify a fuel tank intended for use in a series of boats fuel tank sample shall be installed in a simulated hull section providing the maximum fire exposure representative of that series of boats 24 18 4 5 4 The fuel tank sample and all connecting piping and fittings shall be checked for leakage at an aerostatic pressure of 3 psi 21kPa applied to the tank vent 24 18 4 5 4 1 The size of the fuel tank sample vent shall be determined by the size of the vent fittings provided by the manufacturer 24 18 4 5 5 Following the pressure test the pressure shall be released and the tank vent left open to simulate a normal condition 90 883145 3 10 03 24 18 4 5 6 fuel tank sample shall be filled to quarter rated capacity with gasoline and all openings capped or plugged except for the fuel tank vent that is to be extended without traps outside the first test area 24 18 4 5 7 gt N Heptane shall be poured into all crevices and liquid traps in which fuel could collect in the boat assuming a leak anywhere in the fuel system If possible the amount of fuel in each liquid trap shall be sufficient to burn for a period of 2 minutes 24 18 4 5 8 Thetest method described in 24 18 4 7 shall be used 24 18 4 6 General Installation Fire Test 24 18 4 6 1 This test shall be conducted to qualify fuel tanks where the actual installation condi
87. outboard powered boats with permanently installed fuel tanks the fuel distribution system shall be installed by the boat manufacturer 2414111 Fuel distribution lines provided with anti siphon protection shall be installed in outboard powered boats equipped with permanent tanks and 24 14 11 1 1 fuel line connections to the engine shall terminate at the stern where fuel spillage will not enter the boat 24 14 11 2 Quick disconnect fittings used between fuel distribution lines and outboard motors shall automatically shut off fuel flow when disconnected 1996 American Boat amp Yacht Council Inc 6 3A 52 FUEL DELIVERY SYSTEM AND CARBURETION 24 15 FUEL SYSTEM GROUNDING 24 15 1 Each metal or metallic plated component of the fuel fill system and fuel tank that is in contact with the fuel must be grounded so that its resistance to the boat s ground is less than one ohm 24 15 1 1 Wire ends shall not be clamped between the fill pipes and hose 2416 FUEL SYSTEM LABELING 24 16 1 A warning label shall be placed in a readily visible location on the boat or at a point of frequent servicing of the boat and 24 16 1 1 the label shall comply with ABYC T 5 Safety Signs and Labels and shall contain at least the following informational elements 1 the hazard intensity signal word mature of the hazard 3 consequences that can result if the instructions to avoid the hazard are not followed 4 instructions on ho
88. pump plunger moves upward as happens during throttle closing fuel enters the slotted pump well flows around the side of the pump plunger and into the bottom of the pump well When the throttle valves are opened the connecting linkage forces the pump plunger downward in the well The downward motion of the plunger forces fuel into the pump discharge passage 7 and unseats the pump discharge check ball 5 Fuel then passes on through the passage to the pump jets 2 in the cluster where it sprays into the venturi area The pump discharge check ball is used in the pump discharge passage to prevent air from being drawn into the passage during upward movement of the pump plunger to prevent a momentary delay in delivery of fuel The pump ball is held in the seated position by a spring or weight 42 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Weber Carburetor Emissions IDLE CIRCUIT 90 883145 3 10 03 The PVS circuit is used with the idle circuit When the engine 16 cold the PVS circuit is closed This shuts off a metered air bleed to the idle circuit to maintain a rich idle circuit for warm up Once the engine warms up approximately 1209 549 C the PVS opens allowing a metered amount of air to be mixed into the idle circuit This leans the idle circuit to the proper operating air fuel ratio cont FUEL DELIVERY SYSTEM AND CARBURETION 3A 43 The emission carburetor uses sealed
89. reading It must be battery voltage If not you didn t verify the coil primary windings are good or you didn t find the short to ground in the gray tach lead If the voltage is OK proceed d While observing the voltmeter momentarily connect the negative lead of the 1 5 volt battery to the distributor frame The voltage must drop several volts as the module grounds the negative side of the coil If not replace the ignition module e When the negative battery lead is disconnected from the distributor frame the voltage must rise back to battery voltage and the ignition coil should fire If the voltage changes but the coil does not fire replace the ignition coil the secondary windings are open or shorted f When finished reconnect all leads and connectors IGNITION SYSTEMS 2D 27 3 0L 3 0LX EST Models Engine Wiring Diagram uec Led N B 5 1 0 24 5 WIRING DRIVE UNIT 4 HARNESS OIL LEVEL N 10 3 WATER TEMPERATURE IF EQUIPPED DISTRIBUTOR CTS SHIFT CUTOUT SWITCH PRESSURE 95 ii SWITCH by Up Pe a a vy T 7 E WATER TEMPERATURE SENDER STARTER g SLAVE SOLENOID ON a CIRCUIT BREAKER L2 GROUND ove EA T STUO mere VA NOTE 1 AUDIO WARN ING SYSTEM IS STAN 2 BARREL ONLY DAR
90. same spark plug number Refer to Specifications section for spark plug numbers SECTION 1B 75084 Spark Plug Number 2E 6 IGNITION SECONDARY 90 883145 3 10 03 Replacing 90 883145 3 10 03 4 Inspect each plug individually for badly worn electrodes glazed broken or blistered porcelain and replace where necessary 72734 Porcelain Insulator b Insulator Cracks Often Occur at This Point c Shell d Proper Gap e Side Electrode f Center Electrode When Adjusting Gap DO NOT Bend IMPORTANT Tapered seat spark plugs are not interchangeable with non tapered with gasket spark plugs Do not use gaskets on tapered seat plugs 1 Clean the plug seating area on the cylinder heads Clean the tapered seat area of each tapered seat spark plug 2 Adjust spark plug gap with a round feeler gauge Bend side electrode to adjust gap Refer to Specifications in SECTION 1B for correct spark plug gap 75084 Seating Area b IMPORTANT It is recommended that spark plugs be torqued to the amount specified In the absence of a torque wrench or access problems to the plugs the spark plugs should be hand tightened until the plug seats on the cylinder head Then securely tighten with appropriate wrench and socket On tapered seat plugs only slight rotation approximately 1 8 or less of a full turn after seating is required to create a seal and secure the plug 3 Install soa
91. sensor It does not have an ignition module like the EST system The sensor provides a square wave digital signal to the ECM which is used as an engine speed reference rom and as a timing reference The ECM completely controls ignition timing at all engine speeds This is similar to an EST ignition running in the ECM Control Mode The ignition coil driver transistor which was built into the EST ignition module is now inside the MEFI 3 ECM 439 PNK J2 32 IGNITION TO INJECTORS AND FUEL PUMP RELAY 450 J1 4 ECM GROUND gt 450 715 Ecm GROUND ccu GROUND DIST REF 902 RED 121 WHT 121 WHT J1 2 IGN COIL IGNITION COIL 3B 6 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 3 10 03 555 RPM Input The crank position sensor sends the RPM signal to the ECM 555 through the tan black wire and to the PCM 555 through a tan wire BLK PNK SPLICE 100 de ECM 555 a 5 gt 555 d 5 O lt SPLICE 101 9 66 0 92 8 Qo CD 2 5 6 7 9 A a 9 10 41 12 3 14 15 16 9 10 17 42 13814 19 16 12 13 14 15 10 47 18 19 20 2 17 18 19 20 21 22 23 24 1718 19 20 21 42 23 24 22 23 24 25 26 27 28 29 30 31 32 al gt gt z zi gt PCM 555 SPLICE 100 Crankshaft Position Sensor SP
92. should lightly touch where they cross If not corrections should be made to the engine bed Refer to product Installation Drawings for complete information about stringer height 74903 a Front of Stringer b Rear Mount Strings Cross Suspending The Engine Front and rear lifting eyes on the engine are provided to allow attachment of a suitable sling The engine can then be lifted into position in boat using an overhead hoist Center mounted lifting eyes are for engine alignment ONLY and should never be used to lift an entire engine wt COR teres SR 3 A 74760 74754 Typical Engine Lifting Eyes a Front b Rear 1B 4 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 Avoid product damage or injury Center lifting eye if equipped on top of thermostat housing is used for engine alignment only Do not use to lift entire engine X X om W 7777 50636 496 Magnum Alignment Lifting Hook P N 863375 1 a Alignment Hook b Lifting Eye c Throttle Body Flange 90 883145 3 10 03 ENGINE INSTALLATION AND ALIGNMENT 1B 5 Alignment Tool Requirements A special tool is required to align the engine and the sterndrive unit during engine installation Refer to the specific Installation Manual packaged with the product for complete information and procedures DO use an alignment tool from another manufacturer Alignment tools other than Quicksilver Alignme
93. sure that the propy lene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 7 8 For additional assurance against freezing and rust remove the thermostat cover thermostat Fill the engine seawater cooling system with a mixture of antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lowest tempera ture to which it will be exposed during cold weather or extended storage Using a new gas ket reinstall thermostat and cover Tighten cover bolts to 30 lb ft 41 Nm 72589 Lifting Eye b Cover c Gasket d Hose e Thermostat f Fitting g Housing 76246 NOTE Hoses shown removed only to indicate flow Do not remove hoses 1G 8 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 Draining Seawater Section of Closed Cooled Coolant Models NOTICE Refer to Cold Weather or Extended Storage Precautions in this section BEFORE proceeding If boat is in the water or is to remain in the water seacock if equipped must remain closed until engine is to be restarted to prevent contaminated water from flowing back into cooling system If boat is not fitted with a seacock water inlet hose must be left disconnected and plugged to prevent contaminated water from flowing into cooling system and
94. the engine settles onto the stringers and the mounts are appropriately fastened to stringers Common attachment is using 3 8 in 9 mm lag bolts Both adjustment nuts must be turned equally for proper alignment Alignment must be checked with the sterndrive alignment tool during the final engine mount height adjustment The tool must enter coupling splines freely When this is possible final adjustment is complete The locknuts on the mounts should be secured by bending the locking tabs onto the adjusting nuts NOTE Ensure that the alignment tool is removed after alignment 71649 Typical Front Mount a Nut And Lockwasher b Adjustment Nut Slotted Hole Toward Front Of Engine d Washer ENGINE INSTALLATION AND ALIGNMENT 1B 7 V 6 MODEL SPECIAL MOUNTING INFORMATION Avoid damage to exhaust system On V6 Models with one piece exhaust manifolds stress can be placed on the lower exhaust pipe if front of engine is raised too high while performing engine alignment Ensure that engine is not raised higher than the top of engine mount adjusting stud V 6 Models With One Piece Exhaust Manifolds a Top of Stud Engine Installation Gear Lube Monitor GENERAL INFORMATION To help avoid operating the sterndrive unit without sufficient gear lube a Gear Lube Monitor is provided with the power package This includes connections to the Audio Warning System except on 3 0L models The bracket and gear lube bot
95. the metering rod 6 and allowing additional fuel to flow through the main jets and on into the main well area 3 The fuel flowing through the power system is increased due to smaller diameters on the tips of the metering rods A hole drilled from the carburetor air horn to the bore of the power piston cavity to break any vacuum that might leak around the sides of the power piston The purpose of the vacuum break hole is to prevent the transfer of vacuum from the piston to the top of the fuel in the float bowl Any vacuum acting on the fuel in the float bowl will affect carburetor calibration FUEL DELIVERY SYSTEM AND CARBURETION 39 Weber Carburetor Secondary Initial Discharge DESCRIPTION As the throttle plate rotates 6 air flow increases past the auxiliary valve 5 The increased air flow creates a low pressure area around the secondary initial discharge port 4 Atmospheric pressure forces fuel from the float bowl through the secondary metering jet 1 and into the secondary fuel well 2 Air enters the fuel well through the air bleeds 7 and mixes with the fuel This air fuel mixture is drawn into the air stream through the secondary initial discharge port 4 3A 40 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Weber Carburetor Auxiliary Valve Operation DESCRIPTION 90 883145 3 10 03 As the engine speed increases engine demand increases
96. to the normal idle speed Carburetor with TKS e Operation The new carburetor operates in a manner very similar to the previous MerCarb units but now has the added benefit of having an additional amount of fuel automatically provided to the engine during cold starts Pumping the throttle twice before starting the engine is no longer necessary You just turn the key to start the engine 90 883145 4 0804 FUEL DELIVERY SYSTEM AND CARBURETION 3A 63 TKS fuel path is in the normally open position Electric power causes wax expanding device to expand thus causing the needle to meet the seat and close the additional TKS fuel path e Electric Paths There are two paths for electricity to get to the module one via an additional oil pressure switch and one via an additional engine coolant switch Additional Oil Pressure Switch An oil pressure switch is added to the system using a T fitting One lead is wired into the purple wire in the harness the other to the TKS unit When oil pressure exceeds 4psi i e engine running the oil pressure switch closes sending power to the TKS unit This begins heating the element and causing closure within 6 10 minutes Power will continue to flow to the TKS unit as long as there is power on the purple wire and there is oil pressure Thus if the key is left in the run position with the engine not running the TKS unit will not receive power mE p T TN rS
97. use of or failure to use standards or technical information reports promulgated by it their adaptation to any processes of a user or any consequences flowing therefrom Prospective users of the standards and technical information reports are responsible for protecting themselves against liability for infringement of patents The American Boat amp Yacht Council standards and technical information reports are guides to achieving a specific level of design or performance and are not intended to preclude attainment of desired results by other means 1996 American Boat amp Yacht Council Inc 15 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 3A 61 Notes 3A 62 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 4 0804 Turn Key Start TKS System e his system will be installed on all carbureted engines Production start will be during August through October of 2004 Basic Design Additional fuel is required during engine starting and warm up The new design began with the current casting and components similar to carbureted outboard The casting was modified adding an additional fuel flow path for the TKS module The TKS flow path is normally open and closes using a heat expanding device coupled to a needle seat This device closes the additional fuel flow path after receiving 12 Vdc for 6 10 minutes The engine will run at an elevated RPM 900 1 000 for the 6 10 minutes and then return
98. 0 03 Starting Circuit Positive Current Flow This is a general description of the positive current flow from the battery and through the sys tem until the starter motor cranks Battery to the solenoid switch on starter RED battery cable Solenoid switch on starter e to circuit breaker d RED Circuit breaker to wire junction RED PUR Wire junction to wiring harness plug RED PUR terminal 6 Wiring harness plug to 20 amp fuse b RED PUR 20 amp fuse to ignition switch terminal B RED PUR At this point ignition switch is turned to START Ignition switch terminal B to terminal S Ignition switch terminal S to neutral start safety switch f YEL RED NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION TO START Neutral start safety switch f to wiring harness plug terminal 7 YEL RED Wiring harness plug to starter slave solenoid c small terminal YEL RED Also ensure that black small terminal wire is grounded Starter slave solenoid is now closed completing circuit between large terminal RED PUR and other large terminal YEL RED causing current to flow to solenoid switch on starter motor e which causes starter motor to crank 55 Amp Fuse Replaces Circuit Breaker A 55 Amp fuse is used 1998 and later 3 0L 4 3L and 5 0L Alpha packages in place of a 55 Amp circuit breaker The fuse is located on the large terminal of the starter motor and the RED PUR harness wire connects to it
99. 04R MAY 2004 2004 Mercury Marine Page 3 4 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 71 Computer Diagnostic System NOTE All harnesses are not used with current software revision level Future software releases will use additional harnesses For MEFI 1 2 3 ECM models 84 822560A 2 For PCM 555 models adapts 4 pin MerCruiser connector to 2 pin 84 822560112 Outboard harness 84 822560A 5 ae 555 models 4 pin connectors no additional harness 84 822560 13 1997 and up V6 and V8 Carb Engines with Thunderbolt V Ignition Allows RPM history stored in Ignition Module to be read Use with 84 861540A 1 84 822560A 7 CAN 1 diagnostics cable Connects into a junction box or male to male adapter cable for Command Module configuration Not for use with the 84 892663 DDT Male to male adapter cable Allows connection between CAN 1 communications cable and Command Module harness in applications 84 892452A01 where a junction box is not used Page4 4 2004 Mercury Marine MAY 2004 2004 04R 3B 72 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 90 883145 4 0804 MerCruiser Tool List Fuel System Tools Fuel pressure gauge set Adaptor fitting set MT337 300 Snap On Replacement seals for adapter fittings Snap On GM test port seal large MC Schrater test port seal small O ring TBI adaptor fitting with tire valve fitting Fuel line adaptor with nipple fitting
100. 1 1 DMT2000A and Interface Module 90 883145 4 0804 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 2G 5 Tachometer Secondary Inductive Pick Up IMPORTANT Use the 2STR range for tachometer testing on the Mercury Mariner 4 Stroke Outboards Refer to DMT2000A information in this User s Manual for addi tional information and instructions PROCEDURE Plug interface module into DMT2000A meter refer to Figure 1 2 Red lead plugs into the VQHz port and the Black lead into the COM port Plug Inductive Clamp P N 91 854010 into interface module with lead marked to Red port and lead marked to Black port Position rotary function knob to IP RPM Inductive Depress RANGE button to select 25 ASTR See important above Clip Inductive Clamp to high tension spark plug lead Read RPM on DMT2000A Display Figure 1 2 DMT2000A With Filter and Inductive Clamp 2G 6 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 90 883145 3 10 03 Direct Voltage Adapter DVA Optional Accessory P N 91 89045 PROCEDURE 1 Plug Direct Voltage Adapter into DMT2000A meter refer to Figure 1 3 Red lead plugs into the VQHz port and the Black lead into the COM port 2 Plug Test Leads into Voltage Adapter with Red lead into Red receptacle and Black into Black receptacle 3 Position rotary function knob to DC Voltage scale indicated
101. 2 inches 0 8mm or flexible fuel hose identified as USCG Type see Table I if 24 14 2 1 the line is within an engine compartment or 24 14 2 2 a break at any point in the line will result in discharge of more than 5 ounces 150cc of fuel in 2 minutes including fuel that may drain from the engine or 24 14 2 3 the line is between a remote fuel pump outlet and the engine fuel inlet or 24 14 2 4 the line is for returning excess fuel to the fuel tank 90 883145 3 10 03 H 24 12 96 24 14 3 other fuel distribution and return lines shall be of the type specified 24 14 2 or USCG Type hose See Table I 24 14 4 individual components of the fuel system as installed in the boat shall be capable of withstanding a 2 minute exposure to free burning fuel N Heptane without leaking in accordance with the requirements of 24 5 7 24 14 5 Metal fuel distribution and return lines secured to hull members shall be connected to the engine by a flexible section The rigid metal line shall be supported within 4 inches 102mm of this connection 24 14 6 Fuel systems shall be equipped with an independently supported fuel strainer complying with 24 9 if a strainer is not incorporated in the pickup tube 24 14 7 Fuel filters shall be independently supported on the engine or boat structure 24 14 8 Electric fuel pumps if used shall be independently supported and located within 12 inches 305mm of the engine
102. 3 10 03 Product Identification MerCruiser Sterndrive Gas Typical Serial Number Locations MERCURY MARINE A BRUNSWICK COMPANY FOND DU LAC WI U S A robe to D 123452123 SEI ZW o 48 12345 MerCruiser 1 Engine Serial Number amp Specifications 2 Engine Serial Number P N for Attaching Screw 3 Transom Serial Number 4 Drive Serial Number 5 Propeller Part Number 6 Propeller Pitch 7 Vessel Serial Number 90 883145 3 10 03 USE OF SERVICE LITERATURE 14 1 MerCruiser Inboard Typical Serial Number Locations The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser amp power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers TRANSMISSION IDENTIFICATION ABC123482123 PLATE 1 Engine Serial Number amp Specifications 2 Engine Serial Number 3 Transmission Serial amp Model Numbers 4 Vessel Serial Number 1A 2 USE OF SERVICE LITERATURE 90 883145 3 10 03 MerCruiser Sterndrive Diesel Typical Serial Number Locations The serial numbers are the manufacturer s keys to numerous engineering details which apply to your Cruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbe
103. 4 Replacing Alternators 2C 7 Warranty 2C 7 Alternator Charging Voltage RPM 2C 8 Charging System Testing and Repair 2C 8 2C i CHARGING SYSTEM 90 883145 3 10 03 Electrical Systems Charging System Identification MANDO ALTERNATOR Mando 55 Amp Alternator a Excitation Wire Purple b Sensing Wire Red Purple c Mando Part Number Hidden in This View DELCO ALTERNATOR Delco Alternator a RED and RED PUR Connector b ORN Output Terminal c Ground 90 883145 3 10 03 CHARGING SYSTEM 2C 1 System Components The alternator system consists of the alternator battery the ignition switch and the wiring which connects these components Mando Delco Battery Meter d Witch 7 Harness Plug Alternator Circuit Breaker 12933 a Circuit Breaker b Harness Connector Alternator d Starter e Cranking Battery f Ground Stud 2C 2 CHARGING SYSTEM 90 883145 3 10 03 Alternator Block Diagram with Regulator Detail Typical AC Tap C B Output Rectifer Capacitor Bridge pos noise reduction Regulator Excite Sense Alternator Block Diagram Typical Indicator Light Terminal if equipped R Diode Trio c B Sense Excite i E i g e e p Voltage 74 a Regulator Ground e AC Tap i equipped 90
104. 550 6372 920 921 5330 920 921 6533 920 924 2088 920 924 2096 Product Registration Inquiry Outboard MerCruiser MotorGuide 920 929 5054 Warranty Claim Credit Information Outboard amp MotorGuide MerCruiser Product Protection Dealer Line Consumer Line Fax Printed in U S A 929 5054 929 5893 743 6539 743 6548 920 Fax 920 Phone 405 Fax 405 al 866 521 2024 888 427 5373 920 926 2255 4 12 MERCRUISER APPLICABLE SERVICE BULLETIN LIST Dealer Technical Service Outboard amp MotorGuide Outboard Quick Fax Inflatables Inflatables Fax MerCruiser MerCruiser Quick Fax MercNET MIDAS Customer Service Fax Mercury University Sales Management Courses Service Courses Fax Service Publications Ordering Information Fax 920 929 5884 800 842 4550 920 236 3043 800 926 7013 405 743 6555 800 245 8794 800 556 4327 920 924 1042 888 326 3728 920 929 5220 920 929 5929 920 929 5110 920 929 4894 Quicksilver Generator Sales amp Service Generac Corporation P O Box 8 Waukesha WI 53187 Outboard amp MotorGuide MerCruiser Dealer Locator 800 526 2871 CONSUMER ONLY PHONE NUMBERS 920 929 5040 405 743 6566 800 637 2879 9 831 MU 1 802 90 883145 4 0804
105. 6 ft 1 1 1 8 6 7 1 2 ft 1 8 2 3 m 7 1 2 9 1 2 ft 2 3 2 9 m 9 1 2 12 ft 2 9 3 7 m 12 15 ft 3 7 4 6 15 19 ft 4 6 5 8 m 0000 120mm DIESEL ENGINES 90 883145 3 10 03 Battery Minimum Cable Length Cable Gauge Up to 3 ft 0 9m 3 3 3 4 ft 0 9 1 1m 3 3 4 4 3 4 ft 1 1 1 4m 4 3 4 6 ft 1 4 1 8m 6 7 1 2 ft 1 8 2 3m 7 1 2 9 1 2 ft 2 3 2 9m 0000 120mm 9 1 2 12 ft 2 9 3 7m e 00 70mm 12 15 ft 3 7 4 6m 000 95mm 15 19 ft 4 6 5 8m 0000 120mm e wo cables of specified gauge required for positive and two required for negative lt lt lt BATTERIES WIRING 2 3 With the old battery cable recommendation the negative and the positive battery cables were measured separately and then select the correct cable gauge to fit the length measured for each This was OK if they were both the same length It did not work well if there was a battery switch installed in the positive battery cable between the engine and bat tery Then the positive cable had to use a much larger gauge than the negative did In the example below this would have meant the shorter 36 in 91 4 cm length negative would have used a 4 25mm gauge cable The longer 228 in 579 1 cm positive cable would have used 0000 120mm gauge EXAMPLE A person measures 36 in 91 4 cm length of
106. 75767 On 7 4L MPI MCM 10 24 STERNDRIVE INSTALLATION 90 883145 3 10 03 Bravo Sterndrive Unit Installation 1 Remove trim cylinders support and dust cover from bell housing studs Retain elastic stop nuts and flat washers 2 Remove monitor cap and fill gear lube monitor with Hi Performance Gear Lube 71995 Gear Lube Monitor Push in dribble valve until gear lube appears Once gear lube appears release dribble valve 72471 a Dribble Valve 4 Fill monitor to FILL mark and replace monitor cap 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 25 5 Coat studs with Quicksilver Engine Coupler Spline Grease MM AA LD ar TA NS lt NS aN gt 24725 a Studs 6 Lubricate U joint shaft splines and U joint shaft O rings with Quicksilver Engine Coupler Spline Grease e ow 22026 a Splines b O rings 7 Check to ensure that driveshaft bellows is clean and free of debris 24725 a Driveshaft Bellows 16 26 STERNDRIVE INSTALLATION 90 883145 3 10 03 8 Lubricate O ring seals with 2 4 C W Teflon Marine Lubricant 24726 a O ring Seals 9 Pull out shift linkage as far as it moves Jaws will open as shown 72460 a Shift Linkage IMPORTANT As stern drive is inserted into drive unit entry of the bell housing shift cable must be closely checked to make sure cable enters the Jaws of shift l
107. 8 SERIAL DATA 916 YEL 92 21 MASTER SLAVE 150 BLK DLC CONNECTOR 450 BLK FROM ECM BAT DIAGNOSTIC TEST FUSE a 451 BLK WHT J2 22 TERMINAL p 440 MALFUNCTION INDICATOR ELNE 419 BRN WHT J1 9 LAMP 76079 3B 40 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 ECM Wiring Diagram MEFI 3 Big Block V8 2 of 4 ECM INTAKE AIR TEMPERATUR SENSOR SIGNAL INTAKE AIR 472 J2 30 TEMPERATURE IAT 813 BLK 813 BLK J2 3 SENSOR GROUND THROTTLE PIS STION SENSOR TP THROTTLE POSITION SENSOR SIGNAL 417 DK BLU J2 26 OLTS eon J2 4 REFERENCE MANIFOLD 416 GRY J2 19 B 45 VOLTS REFERENCE ABSOLUTE PRESSURE 432 LT GRN J2 27 MAP SIGNAL MAP SENSOR 814 BLK 814 BLK J2 18 SENSOR GROUND ENGINE COOLANT 814 BLK TEMPERATURE ECT ENGINE COOLANT 410 YEL 042 11 TEMPERATURE SENSOR SIGNAL 76080 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 41 ECM Wiring Diagram MEFI 3 Big Block V8 3 of 4 ECM BATTERY FEED TO FUEL PUMP RELAY FUSE 440 ORN J2 1 ECM BAT FUSE 440 ORN gt gt TODLC DLC 15 CONNECTOR TO SYSTEM IGNITION RELAY B 2 RED T IGN INJ FUSE B E 2 RED 30 902 IGNITION 150 yas orm By IGNITION TO IGN COIL TERM INAL TO INJECTORS
108. 883145 3 10 03 used to push hoses below their connection point NN 76244 b Connection Points IMPORTANT Hoses must be lowered below their connection point on the engine in or der to drain completely hoses do not drain use wire to remove blockage 4 Pull hoses back into original position after draining is complete Reconnect to fittings WINTERIZATION AND RECOMMISSIONING 1G 5 Draining Seawater Raw Water Cooled Models NOTICE Refer to Cold Weather or Extended Storage Precautions in this section BEFORE proceeding 1 Engine must be as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from cylinder block and manifold 71424 a Drain Plug Port and Starboard 3 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NOTE It may be necessary to lift bend or lower hoses to allow water to drain completely when hoses are disconnected 4 Remove and lower the hoses to allow them to drain ULLAS WM N Inlet Hose b Circulating Pump Hose 1G 6 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 9 Insert a small wire repeatedly to make sure that vent holes and water drain holes and passages as shown are unobstructed and open a 7 5 OS en a Speedometer Pitot Tube b Gear Housing Cavity Drain Hole c Trim Tab Cavity Ven
109. 9 16 inch 14 29 24 13 3 Vent system shall have flame arrester that be cleaned unless the vent system itself is a flame arrester 90 883145 3 10 03 NOTE Vent fittings that are removable are considered cleanable 24 13 4 Fuel vent lines shall be metallic or hose 24 13 4 1 Flexible tank vent hose installed in engine compartments shall be USCG Type 1 or A2 See Table I 24 13 4 2 Tank vent hose installed outside of engine compartments shall be any of the hose types specified in 24 6 24 13 5 Separation between compartment ventilation openings and fuel tank vent line termination shall be at least 15 inches 381mm 24 13 5 1 The tank vent shall have provision to minimize the intake of water without restricting the continuous release of vapor 24 13 6 Tank vent systems shall be self draining and connect to the highest point of the fuel tank as installed in the boat under conditions of normal operation and normal trim NOTE In sailing auxiliaries it may be necessary to have dual vents each equal in size to the specification in 24 13 2 24 13 7 All components of the tank vent system shall be accessible 24 44 FUEL DISTRIBUTION AND RETURN SYSTEMS 24 14 1 components of the fuel distribution and return system shall be accessible 24 14 2 Fuel distribution and return lines shail be seamless copper nickel copper or copper nickel with a minimum wall thickness of 029 inches 0 74mm nominal 03
110. 9375 800 344 4013 800 345 2233 Fax 847 662 6808 Fax 810 578 7375 3B 74 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 SERVICE INFORMATION MERCRUISER APPLICABLE SERVICE BULLETIN LIST Table of Contents Page 1990 2004 MerCruiser Service Bulletin Indexes 1990 MerCruiser Service Bulletin Index 4 1 1991 MerCruiser Service Bulletin Index 4 1 1992 MerCruiser Service Bulletin Index 4 2 1993 MerCruiser Service Bulletin Index 4 2 1994 MerCruiser Service Bulletin Index 4 3 1995 MerCruiser Service Bulletin Index 4 3 1996 MerCruiser Service Bulletin Index 4 4 1997 MerCruiser Service Bulletin Index 4 4 1998 MerCruiser Service Bulletin Index 4 5 1999 MerCruiser Service Bulletin Index 4 5 2000 MerCruiser Service Bulletin Index 4 5 2001 MerCruiser Dealer Service Bulletin Index 4 6 2002 MerCruiser Dealer Service Bulletin Index 4 6 2003 MerCruiser Dealer Service Bulletin Index 4 7 2004 MerCruiser Dealer Service Bulletin Index 4 7 1991 2002 MerCruiser Parts Bulletin Indexes 1991 MerCruiser Parts Bulletin Index 1992 MerCruiser Parts Bulletin Index 1993 MerCruiser Parts Bulletin Index 1994 MerCruiser Parts Bulletin Index 1995 MerCruiser Parts Bulletin Index 1996 MerCruiser Parts Bulletin Index 1997 MerCruiser Parts Bulletin Index 1998 MerCruiser Parts Bulletin Index 1999 MerCruiser Parts Bulletin Index 2000 MerCruiser Parts Bulletin Index 2001 MerCruiser Parts Bulletin Index 2002 MerCruiser Parts Bulletin Index
111. CHART Supply water to the seawater pickup pump as outlined in Flushing Cooling System Start engine and closely observe instrumentation to make sure that all systems are functioning correctly Carefully inspect engine for fuel oil fluid water and exhaust leaks 10 Check steering system and shift and throttle controls for proper operation 11 For drive unit refer to appropriate sterndrive manual 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 21 NOTES 1G 22 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 MERCRUISER ELECTRICAL SYSTEMS LEVEL I PF BATTERIES WIRING Table of Contents Page Battery Requirements for MerCruiser PROGUGIS asia Gee as 2 1 Battery Ratings 2A 1 Cold Cranking Amps CCA 2A 1 Marine Cranking Amps 2A 1 Reserve Capacity 2 1 Amp Hour Rating 2A 1 Battery Cables Length and Size 2A 3 Battery 0 2A 4 Hydrometer Tests 2 4 Charging Guide 2A 5 12 Volt Battery Recommended and Time for Fully Discharged Condition 2 5 Wiring Colors for MerCruiser 2A 7 Wiring Harness Service 2A 8 Wire 2A 8 Wiring Connector Service 2A 9 Wiring Diagrams
112. CTION INTRODUCTION 3B 33 NOILONGOYLNI NOILOSPNI 1903 OINOYLOATA 080 9 1689 06 G M E C M Identification MEFI 1 93 Controller MEFI 1 2 96 Controller 3 98 Controller J2 Center of Hole 6 167 Center of Hole Original GM Marine ECM Housing ECM s are MEFI 1 All ECM s have power reduction Center af Hole 4 34 Center nf Hole 13 16 New Small GM Marine ECM Housing To Identify between MEFI 1 amp 2 MEFI 2 have the numbers 729 at the end of the Model number shown below 778 0003010 All other ECM s are MEFI 1 AILE C M s are MEFI3 All current EFI engines use this ECM Delphi ECM number 16236999 have floating desired idle speed Small block and V 6 not including Black Scorpion Delphi ECM number 16237009 don t have floating desired idle speed All current big block and Black Scorpion Note Long term every engine will get the floating desired idle ECM ECM 555 Identification ECM Calibration Label An ECM can be readily identified by the two wire harness connectors A B 4 3L ALPHA a 864270 3 b 884521 MY2002p5AAAV 0038 4 3 ALPHA P 12345678 Typical ECM Calibration Label a Engine Model b Calibration Part Number c Model Year The ECM Calibration label includes the information necessary to determine which calibration an engine is equipped with from th
113. D CARBURETION 59 24 12 96 APPENDIX MARINE FUEL SYSTEM COMPONENT FIRE TEST 1 Method Ap 1 1 Conduct the test in a fire test chamber in a draft free area Ap 1 2 Connect the sample to a system of full size fuel piping complete with a fuel supply tank and the valves as shown in Figure 1 1 3 Center and position the sample vertically 8 to 10 inches above the liquid surface of a pan of sufficient size both to extend beyond the entire horizontal area of the sample and to accommodate enough N heptane to burn continuously for at least 2 1 2 minutes Ap 1 4 Charge the tank and the remainder of the system with N heptane Ap 5 Position two thermocouples in the same horizontal plane as the sample one half inch away from the sample surface with the tips of the thermocouples positioned 1 25 4 mm from the end of each fitting of the sample and 10 254 mm above the surface of the fuel level 1 6 supply tank valve will then be opened and the system bled of all air by allowing fuel to flow through the system from the tank through the open discharge valve 1 7 With the system full of fuel shut off the discharge valve Ignite the pan of fuel and allow it to burn for 2 1 2 minutes Ap 1 8 During the burning record temperatures at intervals not to exceed 15 seconds NOTES If the temperatures measured by one or both thermocouples do not reach 1200 F 648 C at some time during the 2 2 minute time perio
114. D ON LX MODELS HERREN MEME NOTE 2 GRAY LEAD i FOR USE WITH SER A Ignition and Choke System C Audio Warning System VICE TACHOMETER B Starting and Charging System D Instrumentation System 70342 2D 28 IGNITION SYSTEMS 90 883145 3 10 03 EFI Engines with High Energy Ignition and Electronic Spark Timing EST 90 883145 3 10 03 The Electronic Fuel Injection EFI is controlled by an Electronic Control Module ECM This module is the nerve decision center of the system It uses all the information it gathers to man age ignition spark delivering increased fuel economy and maximum engine performance The EFI system uses inputs from sensors to make decisions on the amount of spark advance or retard allowed The EFI system has been designed to control ignition advance and retard electronically by the ECM This electronic advance becomes much more exact and reliable just as EST is more exact and reliable when compared to the breaker point ignition system In order for the ECM to properly calculate spark advance it must always know at what speed the engine is running The engine speed signal is accomplished by a circuit within the EST module which converts the pickup coil voltage to a square wave digital reference signal that can be used by the ECM This square wave engine speed reference signal is known as REF The ECM must also have something to compare the REF HI value against Therefore an additional line is provided
115. Elbows Without Risers Elbows With Risers a Exhaust Elbow b 4 Slot Gasket c 3in 76 mm Exhaust Riser d 152 mm Exhaust Riser e Nut 8 f Stud 8 9 3 8 in 238 mm g Stud 8 10 3 8 in 264 mm Used With Some MIE Remote Oil Filters h Washer 8 Exhaust Manifold j Bolts 14 8 USE OF SERVICE LITERATURE a Clamps b Exhaust Pipe Elbow c Exhaust Hose d Water Shutters e Bolts And Lockwashers f Exhaust Pipe Dry Joint Exhaust System V6 and Small Block V8 S N MIE 0M317000 and Up MCM 0M600000 and Up a Exhaust manifold b Manifold to cylinder head bolt 4 c Restrictor gasket with turbulator seawater cooled models d 76 mm 3 in cold riser e 152 mm 6 in cold riser f Riser to exhaust manifold screw 4 g Full flow gasket with turbulator h Exhaust elbow Exhaust elbow to riser or exhaust manifold screw and washer 4 each j Hose fitting k Pipe plug 90 883145 3 10 03 Typical Inboard Exhaust System Components 1 B a Water Line ee Re ee J b Minimum Exhaust Elbow Height with Maximum Load 15 in 381 mm on 8 1S Models 13 in 330 mm on All Others c 4 in 102 1 0 Minimum Exhaust Hose apum d Exhaust Back Pressure Check Point 12 24 in E 305 610 mm 2 psi
116. Electric Fuel Pump Troubleshooting Official Notification U S Federal Boat Safety Act Required Engine Harness Wiring Change to 470 Type Engines with Belt Driven Alternator Kit P N 804916A 1 Official Recall Notification U S Federal Boat Safety Act Gen Il Throttle Shift Remote Control Cables Computer Diagnostic System MERCRUISER APPLICABLE SERVICE BULLETIN LIST 4 7 1991 2002 MerCruiser Parts Bulletin Index 1991 MERCRUISER PARTS BULLETIN INDEX 91 1 Ignition Module 305 350 CID Engines 91 2 Quicksilver 1991 Accessories Guide 90 42000 91 Top of Page 128 91 3 No Longer Available Rochester 2 BBL Carburetors are Available Again 91 4 V8 Engine Mount Assembly Parts 91 5 Converting Cast Iron in OD and 4 in OD Exhaust Elbows to Stainless Steel 4 in Exhaust Elbows 91 6 Ordering Correct Exhaust Manifolds Eloows Plates and Gaskets 1992 MERCRUISER PARTS BULLETIN INDEX 92 1 V6 262 CID 4 3L Parts Information 92 2 D183 219 530 636 Diesel Engine Parts Information 92 3 MIE 7 4L Inboard with Front mounted Closed Cooling 92 4 Silent Choice Exhaust System 92 5 Dual Stage Coupler Kit 92 6 5 In 127MM Diesel Riser Kit 92 7 Replacement Cylinder Head P N 937 4287A2 92 8 Replacement Pistons and Ring Sets 92 9 Air Horn Gaskets for Weber Carb 1993 MERCRUISER PARTS BULLETIN INDEX 93 1 Change to Remote Control Handle P N 92744A2 93 2 Stainless Steel Thermostats 93 3 Tune Up Kits Distributor Caps Ignition Coil Part Number
117. ING 90 883145 4 0804 5 71 350 Magnum Alpha Engines Thunderbolt V Ignition With Knock Sensor COIL WIRING HARNESS WATER TEMPERATURE SWITCH DRIVE UNIT OIL LEVEL SWITCH TAN BLU 4 Lu N o gt 2 ud to gt 2 Py D pe 2 OIL We PRESSURE 5 a IGNITION 7 SWITCH TRIM SENDER WATER TEMPERATURE SENDER 7 BREAKER ELECTRIC G GROUND o STUD BLK BLACK BLU BLUE BRN BROWN GRN GREEN ORN ORANGE PNK PINK re PUR PURPLE RED RED TAN TAN WHT WHITE A Ignition Components C Audio Warning Components YEL YELLOW LIGHT B Starting Charging and Choke Components D Instrumentation Components DRK DARK NOTE TAN BLU Wire not used at distributor 75120 90 883145 4 0804 BATTERIES WIRING 2A 11 SmartCraft Product Rigging Components Typical System Layouts Single Engine Product Configurations GENERATION 2 SmartCraft 2001 Model Year System Monitor System Tachometer System Link Gauges m System Link Connector SC1000 2RSL System Monitor Harness Key Switch Key Switch Harness 52 Generation 1 supports SmartTach and SmartSpeed on engines only Generation 2 supports all System products System Tach Speed System Monitor
118. LICE 101 Camshaft Position Sensor gt gt 5 Volt Power S i gt 5 Volt Ground 5g 6 Y Signal To The PCM it INN i ABC ABC b CAM CRAN a FO KPOS 77680 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 7 Multi Port Fuel Injection System Fuel Flow VAPOR SEPARATING TANK VST THROTTLE BODY FLAME ARRESTOR FUEL PRESSURE Miri 2227 REGULATOR Wei RETURN LINE LG INJECTORS lt WATER SEPARATING FUEL FILTER L FUEL PUMP SIGHT TUBE TO THROTTLE BODY A S Dl YA MECHANICAL 259 FUEL PUMP 9 Y OX SEAWATER PUM a 1 BOAT FUEL TANK INTAKE MANIFOLD t n 23 90 883145 3 10 03 3B 8 ELECTRONIC FUEL INJECTION INTRODUCTION Throttle Body Injection System 90 883145 3 10 03 1 Throttle Body 2 Gasket 3 4 Adapter 5 Intake Manifold 6 Injector ELECTRONIC FUEL INJECTION INTRODUCTION 3B 9 Early 350 Mag MPI Induction System 1 Nut 4 2 Flame Arrestor 4 3 Stud 4 il 4 Throttle Body 5 Manifold Absolute Pressure MAP Sens 6 Plenum 7 Screw 4 8 Fuel Line From Fuel Filter To Starboard Fuel Rail 9 Fuel Filter 10 Fuel Line From VST To Fuel Filter 11 Fuel Line From Starboard To Port Fuel 12 Fuel Rail 2
119. MEFI 1 amp 2 Similiar 3 Models MEFI 1 amp 2 Similar 1 Intake Manifold 11 Fuel Rail 2 12 Schrader Valve 3 Pipe Plug 13 Screws 1 4 20 x 1 1 2 in 4 Screw 5 16 18 x1 3 8 in 35 mm 14 MAT Sensor 5 Fuel Injector 15 Cap 6 O Ring 16 Fuel Lines 7 MAP Sensor 17 O Rings 8 Clip 18 Location of Fuel Line From Fuel 9 Screw 8 32 x 1 4 in 6 mm Pump 10 Pipe Plug 1 8 in hex head 19 Pressure Sensor 3B 12 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 3 10 03 Later Model 350 Mag MPI Throttle Body Assembly MEFI 3 Later Models 1 Cover 2 Washer 3 Nut 1 4 28 4 Washer 5 Flame Arrestor 6 Throttle Body Assembly 7 Stud 8 Screw 1 4 20 9 Gasket 10 3 16 in Barb Fitting From Fuel Pres sure Regulator 11 Pipe Plug 1 4 18 Socket Head 90 883145 3 10 03 12 Screw 5 16 18 x 1 1 4 in 32 mm 13 Washer 14 Throttle Body Adaptor Plate 15 Gasket 16 Stud Kit 17 Throttle Cable Bracket 18 Screw 5 16 18 x 1 in 19 Washer 20 Washer 21 Stud 1 4 x 1 3 4 in 22 Nut 1 4 28 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 13 Throttle Body Assembly TBI Models 1 Cap Screw 11 Body 2 Cover Assembly 12 Throttle Body To Fuel Meter Body 3 Fuel Pressure Regulator Gasket 4 Cover Assembly Gasket 13 Throttle Body 5 Upper O Ring 14 Throttle Position TP Sensor 6
120. Minimum Water Level b Water Intake Holes IMPORTANT If using flush test device install over water intake holes and connect a water hose as shown Do not use full water tap pressure Also do not run engine above 1500 rpm as suction created could cause water hose to collapse causing water supply to be cut off a Flush Test Device b Garden Hose Hook up Do Not Use Full Water Tap Pressure 90 883145 3 10 03 PREDELIVERY PREPARATION 1F 7 Do leave helm unattended when making test with boat in the water 1 Ensure that cooling system drain plugs petcocks and hoses are installed and tight NOTE Refer to Operation and Maintenance Manual for operating specifications and fluid capacities Check crankcase oil level Check sterndrive unit oil level Check serpentine belt tension Te 0 Test Audio Warning System as follows a Turn key switch to the RUN position Buzzer should sound immediately b Start engine as described in the following step The buzzer should stop as soon as the engine is running 6 Start engine and run at idle RPM until Water temperature is normal 7 Watch all gauges for normal readings 8 Turn steering wheel starboard then port and check to ensure drive unit turns the correct direction 9 Inspect engine compartment for water oil fuel and exhaust leaks If Power Steering pump lugs when steering wheel is turned to end of travel in either direction hard right or l
121. NING HORN TO TEMP GAUGE TAN TO IGN lt i PUR 76082 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 43 PCM 555 Charging Harness gt E 12 J gr 575 V Z 0 mE lt pt GRY mS gt i TAN v __ f dug PPL o oe T dc TAN BLU EL 7 1 BLUTAN m eed FR a 4 UN YEURED i 0 amp 79 p 9 fir ORA DE 4 o Hr PPL 59 B RED PPL 5 EE BLK Gy WES z z BLK RED PPL P Lmm BLK T S 5 T aasN LON lt BLK 2 22 B oziz s
122. Poor Driveability SPECIAL INFORMATION FOR ALL GASOLINE ENGINES Avoid gasoline fire or explosion Gasoline is extremely flammable and highly explo sive under certain conditions NEVER use gasoline as a cleaning solvent 90 883145 3 10 03 IMPORTANT The following information is provided to ensure proper installation of brass fittings or plugs installed into fuel pump or fuel filter base Use 592 Loctite Pipe Sealant with Teflon on threads of brass fittings or plugs DO NOT USE TEFLON TAPE Brass fittings or plugs should first be threaded into fuel pump or fuel filter base until finger tight Fittings or plugs should then be tighten an additional 1 3 4 to 2 1 4 turns using a wrench DO NOT OVERTIGHTEN To prevent over tightening when installing a fuel line the brass fittings should be held with a suitable wrench as fuel line connectors are tightened securely FUEL DELIVERY SYSTEM AND CARBURETION 3A 5 Checking for Restrictions in Fuel Delivery Systems If there are any restrictions in the fuel delivery system the engine may experience vapor lock and other driveability problems MerCruiser specifies that the maximum allowable vacuum when measured at the inlet side of the engine mounted water separating fuel filter is 2 in Hg inches of mercury or 6 9 kPa kilopascals The engine should be tested by installing a T fitting and gauge as shown in the illustration A digital vacuum gauge is recommended because regular v
123. R DEALER SERVICE BULLETIN INDEX 01 1 MerCruiser Scan Tool replaces Service Bulletins 96 9 amp 93 23 01 2 Quicksilver DDT Scan Tool replace Service Bulletin 96 4 01 3 Gasoline and Diesel Engine Propeller Selection 01 4 Priming Fuel System 01 5 496 Mag 8 15 Fuel Line and Fuel Rail Outlet Plug 01 6 Required 496 Mag HO 8 15 HO Push Rod Replacement 01 7 Velvet Drive Marine Gear Distributors USA and International replaces Service Bulletin 95 23 01 8 Hurth Marine Gear Distributors USA and Canada Only replaces Service Bulletin 95 24 01 9 Hino Diesel Engine Distributors USA and International 01 10 Gasoline Engines with Water Damage 01 11 Testing Starter Motors replaces Service Bulletin 99 1 and 95 20 01 12 Testing Alternators 01 13 Gasoline Engines and Water Intrusion 01 14 Required 496 Mag 8 15 Engine Electrical System Repair 01 15 New Gasoline EFI MPI Engine Fogging Procedure 01 16 Required MIE 8 1S 8 1S HO PCM 555 Replacement 01 17 Bravo Gear Change 2002 MERCRUISER DEALER SERVICE BULLETIN INDEX 02 1 Shift Interrupt Switch Availability 02 2 Inline Fuel Filter Kit 02 3 Required Boost Pump Installation 02 4 Required 496 8 15 Water Rail Drain Cap Replacement 02 5 Part Numbers for Water Distribution Housings for MerCruiser Simplified Single Point Water Drain Systems 02 6 Corrosion Prevention and Maintenance 02 7 Warranty and Preparation of New Unsold Non Current Product 02 8 MerCruiser GM Engine Code Iden
124. RBURETION 90 883145 3 10 03 Rochester Quadrajet Idle System 90 883145 3 10 03 et SS 15 B LE T M RM E ED RE no The Quadrajet carburetor has idle system on the primary side fuel inlet side of the carburetor to supply the correct air fuel mixture ratios during idle and off idle operation The idle system is used during this period because air flow through the carburetor venturi is not great enough to obtain efficient metering from the main discharge nozzles The idle system is used in the two primary bores of the carburetor Each bore has a separate and independent idle system During idle the throttle valves 8 are held slightly open by the idle speed adjusting screw The small amount of air passing between the primary throttle valves and bores is regulated by this screw Since the engine requires very little air for idle and low speeds fuel is added to the air to produce a combustible mixture by the direct application of vacuum low pressure from the engine manifold to the idle discharge holes 7 below the throttle valves With the idle discharge holes in a very low pressure area and the fuel in the float bowl vented to atmosphere high pressure the idle system operates as follows Fuel flows from the float bowl down through the main metering jets 5 into the main fuel wells by the two idle tubes 3 one for each primary bore
125. SSIONING 90 883145 3 10 03 The following example uses a 3 0L Alpha engine as a typical MerCruiser power package For any particular engine the appropriate service manual should be used Cold Weather or Extended Storage Precautions 90 883145 3 10 03 Sterndrive unit should be stored in full DOWN position Universal Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service If Power Package will not be used for extended period of time or will be exposed to freezing temperatures drain water from seawater section of cooling system Water MUST BE drained to prevent corrosion and freeze damage to engine If boat is to remain water after draining seawater inlet hose must be removed plugged The plug will prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses DO operate engine without water flowing through seawater pickup pump as pump impeller may be damaged and subsequent overheating damage to engine or sterndrive unit may result Seawater section of cooling system MUST COMPLETELY drained for winter stor age or immediately after cold weather use if the possibility of freezing temperatures exists Failure to comply may result in trapped water causing freeze and or corrosion damage to engine IMPORTANT Observe the following information to ensure complete draining
126. Section Section Section Section MerCruiser Systems 0804 1 ommooo ommoou vr 3 A B 4 Outline MerCruiser PDI and Maintenance Level 1 Use of Service Literature Engine Installation and Alignment Stern Drive Installation Power Steering Installation Throttle Cable Adjustment Pre delivery Preparation Winterization and Recommissioning MerCruiser Electrical Systems Level 1 Batteries Wiring Starting System Charging System Ignition Systems Ignition Secondary Power Trim Electrical Quicksilver DMT 2000 Digital Tachometer Multimeter Information MerCruiser Fuel Systems Level 1 Fuel Delivery System and Carburetion Electronic Fuel Injection Introduction Service Information MerCrusier Applicable Service Bulletin List 90 883145 4 0804 MERCRUISER PDI AND MAINTENANCE LEVEL I USE OF SERVICE LITERATURE Table of Contents Page Product Identification 1A 1 Dealer Service Publications 1A 4 Product Line Familiarization 1A 6 MerCruiser Power Package Components 1A 7 496 Magnum 8 1 Similar 1 7 V 6 Shown Small Block V 8 Similiar 1A 7 Exhaust Systems 1A 8 Cooling System 1A 10 Transom Assembly 1 11 MerCruiser Drives Typical 1A 12 1A i USE OF SERVICE LITERATURE 90 883145
127. Service mode ECM Version XX Prom ID XX Cal Cksum XXXX Press MODE TROUBLE CODES MENU 1 Get Active Codes 2 Get Logged Codes 3 Clear Codes DATA MONITOR SETUP User Number X Select 1 5 Record Mode Stream or Screen Trigger None Beginning Middle or End Go to page 3 DATA MONITOR MENU 1 Standard Data 2 Governor Data 3 Sensor Data 4 EGR Data 9 Fuel Pressure Data Allows customizing of user settings for up to 5 different users If no need for individual customization just select 1 Stream records all data Screen records only screen displayed data Trigger you select how the tool will read the collected data in the buffer None locks out automatic recording of data Beginning collects data after trigger Middle collects data before and after trigger End collects data before trigger gt Not Used At This Time Select 1 if no fuel pressure sensor is used Select 25 if fuel pressure sensor is used This will add fuel pressure sensor info to the DATA LIST SELECT FUNCTION 1 Key On Engine Off 2 Engine Running Service Mode Check Upper Left LED for oue 12 Wait Press MODE to Exit Any failure codes will be displayed after Code 12 just like the code flasher tool Service Mode Engine Spd RPM XXXX Desir Idle RPM Press MODE to Exit Other data is availabl
128. TERCLOCKWISE until it stops approximately 2 turns The red on the handle shaft indicates that the drain system is open Do not force the handle as this will create new threads Immediately remove the blue drain plug from the side of the thermostat housing This must be removed within 30 seconds to properly vent the cooling system 77949 Blue Handle b Blue Drain Plug Location Visually verify that water is draining If water does not drain remove blue drain plug from distribution housing and drain manually A 4 59 NS SIS gt 77917 Drain Location Orange Red b Blue Drain Plug Allow the system to drain for a minimum of 5 minutes Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance 6 Reinstall the blue drain plug in the thermostat housing 90 883145 3 10 03 Close the drain system by rotating the blue handle CLOCKWISE until it stops and install the blue drain plug if removed The handle is fully seated when no red is visible Do not overtighten the handle as this will create new threads Open the seacock prior to operating the engine WINTERIZATION AND RECOMMISSIONING 1G 13 AIR ACTUATED SINGLE POINT DRAIN SYSTEM NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Close the seacock 2 Remove the blue air pump from the
129. The power reduction mode allows normal fuel injection and full power up to 2 800 rpm Above 2800 rpm fuel delivery is limited to 1 injector TBI models or 4 injectors MPI models until rpm falls below 1200 The engine will then resume normal operation with all injectors firing If the problem goes away while power reduction mode is engaged the engine immediately resumes normal operation EFI System Air Delivery Components THROTTLE BODY 90 883145 4 0804 The throttle body assembly is attached to the plenum and is used to control air flow into the engine The Throttle Position TP Sensor is mounted on the throttle body and is used for sensing throttle valve position The Idle Air Control IAC valve is also mounted on the throttle body and is used to control idle speed and to prevent engine stalls due to changes in engine load NOTE Later systems have additional sensors which are covered in the service manuals ELECTRONIC FUEL INJECTION INTRODUCTION 3B 25 Fuel Systems Electronic Fuel Injection Throttle Body Injection With Vapor Separator Tank VST 73895 1 a Fuel Line from boat s fuel tank b Water Separating Fuel Filter Supply pump mechanical or electric d Vapor separator tank e Throttle body with 2 fuel injectors f Fuel pressure regulator g Return line to vapor separator tank 3B 26 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 EFI System Vapor Separator Tank VST
130. The Commander 3000 Classic Control When Used With Alpha One Product 99 7 Gasoline Engine Vapor Locking 99 8 EFI MPI Fuel Pumps With Low Pressure 99 9 New Flushing Procedure For Alpha and Bravo Engines When Using A Flushing Attachment On The Sterndrive 99 10 Exhaust Manifolds Risers and Exhaust Elbows 99 11 3 0L Flame Arrestor Decal 99 12 Water Drain Plugs Installed 97 25R Gasoline Engine Compression Test 2000 MERCRUISER SERVICE BULLETIN INDEX 00 1 Alpha One Delayed Shift 00 2 Bravo Three Blackhawk Lower Unit Oil Seal Installation Tool Modification 00 3 Serpentine Belt Power Steering Pulleys 00 4 Warranty and Registration of Unsold Non Current Mercury MerCruiser Product 90 883145 3 10 03 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 4 5 00 5 Official Notification Under the U S Federal Boat Safety Act Stainless Steel Electric Fuel Pump 00 6 Official Notification Under the U S Federal Boat Safety Act Commander 3000 Remote Control Decal 00 7 Inline D Tronic ECM Idle Speed 00 8 Replacing a Bravo Drive with a Bravo One X Two X Three X Bravo One XR Drive 00 9 Engine Specifications MX 6 2 MPI Sterndrive 00 10 Cylinder Head Re Torque Valve Adjustment On In line Diesels 00 11 Engine Specifications MCM 496 Mag MIE 8 1L 00 12 496 CID 8 1L Crankcase Oil Check 00 13 496 CID 8 1L Exhaust Installation 00 14 Black Sensor Failures in MEFI 3 Mercury Distributors used on V6 and V8 305 350 CID Engines 2001 MERCRUISE
131. Unit Installation Alpha Drive Unit Remote Control and Drive Unit Shift Cables Adjustment Drive Unit Installed Alpha Models Shift Cutout Switch Checking Cutout Switch Timing Models with Plunger Type Switch Checking Operation Troubleshooting Shift Problems Shift Cable Bravo Sterndrive Unit Installation Attaching Speedometer Water Tube Gimbal Housing to Stern Drive Drive Shaft Housing Aft Trim Cylinder Anchor Pin Hole Trim In Limit Spacer Positioning New Replacement Bravo Drive Shaft Housing Bravo Drive Unit Remote Control and Drive Unit Shift Cables Adjustment Troubleshooting Shift Problems Calculating Overall Drive Ratios 1C i STERNDRIVE INSTALLATION 90 883145 3 10 03 Alpha Sterndrive Unit Installation 1 Remove trim cylinder support and dust cover from bell housing studs Retain elastic stop nuts and flat washers 2 Remove gear lube monitor bottle cap Fill with gear lubricant NI 75404 75531 Dribble Valve Stem 4 Once gear lube appears release dribble valve stem 5 Fill monitor to FULL mark 6 Replace monitor cap IMPORTANT Rubber gasket must be properly positioned and glued in bell housing bore before installing
132. V 6 and Small Block V 8 Electric Fuel Pump Used on Carbureted Models 3A 8 MerCruiser Carburetor Adjustments 3A 9 MerCarb Two Barrel MerCruiser Carburetor 10 Identification 10 Description 11 MerCarb Repair Kit Numbers 3A 11 Exploded Parts View 3A 12 Fuel Systems Carburetors 3A 13 MerCarb 13 Vacuum and Fuel delivery 3A 13 Float System 3A 13 Description 3A 13 MerCarb 3A 14 Idle 3A 14 Description 3A 14 Off idle operation 14 MerCarb 15 Main Metering System 3A 15 Description 3A 15 sieur 16 Power System 3A 16 Description 16 MP 3A 17 Pump System 3A 17 Description 3A 17 Adjustable Accelerator Pump Lever 3A 18 uec 3A 19 Choke System 3A 19 Description 19 3A i FUEL DELIVERY SYSTEM AND CARBURETION Page Fuel Systems Carburetors 3A 22 Rochester Quadrajet 3A 22 Rochester Quadrajet 4MV Carbu
133. VACUUM GAUGE VS SENSOR RTI e 9 28 11111112 DU 25 1 HAH 11 9 4 8 TH c o HN Tho 95 N 19 T D 5 S IE TIL Ee l 8 99 6 or c S IE LL LT TN a e g 50 15 2 7 Sete TT Q c 45 h FTTT TT TINT ee l S 40 12 0 le 2 1 8 F ES d 20 0 10 3 1 SLLLLLLLLLLLLLLINS 0246 8 10 12 14 16 18 20 22 24 26 28 30 Hand Vacuum Gauge This graph is correct Sea Level only 3B 4 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 3 10 03 EST Ignition Source of Ref Hi Signal The Electronic Fuel Injection EFI is controlled by an Electronic Control Module ECM This module is the nerve decision center of the system It uses all the information it gathers to manage ignition spark delivering increased fuel economy and maximum engine performance The EFI system uses inputs from sensors to make decisions on the amount of spark advance or retard allowed The EFI system has been designed to control ignition advance and retard electronically by the ECM This electronic advance becomes much more exact and reliable just as EST is more exact and reliable when compared to the breaker point ignition system In order for the ECM to properly calculat
134. Wound Lockwasher ENGINE INSTALLATION AND ALIGNMENT 1B 1 New MerCruiser Sterndrive Rear Engine Mounts Starting Serial Number 0M660000 Do not use double wound lockwashers on the inner transom plate with quick rear mounts 79430 Standard rear mount smooth edge Quick rear mount knurled edge 1 Install the spacer into the flywheel housing IMPORTANT The white 865329 or yellow 865330 paint identifies the top of the mount assembly The bottom has a knurled edge 79435 a Painted top b Smooth edge c Bottom end d Knurled edge 79433 Typical flywheel housing all similar a Painted end not visible b Mount bottom c Knurled edge 1B 2 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 2 On all inner transom plates If equipped remove and discard the double wound lockwashers on the inner transom plate mounts J le b Typical starboard inner transom plate mount port similar a Double wound lockwasher Fiber washer 90 883145 4 0804 ENGINE INSTALLATION AND ALIGNMENT 1B 3 Engine Alignment Checking Stringer Height To achieve approximately equal front mount adjustment ensure that the stringers are equal in height before installing the engine This may be checked by tying a string from the port front mount location to the starboard rear engine mount on transom assembly Another string should be tied from starboard front to port rear The strings
135. YEL BLK E ANZ COG zu gt CD lt lt BLK mmm gt T o LJ 15 BLUTAN m 22 71 A i 2 D Q LT BLU 2 E E c E BRN WHT nn L BRN WHT OS m 6 A HOVL XNV 02 pr mz 2 m O 3B 44 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 PCM 555 Ignition Circuit f u COILS 2 CB A _ gt io 2 p n EX c o1 I EL m a QN SPLICE SPLICE sso 105 101 SPLICE 100 A 3 DE DA 2 p 8 D 8 9 9 49 1213 14 15 16 47 18 19 20 27 SPLICE m lt SS E e SPLICE gt 101 o1 p T Z gt H Lm c WHT BLK COILS 1 pos With initial key ON 12 volt power is sent from the battery through the purple lead in the 10 pin harness to the pink lead at Engine Harness Pin C This is wake up power to the PCM The PCM powers pin B4 which in turn pulls the MPR low The MPR powers the coils through Splice 105 and powers the engine for ignition PCM Pinout Cyl Number PCM Pinout Cyl Nu
136. a Sight Glass SINGLE DIAPHRAGM IN LINE CONNECTOR P N 91 18078 FOR CHECKING FUEL PUMP PRESSURE A service tool is available for MerCruiser engines allowing connection of a fuel pressure gauge to check fuel pump pressure The tool connects between the fuel pump and carburetor Caution must be taken that all fuel lines and fittings are 4 3L 262 CID GM V 6 Gen Il tightened securely ELECTRIC FUEL PUMP 73469 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 3A 3 Fuel Delivery System GENERAL Boating standards NMMA ABYC etc and Coast Guard regulations must be adhered to when constructing the engine compartment The main concern of a boat s fuel system is safety this must be achieved through a technically sound installation and constant inspection The fuel system from the filler pipe to the fuel pump is the same in principle for all boats The fuel tank is an integrated component of the boat Refer to the special information on service and maintenance which you have received from the tank manufacturer Only a few points related to function and safety are listed here Refer to boating standards NMMA ABYC etc and Coast Guard regulations for complete guidelines e All connections should be on the upper side of the tank e The drain plug at the lowest point on the tank serves to permit the removal of water and sediment e The filler pipe outer diameter should be at least 2 in 50 mm e The ta
137. a BLK wire connected to it it is grounded internally Con nect voltmeter lead to unpainted surface of the alternator c Start engine increase rpm to 1300 and observe voltmeter reading The maximum allowed is 0 5v d To find the point where the resistance is highest leave the voltmeter lead on the battery post and move the voltmeter lead to the alternator BLK wire ring terminal NOTE If alternator does not have a BLK wire connected to it go to e Then move voltmeter lead to the BLK wire itself that is inside the crimped ring ter minal f Next move voltmeter lead to the ground stud where the battery cable is con nected g Move the voltmeter lead to the battery cable ring terminal that is on the ground stud h Move voltmeter lead to the battery cable itself that is inside the crimped battery cable ring terminal 2C 6 CHARGING SYSTEM 90 883145 3 10 03 i Test each battery cable connection in this manner all the way back to the battery post 0 5v Max Replacing Alternators Warranty 90 883145 3 10 03 When an alternator is replaced retest the voltage at the battery posts to ensure that the alternator is charging the battery If a complete alternator is needed for warranty replacement it must be ordered from Mercury Parts The use of any other company s alternator as a warranty replacement is not allowed Any alternat
138. able other languages will be supported in future releases The CDS system will use the same diagnostic harness assemblies as the DDT Diagnostic harness assemblies are not included in the kit from SPX and must be ordered from Mercury Precision Parts The diagnostic harness assemblies are listed at the end of the bulletin Minimum System Requirements 900 MHz Pentium Processor PCMIA slot USB port 256MB Ram Windows 2000 DVD Drive 56K Modem 10 GB Hard Drive Ordering Information To get additional information pricing or to order the Computer Diagnostic system contact SPX Corporation 28365 Mound Warren MI 48092 or call USA 1 800 345 2233 Canada 800 345 2233 Europe 49 6182 959 149 Australia 03 9544 6222 Adapter Cable Harnesses Mercury Mariner Outboard and Jet Drive Adapter Harnesses Harnesses are purchased from Mercury Precision Parts Page 2 4 2004 Mercury Marine MAY 2004 2004 04R 3B 70 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 Computer Diagnostic System NOTE All harnesses are not used with current software revision level Future software releases will use additional harnesses 1994 3 0L Carb Engines 84 822560A 1 1994 1 2 and up 2 5L EFI with 824003 ECM only 1994 1 2 Pro Max Super Max Super Magnum 84 822560A 5 1997 and up DFl OptiMax Outboards 1995 2001 3 0L EFI and Carb Outboards Use with 84 822560A 7 84 822560A 6 1995 2001 3 0L EFI and Carb Outboards Use wi
139. actuated 2 Install cable end guide on throttle lever and then push cable barrel end lightly toward throttle lever end This will place a slight preload on the cable to avoid slack in cable when moving remote control lever Adjust barrel on throttle cable to align with anchor stud 3 Secure throttle cable with hardware as shown DO NOT OVERTIGHTEN as cable must pivot freely Tighten securely and then loosen locknuts 1 2 turn to allow cable to move freely 4 Place remote control throttle lever in the WOT position Ensure that throttle shutters are completely open 5 Return remote control throttle lever to idle position and ensure that throttle lever contacts idle speed adjustment screw 76900 2 BBL V6 and V8 Models a Cable End Guide b Throttle Lever Screw c Locknut and Flat Washer Small d Throttle Lever e Idle Speed Adjustment Screw f Idle Cam g Throttle Bracket h Cable Barrel i Flat Washer and Locknut Large Throttle Cable Anchor Stud 90 883145 3 10 03 THROTTLE CABLE ADJUSTMENT 1E 1 70392 71159 4 BBL V6 Models a Cable End Guide b Flatwasher and Locknut c Cable Barrel d Throttle Lever Contacts e in Idle Position e Idle Speed Adjustment Screw f Throttle Shaft Lever Contacts g at WOT Position g Carburetor Body Casting 50634 3 0L Models a Cable End Guide b Anchor Screw Tighten Securely c Cable Barrel d Elastic Sto
140. acuum gauges are for the most part inaccurate at these low readings The engine should be run at idle 3 000 rom WOT and back at idle rom Gauge readings should not exceed the maximum allowable vacuum specification at any of these throttle settings Restrictions in the delivery system can be caused by sticky anti siphon valves too small a diameter of fuel lines and fittings extra fuel fittings 90 additional fuel filters clogged filters plugged fuel tank pick ups etc See MerCruiser Service Bulletin 99 7 v Digital Vacuum Gauge 250525052 60 CX XJ 009600000000 0 Fitting 5 77 9910 dl Fuel MAD ST Pump Carburetor j 37 NR Water Separating Fuel Filter Fuel Tank 3A 6 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Testing Fuel System Pressure EFI Throttle Body Injection Systems 91 16850A7 a Remove Fuel Line from Throttle Body Unit and Install Fuel Fitting Connector P N 91 806901 Connect Fuel Pressure Gauge Kit P N 91 16850A7 to test system pressure 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 7 V 6 and Small Block V 8 Electric Fuel Pump Used Carbureted Models For engine starting and running the electric fuel pump uses two electric circuits These two circuits are designed to prevent the fuel pump from running if the key is accidently left on A jumper wire connec
141. acuum operated power piston 6 and a spring located in a cylinder connected by a passage to intake manifold vacuum The spring 12 under the power piston pushes the piston upward against manifold vacuum force tending to pull the piston downward During part throttle and cruising ranges manifold vacuums are sufficient to hold the power piston down against spring tension so that the larger diameter of the primary metering rod tip 7 is held in the main metering jet orifice to provide leaner mixtures during these periods of engine operation However as engine load 15 increased to a point where extra mixture enrichment is required the power piston spring overcomes the vacuum pull on the power piston and the tapered tip of the primary metering rods moves upward in the main metering jet orifice The smaller diameter of the metering rod tip allows more fuel to pass through the main metering jet and enrichen the fuel mixture to meet the added power requirements As engine load decreases the manifold vacuum 15 rises and extra mixture enrichment is no longer needed The higher vacuum pulls downward on the power piston against spring tension which moves the larger diameter of the metering rod into the metering jet orifice returning the fuel mixture to normal economy ranges cont 3A 28 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 The primary side of the carburetor provides adequate air and fuel for low speed operation However at h
142. an be ordered separately or as a combined update kit including soft ware Kame Spark 11 5 m pen 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 61 Windows PC Software Available A completely new Diacom Marine diagnostic package not shown is available for Windows 98 MF NT and Windows 2000 equipped laptop computers Diacom Marine software allows a PC to function as a high performance scan tool capable of diagnostics The software provide a live view of the engine sensor and control system information Data can be viewed numeri cally displayed graphically or saved on a disk for review off line The software is supplied with a special cable allowing the PC to connect to the engine s DLC Diacom Marine also pro vides instant access to electronic service information when it is available from the manufac turer Ordering New or Updating Older Scan Tools English Language Update Kit Instructions come with the kit and it takes about 10 minutes to install it International Update Kit International dealers can order directly from Rinda Instructions come with the kit and it takes about 10 minutes to install it New Scan Tools Diacom software update kits and adapters are available directly from Rin da The warranty on a new Scan Tool is for one year Rinda can ship internationally Prices shown do not include shipping cost Rinda Technologies Inc will also
143. and Weight Assembly 47 Plunger Washer 48 Plunger Guide 49 Accelerator Pump 50 Spring Accelerator Pump 51 Float Bowl Body Carburetor Bottom The carburetor body has two cast in float bowls Each float bowl will feed a primary secondary circuit Fuel flowing through the primary jets feeds both the idle circuits and primary ventura Fuel mixture for the idle circuit is controlled by mixture screws located in the front of the carburetor body Fuel for the secondary circuit flows past two secondary fuel jets Extra fuel required by the Power Circuit is controlled by the metering rods in the air horn 3A 34 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Fuel Systems Carburetors Weber Carburetor Float System DESCRIPTION 90 883145 3 10 03 The carburetor float system controls the fuel level in the carburetor bowl Fuel level is very important because it must be maintained to give proper carburetor metering throughout all ranges of engine operation If the fuel level is too high in the float bowl problems such as rich mixtures affecting fuel consumption fuel spillage from the main discharge nozzles on turns and engine loading can result If the fuel level is lower than the specified setting it can cause lean mixtures hesitation on acceleration engine surge plus engine cut out during heavy fuel demands The Weber carburetor uses tw
144. anufactured and or installed after July 31 1998 24 1 PURPOSE These standards and recommended practices are guides for the design choice of materials for construction installation and maintenance of gasoline fuel systems on boats EXCEPTION Portable fuel systems covered by ABYC H 25 Portable Fuel Systems NOTE The United States Coast Guard has promulgated mandatory requirements for gasoline fuel systems in Title 33 CFR Subpart J Sections CFR 183 501 183 590 Refer to the CFR for complete current federal requirements 24 2 SCOPE These standards and recommended practices apply to all parts of installed gasoline fuel systems from the fuel tank fill opening to the point of connection to the propulsion engine and or to any auxiliary equipment on inboard and outboard powered boats 24 3 REFERENCED ORGANIZATIONS ABYC American Boat amp Yacht Council Inc 3069 Solomons Island Road Edgewater MD 21037 1416 Phone 410 956 1050 Fax 410 956 2737 Web site www abycinc org ASTM International American Society for Testing and Materials International 100 Barr Harbor Drive West Conshohocken PA 19428 2959 Phone 610 832 9585 Fax 610 832 955 Web site www astm org American Welding Society 550 NW 4274 Avenue 100 Miami FL 33126 Phone 305 443 9353 Fax 305 443 7559 Web site aws org CFR Code of Federal Regulations and other government publications Obtain from the Superintendent of D
145. ard The maximum float drop must be maintained so that the float assembly will drop sufficiently to allow maximum fuel flow under heavy engine demands An internal fuel filter is located behind the fuel inlet fit ting The filter assembly consists of a spring filter ele ment relief spring and a gasket The open end of the filter faces the fuel inlet nut The filter element is spring loaded to provide a pressure relief so that in the event the filter should clog the restriction will cause the fuel pump pressure to overcome the filter relief spring pressure and allow fuel to by pass the fil ter to keep the engine running and enable the driver to get a service outlet for repair The bowl vent 7 is internal inside the air horn just below the flame arrestor The amount of fuel metered by the carburetor is dependant upon the pressure in side the float bowl causing the fuel to flow The vent system assures that any pressure build up in the float chamber during hot engine operation caused by fuel vapors will be relieved into the flame arrestor During normal engine operation when the engine is running manifold vacuum pulls the fuel vapors into the engine FUEL DELIVERY SYSTEM AND CARBURETION 13 MerCarb Idle System DESCRIPTION The MerCarb has an idle system to supply the correct air fuel mixture ratios to the engine during idle and low speed operation The idle system is necessary during this period be
146. arp bends and or contact with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated 2 3 Remove the flame arrestor a Install cable end guide b on throttle lever stud then push cable barrel f lightly toward throttle lever end This will place a slight pre load on shift cable to avoid slack in cable when moving remote control lever 4 Adjust barrel f on throttle cable to align with anchor bracket stud 0 Secure throttle cable with hardware as shown Tighten until nut bottoms Then back off 1 full turn Cable must pivot freely Place remote control throttle lever in the wide open throttle WOT position Ensure that throttle shutter is completely open Return remote control throttle lever to idle position Ensure that throttle lever contacts the stop Adjust cable barrel to achieve these settings Install flame arrestor and tighten securely a Flame Arrestor b Cable End Guide c Throttle Lever Stud Elastic Stop Nut and Flat Washer Tighten Until Nut Bottoms Out Then Back Off 1 Full Turn d Throttle Lever e Anchor Bracket f Cable Barrel g Anchor Bracket Stud Flat Washer and Elastic Stop Nut 1E 4 THROTTLE CABLE ADJUSTMENT 90 883145 3 10 03 MERCRUISER EN PDI AND MAINTENANCE LEVEL I PREDELIVERY PREPARATION Table of Contents Page Predelivery Preparation 1F 1 Battery Connection
147. ass Activated BLK RED Dist Reference LOW ECM Control Mode 90 883145 3 10 03 IGNITION SYSTEMS 2D 31 EFI Engines with Mercury Marine Thunderbolt V Distributor and MEFI 3 ECM 1999 V 6 and Small Block V 8 Engines These EFI MPI engines V 6 Small Block V 8 originally used an EST type of distributor They now use 1999 and later a Mercury Marine Thunderbolt V style distributor This unit only has an ignition sensor It does not have an ignition module like the EST system The sensor provides a square wave digital signal to the ECM which is used as an engine speed reference rom and as a timing reference The ECM completely controls ignition timing at all engine speeds This is similar to an EST ignition running in the ECM Control Mode The ignition coil driver transistor which was built into the EST ignition module is now inside the MEFI 3 ECM IGN INJ FUSE 902 RED 439 PNK J2 32 IGNITION TO INJECTORS AND 902 RED FUEL PUMP RELAY DISTRIBUTOR ED ECM WHT GRN WHT RED GROUND 450 BLK ECM GROUND E ECM GROUND 439 PNK 430 PPL WHT DIST REF 902 RED 121 WHT 121 WHT IGN COIL IGNITION COIL Tach Lead Changes to Gray color 2D 32 IGNITION SYSTEMS 90 883145 3 10 03 P N 91 805747A2 Timing Tool for MerCruiser Engines 90 883145 3 10 03 IMPORTANT The engine must be completely warmed up to normal operating tempera ture befo
148. assage It passes through the filter element 8 fuel inlet valve 3 amp 4 and on into the float bowl chamber 10 As the incoming fuel fills the float bowl to the prescribed level the float pontoon 7 rises and forces the fuel inlet valve closed shutting off fuel flow As fuel is used from the float bowl the float drops allowing the float valve to open allowing more fuel to again fill the bowl This cycle continues maintaining a constant fuel level in the float bowl The float pontoon is solid and is made of a light weight closed cell plastic material This feature gives added buoyancy to allow the use of a single float to maintain constant fuel levels A float clip 1 fastened to the float valve hooks over the edge of the float arm at the center Its purpose 15 to assist in lifting the float valve off its seat whenever fuel level in the float bowl is low The plastic filler block is located in the top of the float chamber over the float valve to prevent fuel slosh into this area The carburetor float chamber is internally vented on all models through a vent tube or tubes 2 located on the air horn The internal vent tube s leads from beneath the flame arrestor to the float bowl chamber The purpose is to balance air pressure acting on the fuel in the bowl with air flow through the carburetor bores In this way balanced air fuel mixtures ratios can be maintained throughout all carburetor ranges 3A 24 FUEL DELIVERY SYSTEM AND CA
149. at or starting the engine close the drain system by installing the four blue drain plugs 8 Open the seacock prior to operating the engine 1G 16 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 Boat Out Of The Water MANUAL SINGLE POINT DRAIN SYSTEM 1 Rotate the blue handle COUNTERCLOCKWISE until rotation stops approximately 2 turns The red on the handle shaft indicates that the drain system is open Do not force the handle as this will create new threads UM rcu qd D CS SS 77947 a Blue Handle 2 Visually verify that water is draining If water does not drain remove blue drain plug from distribution housing and allow to drain manually SA e X A 77917 Drain Location Orange Red b Blue Drain Plug 3 Allow the system to drain for a minimum of 5 minutes Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained 4 Close the drain system by rotating the blue handle CLOCKWISE until it stops or installing the blue drain plug The handle 15 fully seated when no red is visible Do not overtighten the handle as this will create new threads 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 17 AIR ACTUATED SINGLE POINT DRAIN SYSTEM NOTE This procedure is written for the air pump that is attached to the engine However any ai
150. ata Worksheet Engine Type Year ZR Serial No MECE Contact Tel Date Spark Advance 115 deg 5 Por Gasoline EFI MEFI Ill ECM Scan tool requires adapter 494005 for this application Scan Tool Data List 1 Data Item Current Normal Commenis Reading Reading Engine Speed Des Idle Speed Coolant Temp Manifold Air Tmp TPS Volts Throttle Pct MAP Volts Manifold Pres Baro Pres Battery Volts Spark Advance Engine Knocking Knock Retard IAC Position Base IAC Pos IAC Follower Injector ON Time Fuel Flow Rate Engine Run Time Calibration ID Memcal Checksum Engine Overtemp Power Reduction Rev Limiter Input J2 9 E Stop Status Diagnostic Input Low Oil Level Oil Level Lamp General Warn 1 General Warn 2 Input J2 20 Fuel Pump Status Check Engine Lamp Check Gauge Lamp RPM Ctrl Output Rinda Technologies Inc Chicago IL Tel 773 736 6633 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 67 555 Data Log Sheet Rinda Scan Tool Engine Model Serial Number Customer RO Test RPM conditions Type exhaust Prop type and pitch Altitude PCM ECM Calibration Ambient Temperature oea Lake River Temperature Data Item english units Current Reading Comments Engine Speed Rpm Fuel Flow Rate gph Lake Sea Temp F Paddle Wheel Hz Pitot ADC Trim Position Trim Volts Fuel Level Availab
151. aximum of 30 percent of the tank cross section in the plane of the baffle 24 18 2 7 1 Baffle openings shall be designed so they do not prevent the fuel flow across the bottom or trap vapor across the top of the tank 24 18 2 8 Threaded connections into fuel tanks shall be in accordance with the American Standard Taper Pipe Thread NPTF and shall provide for thread engagement in accordance with TABLE V 24 18 2 9 Rigid fuel pick up tubes and fill pipes that extend near the tank bottom shall have clearance to prevent contact with the bottom due to flexing of the tank 24 18 210 If a pick up tube is equipped with a fuel strainer it shall 24 18 2 10 1 permit water contamination to be withdrawn from the tank with the fuel 24 18 2 10 2 have a micron rating of 500 minimum 600 maximum 1996 American Boat amp Yacht Council Inc 7 FUEL DELIVERY SYSTEM AND CARBURETION 3A 53 24 12 96 Corrected 7 98 24 18 2103 be resistant to salt water alcohol and stale gasoline and 24 18 2 10 4 be accessible for servicing 24 18 2 11 If the fuel pick up tube is not furnished as part of the tank the tank manufacturer shall provide a detailed construction print of the tank and the pick up tube installation 24 18 2 12 The fuel return line terminus shall be above the level of the fuel when the tank is filled to its rated capacity 24 18 2 13 Fuel tanks shall be designed to withstand the applicable tests indicated i
152. be the repair facility for these Scan Tools Rinda Technologies Inc 4563 N Elston Ave Chicago IL 60630 Phone 773 736 6633 E Mail sales rinda com Fax 773 736 2950 Website www rinda com Scan Tools with Carrying Case Part Number 2001 4 0 Version English 94050m 2001 4 0 Version English German 940550 2001 4 0 Version English Italian 94055i 2001 4 0 Version English French 94055f 2001 4 0 Version English Spanish 94055s 2001 4 0 Version English Swedish 94055w Scan Tool Software Update Kits Includes P N 94006 PCM 555 Adaptor Part Number 2001 4 0 Version English 94056 2001 4 0 Version English German 94056g 2001 4 0 Version English Italian 940561 2001 4 0 Version English French 94056f 2001 4 0 Version English Spanish 94056s 2001 4 0 Version English Swedish 94056w Optional Scan Tool Adapters Part Number MerCruiser PCM 555 4 pin Adaptor 94006 MerCruiser Thunderbolt V Ignition Adapter 94020 D2 8L and D4 2L D Tronic Diesel Adapter 94014 D7 3L D Tronic Diesel Adapter 94021 3B 62 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 080 9 16988 06 9 NOILONGOYLNI NOLLO3fNI 1914 OINOYLOA 13 Press Setup Settin Language opti page ECM Service Output Power Data Mode Tests Balance ReviewData FaultCodes ECM Verification Operating Hours Fault Codes for English Metric GPH Scaling Save gs Screen Adjust Language on only available in International Model Conne
153. between the ECM and the EST module that is known as REF LO These two lines between the ECM and the distributor provide a precise indication of engine speed The two other lines between the ECM and distributor which control the Electronic Spark Tim ing EST operation are known as the bypass and IC Ignition Control circuits IGNITION SYSTEMS 2D 29 EST Operation Cranking Distributor Module Mode The following describes EST operation during cranking and when the engine starts running To help understand how EST circuits operate a relay with a double set of contact points is shown in the module refer to the figures Distributor Module Mode and ECM Control Mode Solid state circuitry is used in the module but adding the relay makes it easier to visu alize how EST functions During cranking the relay is in the de energized position see figure Distributor Module Mode This connects the pickup coil to the base of the transistor When the pickup coil ap plies a positive voltage to the transistor it turns ON When voltage is removed the transistor turns OFF When the transistor turns ON current flows through the primary winding of the ignition coil When it turns OFF the primary current stops and a spark is developed at the spark plug A small amount of advance is built into the EST module via a timing circuit in case the engine remains in the distributor module timing mode With the relay de energized a set o
154. by V DMT 2004 VHz 4 Read DC Voltage on DMT2000A Display Figure 1 3 DMT2000A with Direct Voltage Adapter and Test Leads Attaching Alligator Clips PROCEDURE 1 Screw alligator clips over ends of probes with Red to Red and Black to Black Refer to Figure 1 4 Attaching Alligator Clips 2 Tighten alligator clips finger tight Figure 1 4 Attaching Alligator Clips 90 883145 4 0804 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 2G 7 Temperature Probe PROCEDURE 1 Plug small Thermocouple Plug into Thermo couple Probe with to and to refer to Figure 1 5 2 Plug Thermocouple Probe into DMT2000A with side to VQHz port refer to Figure 1 6 3 Position rotary function knob to TEMP position Use FUNCTION key to toggle between C and 4 Read temperature on DMT2000A Display D i US Pur C e Pm eg BE a 22 98 EM Figure 1 6 Thermocouple to Meter 2G 8 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION Figure 1 5 Thermocouple Plug 90 883145 3 10 03 Clamp On Current Probe Optional Accessory P N 91 802650 IMPORTANT Refer to Users Guide supplied with Clamp On Current Probe for proper testing procedures PROCEDURE 1 Plug end of Clamp On Probe with side marked into VQHz port and side with to COM port refer to Figure 1 7
155. ca and Ah Amp hour ratings required for use on MerCruiser products The Amp hour rating is used outside the USA and Canada GASOLINE ENGINES Minimum Required Engine Cranking Battery Size 3 5 cca or 475 mca or 90 Ah 450 cca or 575 mca or V8 Carb V8 550 V8 Carb 700 V8 120 Ah 600 cca or 750 mca All EFl and MPI 750 cca or 950 mca Models or 180 Ah DIESEL ENGINES 750 cca or 950 mca or 180 Ah 2A 2 BATTERIES WIRING 90 883145 3 10 03 Battery Cables Length and Size NOTE Battery should be located as close to engine as possible 1 Select proper size positive and negative battery cables using the chart a Add the positive and negative cable lengths together b Divide by 2 to obtain the average cable length IMPORTANT Terminals must be soldered to cable ends to ensure good electrical con tact Use electrical grade resin flux solder only Do NOT use acid flux solder as it may cause corrosion and a subsequent failure IMPORTANT Tapered post connectors with wing nut connections can be used The tapered posts must be used for the engine battery cables The wing nut connections should be used only for the power trim pump and accessories It is recommended that the wing nuts be replaced with regular nuts to ensure that the connections are tightened securely GASOLINE ENGINES Battery Minimum Cable Length Cable Gauge Up to 3 1 2 ft 1 1 m 4 3 1 2
156. cause air flow through the carburetor venturi is not great enough to cause fuel to flow from the main discharge nozzles At idle speed the throttle valves 8 are held slightly open by the idle speed screw The small amount of air which passes between the throttle valves and bores is regulated by the screw to give the desired idle speed oince the engine requires very little air for idle and low speed fuel is added to the air by the application of vacuum low pressure from the intake manifold directly through the idle system to the fuel in the carburetor float bowl With the idle mixture screw 7 holes located in a high vacuum low pressure area below the throttle valves and fuel in the float bowl vented to atmosphere the idle system operates in the following manner Fuel from the float bowl flows through the main metering jets 1 into the main fuel well 2 It is then picked up and metered by the calibrated orifice at the tip of the idle tubes 3 It then passes up the idle tubes and is mixed with air from the air bleeds 4 located on the top of the idle tubes and in the idle cross channels in the venturi cluster casting The mixture then passes downward in the idle channels 6 through a calibrated restriction 5 to the off idle discharge slots 9 Here the fuel mixture is again bled with air and then moves to the idle mixture screw holes where it is discharged and blends with the air passing the slightly open throttle valves and enters t
157. ch opens closes Circuit should open or close when the activating lever assembly is moved 3 16 in or 1 32 in Measure with 6 in steel rule 75225 Cutout Switch b Movement of Activating Lever Assembly c 6 in Steel Rule 4 After adjustments are made and are within 3 16 in or 1 32 in tighten the screws on the cutout switch After tightening screws recheck the plunger pin position 1 20 STERNDRIVE INSTALLATION 90 883145 3 10 03 Checking Operation 1 Reconnect throttle cable s removed earlier 2 Place boat in water and start engine Check the following a Shift into forward and reverse gear making sure that clutch engages before engine be gins to accelerate b Accelerate engine in forward and reverse gear to ensure engine does not shut down Check that shift cutout switch plunger is centered in notch of shift cutout lever with drive unit in forward and reverse gear d Shifting from IN gear position to neutral ensure drive unit is in neutral before remote con trol shift lever comes to neutral detent position Troubleshooting Shift Problems Information from MC Service Bulletin 96 5 Rev Nov 1999 NOTE The following information is provided to assist an installer in troubleshooting if hard shifting or chucking racheting is encountered when shifting into forward gear 1 When installing the control box in the side panel of the boat make sure that the cables have enough
158. ch would keep the engine running after a commanded stop Coolant Temperature Switch 90 883145 4 0804 FUEL DELIVERY SYSTEM AND CARBURETION 65 e Troubleshooting and Repair The TKS system has very few repair parts The TKS Module The oil pressure switch The coolant temperature switch and diode TKS Module There are essentially three failure modes Hard Starting Cold In this mode the TKS fuel path is closed As the module is normally open there are 3 possible root causes Continuous power is getting to the TKS module Debris in the TKS fuel path The TKS module has failed Hard Starting Hot In this mode the TKS fuel path is open As the module is normally open there are two possible root causes Continuous power is not getting to the TKS module The TKS module has failed Poor running running rich excessive fuel consumption In this mode the TKS fuel path is open and the causes are the same as Hard Starting Hot 3A 66 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 4 0804 TKS Retro Retro Fit Kits will be available for all engine lines the end of the year 2004 3 0L 1996 2004 4 3L 1998 2004 9 0L 1998 2004 o L 1998 2004 Anti Dieseling Kits are not compatible with TKS carburetors or Retro Fit Kits Each kit will come with some or all of the components shown below depending on engine model that are necessary for installa
159. cht Council Inc 11 FUEL DELIVERY SYSTEM AND CARBURETION 3A 57 24 12 96 TABLE IV METALLIC FUEL TANK MATERIAL AND FABRICATION REQUIREMENTS FOR CORROSION RESISTANCE MINIMUM NOMINAL SHEET THICKNESS MATERIAL See Note 1 SPECIFICATION GAUGE Nickel Copper ASTM B127 Class A 031 in 79mm 22 US std Copper Nickel ASTM B122 045 in 1 14mm 17 A W G Type E T P Copper Silicon ASTM B97 16 A W G ypes B amp G Steel Aluminum Alloy 5052 or 090 in 2 29mm 5083 5086 NOTES 1 See American Welding Society recommendations for welding processes 2 Only cylindrical stainless steel tanks with domed heads and a capacity of less than 20 gallons are permitted TABLE V TAPERED PIPE THREAD ENGAGEMENT 114 1 1 2 21 436 NOTE minimum lengths of thread engagement are those that can normally be achieved by hand when assembling male and female pipe thread together Additional tightening is necessary to make a joint that will not leak 1996 American Boat amp Yacht Council Inc 12 3A 58 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 H 24 12 96 FIGURE 1 ENCLOSURE BELOW DECK INSTALLATION We HP c TANK SUPFORTS TEST FUEL FIGURE2 ENCLOSURE ABOVE DECK INSTALLATION FUEL 1996 American Boat amp Yacht Council Inc 13 90 883145 3 10 03 FUEL DELIVERY SYSTEM AN
160. clearance to operate This is necessary because the cables move up and down when the shift handle is moved If the control box is mounted too far back toward any fiberglass structure the cables will be interfered with this will cause very hard shifting NOTE The control box housing can be rotated in 30 increments to improve cable routing 74688 74689 Improper Cable Bend 2 Make sure that when the shift cable from the control box is led through the side gunnel of the hull it does not have any extremely sharp bends in it as this will cause stiff shifting 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 21 3 Before installing the shift cable into the control box extend the stainless rod eye end of the cable and grease it with 2 4 C Marine Lubricant with Teflon Move it back and forth to allow even distribution of the grease 4 Do not strap or clamp the control cables to any other cables or rigid structure within 3 ft 914 mm of the control box Be sure the cable is not permanently kinked 6 Make sure there is proper clearance for cable movement when the control box is installed in the side panel The cables must have room to move up and down when the control handle is shifted into either forward or reverse 7 Ensure that the engine was not set down on the intermediate shift cable during installation as this will crush the inner cable tubing and cause improper and or stiff shifting 8 DO NOT fasten the shift cabl
161. control module receives it s power from the PURPLE wire 4 Knock module ground is accomplished thru the BLACK wire 2 The PURPLE WHITE wire 3 carries the signal from the knock control module to the ignition control module The BLUE wire 1 carries the signal from the knock sensor to the knock module Ignition Control System Timing Lead The ignition control system has a lead with bullet connector 13 that is connected into the PURPLE WHITE wire 3 This lead is used for performing the following tests and procedures Setting Base Ignition Timing Setting Engine Idle Speed Setting Idle Mixture Testing Knock Control Circuit This lead when connected to an engine ground locks the ignition control module into the Base Timing mode 2D 12 IGNITION SYSTEMS 90 883145 4 0804 Thunderbolt V Ignition System Wiring Diagram 1997 and Older Models with Distributor Mounted Module Bravo shown BLK BLU BRN GRY GRN ORN PNK RED TAN WHT YEL LIT DRK 90 883145 3 10 03 TO ENGINE HARNESS
162. ct Connection A designer or the installer may require an installation similar to one of the following four ex amples All exhaust hoses and or tubes must be secured with two clamps at each connec tion 73961 V8 Models Through Transom Exhaust a Hose Clamps b Exhaust Hose Tube c Exhaust Pipe 1B 14 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 22059 V6 with 2 Exhaust Manifold and V8 Models Through Propeller Exhaust 7 e wd 74773 E T J 50633 3 0L Models Through Propeller Exhaust a Hose Clamps b Exhaust Hose Tube c Exhaust Pipe Elbow 90 883145 3 10 03 ENGINE INSTALLATION AND ALIGNMENT 1B 15 Methods of Measuring Exhaust Elbow Height The following information outlines two different methods of measuring exhaust elbow height to determine if risers are needed Refer to Measuring Procedures for instructions on proper loading of the boat and complete measurement instructions Straight Edge Method TOOLS Part Number ain Loca Straight Edge long enough to cross port to starboard gunwales INSTRUCTIONS 1 Place a long straight edge across boat 2 With the straight edge above the engine and parallel to the water measure the distances between the straight edge and the top of the exhaust elbow 3 With the straight edge above the engine and parallel to the water m
163. ct Tool Start Here MerCruiser EFI Merc Thunderbolt V Mercury InjectorTest Outboard PCM ad Engine 1 Engine 2 Data Retrieval EngineSelect Output Power Verification Balance Test Test Functions EraseFaults FaultCodes Multi Pulse Test Single Pulse Test Time Set Support Info MerCruiser Mercury Scan Tool 4 epurg Jesin42J9 N MerCruiser Rinda Function Flowchart Continued Continued from the previous page MerCruiser 555 PCMData Fault History RPMHistory bui Wa oystem Info Display Read RPMI Erase RPM History History Head Fault Read Fault History Seconds Read History Freeze Frame Data Erase Fault History amp Freeze Read Engine Frame Data Hours Read Read Current reeze Faults Frame Data Erase Current Faults Scanner Function Auto Output IAC Set Engine Induced Set Trim Self Test Tests Test Location Misfire Test Limit Fuel Injector Fuel Pump Ignition Coil Warning Tachometer Test Relay Test Test Horn Test Output Test 3B 64 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 MC RINDA MEFI I DATA SHEET Engine Data Worksheet Engine Type Year Serial No Contact Tel Date Spark Advance deg Gasoline EFI MEFI ECM Scan tool requires adapter 94005 for this application n Tool D ist 1 Data Item Current Normal
164. d b Star Washer and Screw c 90 Hose Fitting d Quick Release Button e ACCEPTABLE Positions f NOT ACCEPTABLE Position ENGINE INSTALLATION AND ALIGNMENT 1B 11 Trim Position Sender Harness Mercury MerCruiser provides an instrumentation harness that includes trim position sender wiring The installer must connect the trim position sender wires from transom assembly to engine harness The instrumentation must include a trim position gauge mU d 579 ANC BE e s EE V6 and V8 Models 3 0L Similar a Engine Harness Bullet Connectors b Engine Harness c Transom Assembly Wires 74029 SmartCraft Transoms The port side sender has a 3 wire quick connector that goes to the SmartCraft Transom Har ness on the engine It sends a signal to the ECM that processes both trim limit and trim posi tion information and then a signal is sent to the trim pump or SmartCraft gauges as required Key switch must be ON for trim limit to function The starboard side trim position sender is for use with older analog trim gauges 1B 12 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 Power Steering Hose Routing IMPORTANT When installing power steering hoses observe the following e Make hydraulic connections as quickly as possible to prevent fluid leakage careful to cross thread or overtighten fittings Power steering fluid hoses are provided with th
165. d then the test shall be repeated with a new sample Ap 1 9 At the end of the 2 2 minutes extinguish the fire by fully discharging a ten pound carbon dioxide extinguisher Ap 1 9 1 The fuel lines and the sample shall not be disturbed Ap 1 10 Immediately after the fire is extinguished the discharge valve shall be opened and fuel allowed to run through the system until a steady stream is obtained 1 11 Then close the discharge valve place the system under a hydrostatic pressure of three feet of head and monitor the sample for leakage for a period of five minutes 1996 American Boat amp Yacht Council Inc 14 3A 60 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 H 24 12 96 Ap A FIGURE 1 FUEL SYSTEM COMPONENT FIRE TEST APPARATUS Metal WISI Discharge vee Test Unit Receiving Pan IL 77 7 Fuel System Component Fire lest Test Apparatus ABYC technical board rules provide that all reports including standards and technical information reports are advisory only Their use is entirely voluntary They are believed to represent as of the date of publication the consensus of knowledgeable persons currently active in the field of small craft on performance objectives that contribute to small boat safety The American Boat amp Yacht Council assumes no responsibility whatsoever for the
166. d followed exactly when wires have been disconnected or when wire replacement is necessary Failure to route wires properly can lead to radio frequency interference cross firing of the plugs and or shorting of leads to ground IMPORTANT Use only spark plug wires recommended for Marine application NOTE When replacing spark plug wires it is good practice to replace one wire at a time to reduce the risk of error 1 Disconnect individual spark plug wires 2 Install spark plug wires in proper order Observe the following IMPORTANT When replacing plug wires route the wires correctly through the proper supports Correct positioning of spark plug wires and supports is important to prevent cross firing a Position wires in spark plug wire supports and retainers as provided b Attach plug wires to appropriate spark plug and terminal on distributor cap Each end should fit securely Engine Rotation And Firing Order a Front IMPORTANT Before installing coil wire high tension lead to coil apply approximately 1 2 oz of Silicone Dielectric Compound an electrical insulating compound Quicksil ver 92 802882A1 around top of coil high tension lead tower Do not apply to inside of tower hole c Apply Silicone Dielectric Compound Attach coil wire high tension lead to center ter minal on distributor cap 2E 4 IGNITION SECONDARY 90 883145 3 10 03 d Push end of high tension wire into coil tower Position boot over
167. d how EST circuits operate a relay with a double set of contact points is shown Solid state circuitry is used in the module but adding the relay makes it easier to visualize On the 3 0L 3 0LX models with the engine running the relay is in the de energized state This connects the pickup coil to the base of the transistor The voltage output from the magnetic pickup assembly is used to turn the transistor in the module on and off A transistor has polarity so as a result it turns on like a switch but only when the polarity is correct to flow through itself in one direction only When the time core teeth start to approach the pole piece teeth voltage rises closing the transistor and allowing current to flow through the primary ignition coil to ground As the pole pieces align and pass the polarity of the pickup voltage begins to reverse As the polarity reverses the transistor will turn off causing the current to stop flowing through the primary ignition coil windings The exact moment the transistor is turned off there is a spark in a cylinder The length of time there is current flowing through the coil is called dwell Dwell is measured in terms of degrees of distributor rotation As the engine RPM increases the time available for dwell is decreased causing the secondary coil output to decrease To help reduce this as engine RPM increases the dwell increases by starting the ground path of the primary earlier so as not to affect ig
168. d on the fuel tank samples that have contained ASTM Reference Fuel C for 30 days at room temperature 70 F 80 F 21 1 C 26 7 C 24 18 5 2 2 The fuel tank sample filled to capacity with water shall be mounted to a platform using supports chocks or hangers either furnished with the tank or intended to be used in a boat installation 24 18 5 2 3 The platform shall be connected to a device that will repeatedly raise and drop the platform at a rate not to exceed 80 impacts per minute By varying the height of the drop and or cushioning under the platform the top surface of the platform shall be calibrated as close to the tank center of gravity as is practicable to provide the specified shock impacts 24 18 5 2 4 The tank shall be tested to meet the requirements of 24 18 5 1 24 18 5 3 Pressure Impulse Test Representative samples of 25 gallons 95 liters capacity and more shall not leak or show signs of permanent deformation or other signs of failure following 25 000 cycles of pressure impulse 24 18 5 3 1 Pressure Impulse tests for non metallic fuel tanks shall be conducted on the fuel tank samples that have contained ASTM Reference Fuel C for 30 days at room temperature 70 F 80 F 21 1 C 26 7 C 24 18 5 3 2 The fuel tank sample filled to capacity with water shall be mounted using support chocks or hangers either furnished with the tank or intended to be used in a boat installation 24 18 5 3 3 The fuel tank sampl
169. downward in the idle channels 5 to the off idle discharge slots 8 Here the fuel mixture is again bled with air and then moves to the idle mixture screw holes 9 where it is discharged and blends with the air passing the slightly open throttle valves and enters the intake manifold as a combustible mixture The idle mixture screw controls the amount of fuel mixture which enters each carburetor bore If the idle mixture screw or needle is backed out more mixture is admitted to the intake manifold and the engine runs rich If the screw is turned in the engine runs lean In this manner the idle mixture is varied for best idle OFF IDLE OPERATION 90 883145 3 10 03 As the throttle valves are opened and more air is entering the engine to increase engine speed additional fuel is needed to combine with the extra air This is accomplished by the off idle discharge slots As the throttle valves move past the off idle slots they become progressively exposed to high vacuum below the throttle valves and the extra fuel needed is supplied by these slots The idle holes and off idle slots supply sufficient fuel for engine requirements until air velocity is high enough in the venturi are to obtain fuel flow from the main metering system FUEL DELIVERY SYSTEM AND CARBURETION 3A 37 Weber Carburetor Main Metering System Primary Side DESCRIPTION The main metering system supplies fuel to the engine from off idle t
170. drive unit or water may leak into boat 7 Ensure that rubber gasket and water passage O ring are properly positioned in bell hous ing The rubber gasket must be glued in place or water may leak into the u joint bellows and then into the boat 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 1 8 Coat entire stud and threads with 2 4 C Marine Lubricant with Teflon Bs 8 Pa 75531 a Rubber Gasket b Water Passage O Ring c Studs 9 Coat drive unit pilot drive shaft O rings and drive shaft splines with Quicksilver Engine Coupler Grease 92 816391A4 a Drive Shaft Pilot b Drive Shaft O Rings Drive Shaft Splines 1C 2 STERNDRIVE INSTALLATION 90 883145 3 10 03 90 883145 3 10 03 10 Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft Do this by placing remote control shift lever in Forward gear position for RH drive or Reverse gear position for LH drive unit 75525 a Shift Shaft b Shift Shaft Coupler c Shift Slide IMPORTANT Shift slide assembly is free to rotate on core wire therefore be careful that shift slide remains in upright position and is properly engaged with shift shaft lever roller while installing drive unit 11 Engage shift shaft roller into shift shaft lever Snap the Shift Shaft Slide Stabilizer Tool onto stud directly below shift slide and position as shown d
171. ds touched together the display reads 0 3 Ohms A This is the actual value of the test lead resistance To zero the display for accurate low Ohms touch the leads together and depress the Rel button to zero e Q Inductive RPM function how do set the number of cylinders A t is not necessary when using this technique to measure RPM 90 883145 3 10 03 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 2G 3 01m 71 Haud MARINE PARTS AND ACCESSORIES 91 854009A 3 DMT2000A Digital Tachometer Multi Meter Kit Instructions similar for a DMT 2004 version DMT 2004 Complete Kit P N 91 892647A01 DMT 2004 similar to DMT 2000A It has a serial port for connecting meter to a CDS unit 2G 4 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 90 883145 4 0804 Meter Connections and Hook up Interface Module Battery Check IMPORTANT The internal battery for the Interface Module P N 91 854013 1 MUST BE in good working condition to obtain stable tachometer readings A low battery voltage will give erratic readings PROCEDURE 1 Plug interface module into DMT2000A meter Refer to Figure 1 1 Red lead plugs into the VQHz port and the Black lead into the COM port 2 Position rotary function selector to DC Voltage V position DMT 2004 VHz 3 Reading should be 2 8 Volts or higher 4 Replace interface module battery if reading is below 2 8 Volts Figure
172. e Aluminum Module 1 b Spark Advance Degrees Distributor Mounted Module 3 C P Engine Type Old Aluminum New Plastic Distributor Module 1 Module 2 4 ZEBA Ignition System Advance Specifications S B 91 12 y Incorrect Module 502 Magnum 5 90 16 4H V8 V6 High Speed Miss S B 89 27 Using Timing Advance Lights S B 86 4 2 1372 Amplifier Advance Curve Change 5 87 17 a Engine Type Shaft Roll Pin Hole Oversize S B 89 7 b Spark Advance Degrees c Vendor Code Plastic Module 2 90 883145 3 10 03 IGNITION SYSTEMS 2D 3 Sensor The Hall effect sensor is mounted in the distributor The Hall effect sensor or switch is thin wafer of semiconductor material which constantly has voltage applied to it A magnet is located opposite the sensor with an air gap between the sensor and the magnet The magnetic field acts on the sensor until a metal tab sensor wheel is placed between the sensor and magnet This metal tab does not touch the magnet or the sensor When contact between the magnetic field and sensor is interrupted it causes its output voltage to be reduced This signals the ignition module to turn the power transistor off which interrupts primary current to the ignition coil causing it to fire A magnetic field can act on a Hall effect sensor b When the metal tab attached to the distributor shaft rotates between the magnet and Hall effect sensor the magnetic
173. e but do not access from this screen 2 Go to page 3 Bos Page 2 Service Mode User List 1 5 X Press Enter Select 1 SET OUTPUTS 1 RPM Control 2 Fuel Pump 3 IAC Reset 080 971689 06 NOILONGOUYLNI NOILOAFNI 136014 OINOYLOA 13 Cont from page 2 DATA MONITOR SETUP User Number X Select 1 5 Record Mode Stream or Screen ZEE TRIGGER MODE Trigger None Beginning Middle or End Select B M or E Manual or Fault Adjust RPM Engine Spd RPM Desir Idle RPM ais Press MODE to Exit Select None gt DATA LIST See data list per sheet Select 4 Press 1 4 on keypad to lock choices on screen Scroll thru list on screen to make selections When item is locked in the first letter in line is underlined Press to start recording and again to stop recording Records until data buffer is full 13 30 sec Cont from page 2 SET OUTPUTS 1 RPM Control 2 Fuel Pump 3 IAC Reset Press Left or Right arrows to lower or raise RPM IAC is being manually controlled to raise or lower idle RPM Checks IAC function Other data is available but use caution as some data will be affected by being in this RPM control mode Fuel System Prime Press MODE to Exit Reset Off Engine Spd RPM
174. e factory The top line is the engine model designation It is important that Alpha are only used on Alpha models and Bravo are only used on Bravo models and Inboard ECM s are used only inboards The second line specifies the simple calibration number and version In this case it is calibration 864270 version 3 The bottom line lists the model year of the ECM in this case 2002 followed by detailed identifica tion numbers of the exact calibration When calling customer service make sure you have this information before making the call 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 35 PCM 555 Identification Typical PCM Calibration Label A PCM can be readily identified by the three wire harness connectors A B C Yaa o NS ND AR AUT Zy 7 pe 27 UX 77498 Connector b Connector Connector d PCM 555 496 MAG HO a 863619 6 b 859610 MY2002pOAACS 0091 8 1 HOSDM P AB12345678 Typical PCM Calibration Label a Engine Model b Calibration Part Number Model Year The PCM Calibration label includes the information necessary to determine which calibration an engine is equipped with from the factory The top line is the engine model designation It is important that Bravo ECM s are only used on Bravo models and Inboard are only used on inboards Inboard calibrations will contain the acronym MIE at the end of th
175. e fuel pump relay ON causing the fuel pump to start If the ECM does not receive ignition reference pulses engine cranking or running it shuts OFF the fuel pump relay causing the fuel pump to stop When the pump operates fuel is drawn from the boat s fuel tank a and through the water separating fuel filter b WATER SEPARATING FUEL FILTER B This is a spin on cartridge similar to an oil filter that traps most fuel contaminants It is easily serviced by replacing the spin on cartridge The fuel then passes to the electric fuel pump c through a fuel line from the filter ELECTRIC FUEL PUMP C The electric fuel pump is mounted parallel to and beneath the fuel cooler d This is the only fuel pump used in the Cool Fuel fuel delivery system It is used to draw fuel out of the fuel tank and also to pressurize the fuel delivered to the engine Fuel is then sent to the fuel cooler d under pressure FUEL COOLER D Engine cooling water is passed through the center of the fuel cooler The fuel flows through a separate passage that surrounds the outside of the water passage tube Fuel can exit the cooler at two locations The first is through a fuel line to the fuel rail 1 and the second is through the fuel pressure regulator e Fuel that is sent to the engine passes from the fuel cooler to the fuel rail i through a fuel line FUEL RAIL 1 The fuel rail assembly is located on top of the intake manifold Some systems
176. e gear Retighten stud Shift remote control several times and stop in reverse to recheck shift cutout switch position Roller or plunger pin must be centered LEFT HAND LH propeller rotation drive unit While turning propeller shaft clockwise move remote control shift handle into full forward position Clutch should engage before shift lever comes to a stop If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with forward gear Retighten stud Shift remote control several times and stop in forward to recheck shift cutout switch position Roller or plunger pin must be centered STERNDRIVE INSTALLATION 1C 17 50309 a Adjustable Stud b Shift Cutout Switch Roller c Shift Cutout Switch Plunger Pin 16 18 STERNDRIVE INSTALLATION 90 883145 3 10 03 Alpha Models Shift Cutout Switch Checking Cutout Switch Timing Models with Plunger Type Switch 1 While holding the retainer nuts on the back of the shift plate loosen the two phillips head screws on the shift cutout switch and slowly move the switch either forward or aft a Switch Plunger Pin b Activating Lever Assembly c 1 32 Adjustment d Two Screws 2 Adjust switch to locate plunger pin to 1 32 in between plunger pin and activating lever assembly a 1 32 in Drill Bit 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 19 3 Slowly move activating lever assembly off until cutout swit
177. e is to be attached to a regulated source of pressure of either air nitrogen or water The control mechanism of the pressure source 15 then to be set to cause the pressure in the sample measured at its top most surface to vary from 0 to 3 to 0 psig 0 to 21 to 0 kPa at a rate of not more than 15 cycles per minute 24 18 5 3 4 fuel tank shall be tested to and meet requirements of 24 18 5 1 1996 American Boat amp Yacht Council Inc 10 3A 56 FUEL DELIVERY SYSTEM AND CARBURETION 24 18 5 4 Slosh Test Representative samples of fuel tanks of 200 gallon 755 liters capacity and more shall not leak or show signs of permanent deformation or other signs of failure following 500 000 cycles of rocking motion This test shall be performed following the Pressure Impulse Test on the same fuel tank sample 24 18 5 4 1 X Slosh tests for non metallic fuel tanks shall be conducted on the fuel tank samples that have contained ASTM Reference Fuel C for 30 days at room temperature 70 F 80 F 21 1 C 26 7 C 24 18 5 4 2 fuel tank sample used for this test is to be provided with all attachments specified by the manufacturer 24 18 5 4 3 The fuel tank sample is to be centered on a rocker assembly to simulate the recommended tank installation using supports chocks or hangers either furnished with the tank or intended to be used in a boat installation 24 18 5 4 4 The fuel tank sample is to be filled with dye
178. e of each valve passes the accelerating well ports 11 one for each bore As the edge of the air valve pass the ports they are exposed to manifold vacuum and immediately feed fuel from the accelerating wells located on each side of the float bowl chamber The accelerating well is easily depleted Each accelerating well has a calibrated orifice which meters the fuel supplied to the well from the float chamber The secondary main discharge nozzles one for each bore are located just below the center of the air valves and above the secondary throttle valves The nozzles being located in a low pressure area feed fuel as follows As the secondary throttle valves are opened atmospheric pressure opens the air valves This rotates a plastic eccentric cam 8 attached to the center of the air valve shaft As the cam rotates it lifts the secondary metering rods out of the secondary orifice plates through the metering rod lever 10 which follows rotation of the cam Fuel flows from the float chamber through the secondary metering orifice plates into the secondary main wells where it is mixed with air from the secondary main well air bleed tubes 3 The air emulsified fuel mixture travels from the main wells through the secondary discharge nozzles 9 where it sprays into the secondary bores Here the fuel is mixed with air traveling through the secondary bores to supplement the air fuel mixture delivered from the primary bores and goes on into the engi
179. e power package Proper routing and installation of the hoses is required to avoid problems related to power steering system Observe the following e Hoses must be routed over top edge of transom plate e Hoses must be secured to avoid contact with moving components both power steering hose fittings to 23 lb ft 31 Nm after connecting to control valve Avoid stress on hose fittings and avoid kinks hoses Install and route power steering hoses exactly as shown in specific Installation Manual provided with power package Eu 75117 Example Of Power Steering Hose Routing and Fittings At Control Valve a Rear Fitting Pressure Hose b Front Fitting Return Hose NOTE When routing power steering hoses avoid sharp bends 90 883145 3 10 03 ENGINE INSTALLATION AND ALIGNMENT 1B 13 Exhaust Hose Routing Exhaust hose routing is dependent upon the various power package and boat designs How ever in all cases care must be exercised in the proper installation of an exhaust hose tube or hose may fail Avoid exhaust hose failure Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots that could eventually result in burned through exhaust hoses Exhaust hoses and or tubes must be correctly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow 71653 Correct Connection Incorre
180. e spark advance it must always know at what speed the engine is running The engine speed signal is accomplished by a circuit within the EST module which converts the pickup coil voltage to a square wave digital reference signal that can be used by the ECM This square wave engine speed reference signal is known as REF The ECM must also have something to compare the REF HI value against Therefore an additional line is provided between the ECM and the EST module that is known as REF LO These two lines between the ECM and the distributor provide a precise indication of engine speed The two other lines between the ECM and distributor which control the Electronic Spark Timing EST operation are known as the bypass and IC Ignition Control circuits PICK UP 55 COIL MODULE RELAY ADVANCE ited PNK i Battery Ignition Coil Trigger Signal ignition Control iC fa 20 Dist Reference HIGH cip By Pass Not Activated Dist Reference LOW 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 5 EFI Engines with Mercury Marine Thunderbolt V Distributor and MEFI 3 ECM 1999 V 6 and Small Block V 8 Engines These EFI MPI engines V 6 Small Block V 8 originally used an EST type of distributor They now use 1999 and later a Mercury Marine Thunderbolt V style distributor This unit only has an ignition
181. e top line The second line specifies the simple calibration number and version In this case it is calibration 863619 version 6 The bottom line lists the model year of the ECM in this case 2002 followed by detailed identification numbers of the exact calibration When calling cus tomer service make sure you have this information before making the call 3B 36 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 PCM 555 Engine Guardian Strategy 90 883145 4 0804 Engine Guardian is the focal point of the self diagnostic strategy of PCM 555 It helps protect the engine from possible damage that could result from several faulty conditions The system monitors the sensors incorporated on the engine and if a malfunction is discovered a fault description is stored in the PCM and available power is normally reduced By ensuring engine output is at a low enough level the engine is better protected from thermally induced failures For example if an open or short is found in an exhaust manifold sensor available power will be reduced to 90 of total the warning horn will sound 2 beeps per minute and the MercMonitor gauge SC 1000 will display a warning lamp In an exhaust manifold overheat condition the maximum rpm will vary with the temperature of the manifold and could be limited to idle in extreme cases of overheating a continuous horn will sound and the SC1000 will display a warning lamp IMPORTANT Engine Guardian cannot guarant
182. e with straps or clamps to any other cable within 5 ft 1 5 m of the shift plate 9 DO fasten the shift cable to the transom with any type of plastic clips or fasteners with in 5 ft 1 5 m of the shift plate 10 DO NOT overtighten the throttle or shift cable attaching nuts at the engine end Barrel and cable end must be free to rotate on the mounting stud NOTE Lubricate attaching points with motor oll 11 Check the intermediate shift cable routing from the transom assembly to the shift plate as fol lows a cable should come through the transom above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing b The cable should then be routed under the starboard rear engine mount and turn toward the transom c cable should then go up behind the power steering valve and loop over to the shift plate on the engine where it is connected to the anchor points on the shift plate Following this routing will prevent the engine coupler from damaging the cable NOTE A final check of the adjustments should be made with the boat in the water and engine running This should be done as part of the pre delivery inspection 16 22 STERNDRIVE INSTALLATION 90 883145 3 10 03 Shift Cable Routing ZF 74904 All V 6 and V 8 Bravo Models except 7 4L L 29 MPI 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 23 gt gt y NF
183. eality the system is simple rugged and works extremely well But the ECM cannot compensate for changes in volumetric efficiency of the engine 3B 2 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 3 10 03 How does the ECM get the Speed Density data input The engine speed sensor 15 already available to the ECM This information can come from the ignition distributor The density sensor will have to be created and added to the engine This sensor is called the Manifold Absolute Pressure Sensor or MAP sensor It can be thought of as an electric barometer A MAP sensor 15 different than a hand held vacuum gauge in that the vacuum gauge reads in inches of mercury below the current barometric pressure A MAP sensor reads in inches of mercury above absolute zero like a barometer so that it can cor rect for day to day variations of the barometric pressure An electrical signal will be sent from the MAP sensor to the ECM Near Perfect Vacuum 1 Atmosphere 414 7 psi 29 92 in Mercury 101 kPa V Vent to Atmosphere Atmosheric Pressure Flexible Diaphragm Hose Fitting Rarometer Scaled in inches of Mercury in Hg Vacuum Gauge Measures a vacuum with respect to atmpsheric pressure Measures atmospheric pressure also called gauge pressure Figure1 Manifoid Absolute Pressure Barometric Pressure Gauge Pressure 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 3
184. easure the distance between the straight edge and the outside waterline 4 The difference between these two measurements is the exhaust elbow height above the water line Refer to Measuring Procedure and compare measurement to Mercury MerCruiser s specifications 76859 72700 Straight Edge Method For Measuring Exhaust Elbow Height a Waterline Outside of Boat b Top Of Exhaust Elbow c Straight Edge d Measurement Between Straight Edge And Top Of Exhaust Elbow e Measurement Between Straight Edge And Water Line 1B 16 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 Clear Hose Method TOOLS INSTRUCTIONS 90 883145 3 10 03 Part Number 5 16 3 8 in 8 10 mm Clear Plastic Hose 15 ft 4 5 m Long Obtain Locally Metal Fitting or Weighted Object To attach to one end of plastic hose 1 2 Ensure that the boat is at rest in the water Put a metal fitting or a weight on one end of the clear plastic hose The weight helps keep that end of the hose below the water line Put the weighted end of the hose over the port or starboard side of the boat keeping it in line with the engine s exhaust elbow Route the remainder of the hose toward the engine s exhaust manifold and elbow Ensure that this open end section of the hose is as vertical as possible from the boat s bilge to the top of the exhaust elbow 9 Coil excess hose in bilge of boat keeping it below the boat s water line Lower
185. ed must be Coast Guard approved USCG 1 Diameter of fittings and lines must not be smaller than 5 16 in 8 mm ID on 262 CID 4 3L and 305 CID 5 0L and 350 CID 5 7L engines Diameter of fittings and lines must not be smaller than 3 8 in 10 mm 1 0 on 377 CID 6 2L 454 CID 7 4L and 502 CID 8 2L engines 5 Multi Engine Gasoline Installations It is best to use a fuel pickup and supply line for each engine If a single pickup and line is used line must not be smaller than 1 2 in 13mm I D 4 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Larger diameter than previously specified lines and fittings must be used on installations requiring long lines or numerous fittings Fuel line s should be installed free of stress and firmly secured to prevent vibration and or chafing Sharp bends in fuel lines should be avoided 9 A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to absorb deflection when engine is running SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS CAUTION The electric fuel pump and factory installed water separating fuel filter have been care fully designed to function properly together Do not install additional fuel filters and or water separating fuel filters between fuel tank and engine The installation of additional filters may cause Fuel Vapor Locking Difficult Warm Starting Piston Detonation Due to Lean Fuel Mixture
186. ee that engine damage will not occur when adverse operating conditions are encountered Engine Guardian is designed to warn the operator of an adverse condition and to reduce power by limiting rpm in an attempt to reduce possible engine damage The boat operator is ultimately responsible for proper engine operation ELECTRONIC FUEL INJECTION INTRODUCTION 3B 37 Typical Starting and Charging System Harness Small Block MEFI 3 A Audio Warning Components 1 Oil Pressure Switch E o gt B Instrumentation Components 1 Oil Pressure Sender 2 Trim Sender C Charging and Starting Components Alternator Ground Stud Starter Circuit Breaker Starter Slave Solenoid Jumper Wire Connection Battery GRY 2 PUR 5 TAN BLU 4 RED PUR 6 BLK 1 YEL RED 7 LIT 8LU 8 TAN 3 BRN WHT 10 a Positive Power Wire EFI System Harness b Harness Connector To EFI System Harness c Auxiliary Tachometer Lead 76061 3B 38 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 EFI System Harness 454 502 8 2L Models except 129 MEFI 3 NOTE All BLACK wires with a ground symbol are interconnected within the system harness NOTE Component position and orientation shown is arranged for visual clarity and ease of circuit identification 1 Fuel Pump 13 Fuses 15 Amp Fuel Pump 15 Amp ECM 2 Distributor DLC
187. eeds the air fuel mixture to the engine remains constant throughout part throttle range FUEL DELIVERY SYSTEM AND CARBURETION 34 15 MerCarb Power System M 4l gt DESCRIPTION The power system in the MerCarb provides extra mixture enrichment to meet power requirements under heavy load and high speed operation The richer mixtures are supplied through the main metering system The spring loaded power piston 2 located in the cavity of the air horn directly above the power valve 5 is held in the up position by engine manifold vacuum supplied directly through a connecting passage from the base of the carburetor The power system is exposed to manifold vacuum at all times During idle and cruising ranges the relatively high engine vacuum holds the power piston in the up position against tension of a calibrated spring located on the power piston stem During this period the power valve remains closed Increases in engine load lower the manifold vacuum when it has dropped sufficiently the power piston spring 4 overcomes the upward vacuum pull and the power piston moves downward opening the power valve to allow additional fuel to flow through the calibrated restrictions 6 and on into the main well area 7 The fuel flowing through the power system supplements the fuel passing through the main metering jets to give the proper mixtur
188. eft damage to the transom assembly and or Power Steering system could occur If pump lugs when performing the following checks release steering wheel immediately 10 Check for lugging condition a Turn steering wheel completely left and continue to exert pressure If pump lugs en gine RPM drops and or power steering pump tone changes proceed as follows 1 Check for an obstruction between gimbal ring and gimbal housing and between all moving steering components 2 Check that steering lever is not contacting cutout in transom If contact is being made modify cutout 3 Check fluid level b steering wheel right until it stops and continue to apply pressure If pump lugs engine rpm drops and or power steering pump tone changes check the following 1 Check same items as 1 and 2 above 2 Check steering cable end dimension with cable FULLY EXTENDED See Instal lation Requirements for proper steering cable dimensions 3 Check fluid level 1F 8 PREDELIVERY PREPARATION 90 883145 3 10 03 Boat In The Water Tests ENGINE IDLE SPEED ADJUSTMENT Avoid engine damage Ensure cooling water is supplied to the engine if it will be run with boat out of the water See instructions in the Operation and Maintenance Manual entitled Flushing Cooling System for instructions on connecting flush de vice Engine should idle at rom as specified in Operation and Maintenance Manual
189. els with the exception of early models On early models refer to Service Bulletin 94 12 If these engines are equipped with the original ECM 87 AKI fuel must be used and higher octane fuels must NOT be used Early Black Scorpions Black Scorpions with serial number 010058999 and below must use fuel with a 91 AKI minimum Black Scorpions with serial number 010059000 and above can use fuel with a 87 AKI minimum Outside USA and Canada MerCruiser engines with the exception of the early Black Scorpions specified below outside the USA and Canada will operate satisfactorily when using a major brand of unleaded gasoline having a MINIMUM research octane number RON of 90 The use of leaded gasoline is acceptable unless prohibited by government regulations Higher octane fuels can be used on all models with the exception of early models On early models refer to Service Bulletin 94 12 If these engines are equipped with the original ECM 90 RON fuel must be used and higher octane fuels must NOT be used Early Black Scorpions Black Scorpions with serial number 010058999 and below must use fuel with a 98 RON minimum Black Scorpions with serial number 0L0059000 and above can use fuel with a 90 RON minimum USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alcohol Ethanol or Ether or ETBE
190. engine 3 Ensure that lever on top of pump is flush with the handle horizontal 4 Install the air pump on the fitting in the air manifold 77638 Green Indicators 5 Pull lever on the air pump up vertical to lock pump on the fitting 6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 7 Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger This must be removed within 30 seconds to properly vent the cooling system 15 _ 2 E IX ith ji Z 77955 Closed Cooled Models Seawater Cooled Models a Blue Drain Plug Location b Blue Air Pump c Air Manifold d Green Indicators 1G 14 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 8 Verify that water is draining from each opening If not use the 3 Point Manual Drain System instructions a Port Side Drain Location b Starboard Side Drain Location 9 Allow the system to drain for a minimum of 5 minutes Add air as necessary to keep the green indicators extended 10 Crank engine over slightly with starter motor to purge any water trapped in seawater pump Do NOT allow engine to start 11 Reinstall the blue drain plug in the thermostat housing 12 Remove the air pump from the air manifold and re
191. ent 24 5 2 Fuel systems shall be liquid and vapor tight to the hull interior EXCEPTIONS 1 Permeation of hoses within the limits of SAE J1527 2 Permeation of fuel tanks within the limits of CFR 33 Subpart K CFR 183 620 a 5 i and of ABYC H 2 Ventilation of Boats Using Gasoline 24 5 3 Fuel systems shall be designed to withstand an ambient temperature range from 40 F 40 C to 176 F 80 C without failure or leakage 24 5 4 Valves or petcocks for drawing fuel from system shall not be installed See 24 9 3 24 5 5 Metallic components used in fuel system shall be corrosion resistant or finished to inhibit corrosion and shall be selected and assembled to minimize galvanic action 24 5 6 Gaskets and joint sealers shall be designed to withstand exposure to ASTM Reference Fuel C for 30 days at which time there shall be no leakage when subjected to the fuel system pressure in accordance with 24 17 4 for 24 hours 24 5 7 individual components of the fuel system as installed in a boat shall be capable of withstanding a 2 minute exposure to free burning fuel N Heptane without leakage as required by Title 33 CFR Section CFR 183 590 and as required for individual components in H 24 See APPENDIX A EXCEPTIONS 1 Portions of fuel distribution systems if a break at any point in this system will result in the discharge of no more than five ounces of fuel in 2 minutes including fuel that may drain
192. entification 91 22 Alpha One vs Alpha One Upper Drive Shaft 91 23 Use of Priority Valve Kit for Dual Power Steering on 3 0L and 3 0LX 91 24 Alpha One MC 1 1990 and Prior Lower Drive Shaft 91 25 New Oil Seal Bushing for Bell Housing 91 26 Bravo Cone Clutch 91 27 Required Water Separating Fuel Filter Replacement V8 91 28 Required Water Separating Fuel Filter Replacement V6 1992 MERCRUISER SERVICE BULLETIN INDEX 92 1 224 CID 3 7L Piston Identification Type and Clearance 92 2 Pump 110 Amp Fuse 92 3 Bravo Lower Gear Housing Pinion Nut 92 4 New Trim Cylinder Spanner Wrench Tool 91 821709 92 5 Required Warning Decal Installation 92 6 MerCarb 92 7 Seawater Fuel Pump Hose Connection 92 8 Engine RPM Hunts at Idle Speed 92 9 Engine Alignment Tool Modification 92 10 Required Distributor Cap Gasket Replacement 92 11 Testing Thunderbolt IV HEI Ignition System 92 12 New Trim Limit Switch and Trim Sender Kit 92 13 Leakage Between Exhaust Pipe and Gimbal Housing Assembly 92 14 MCM 502 Magnum MIE 8 2L Inboard GM Gen V Engine Specifications 92 15 Required Electric Fuel Pump RFI Filter Replacement 92 16 5 7L Alpha MIE 5 7L and 5 7L Comp Ski Engines Weber Carburetor opecifications 92 17 Additional Ignition System Advance Curve Specifications 92 18 Weber Carburetor Adjustable Accelerator Pump 92 19 Torsional Crankshaft Damper Bolt Torque Change 92 20 Alpha One Alpha One Gen II R MR Gear Sets 92 21 New
193. er e Fuel Line 75708 There are 2 ways of identifying each regulator by looking at them By a colored paint mark on its mounting flange and by a small ring that is on the regulator s hose fitting ALL TBI ENGINES AND SMALL BLOCK MPI ENGINES Black Scorpion with Cool Fuel module on starboard side has a 43 PSI fuel system 30 psi 207 kPa Paint Mark Pink Ring on Regulator s Hose Fitting None ALL 7 4L MPI 129 ENGINES AND ALL 454 502 MAG EFI MPI ENGINES WITH MEFI 3 ECM S AND ECM PCM 555 ENGINES 43 psi 296 kPa Paint Mark Blue Ring on Regulator s Hose Fitting Green ALL 454 502 MAG MPI ENGINES WITH MEFI 1 ECM S 36 psi 248 kPa Paint Mark Yellow and Orange Ring on Regulator s Hose Fitting Black 3B 30 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 Testing Fuel System Pressure EFI Throttle Body Injection Systems a Remove Fuel Line from Throttle Body Unit and Install Fuel Fitting Connector P N 91 806901 Connect Fuel Pressure Gauge Kit P N 91 16850 7 to test system pressure Testing Fuel System Pressure on Multi Port Injection MPI Systems Multi port MPI systems have a permanently installed fuel pressure test port The location of the test port varies on each model The fuel system drawings at the beginning of this section show the different port locations There are two different size test ports used One is a Schrader valve and the other one is a G M style valve large
194. er in Starter Motors Testing the Starter Motor with a Water or Corrosion Inspection Replacing Starter Motors Warranty 2B i STARTING SYSTEM 90 883145 3 10 03 Replacement Parts 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 mini mize risks of fire and explosion Use of replacement electrical ignition or fuel system components that do not comply with these rules and regulations could result in a fire or explosion hazard and should be avoided Maintenance Do not use jumper cables and booster battery to start engine Do not recharge weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames Batteries contain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries also produce hydrogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged sparks or flames can ignite the gas and cause an explosion that may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte Hyd
195. er the engine is cranked with the throttle handle held at the wide open throttle position a 080 In 0 2 mm Drill Rod b Choke Plate Air Horn 20 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 NOTES 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 21 Fuel Systems Carburetors Rochester Quadrajet The Quadrajet is a 4 barrel two stage carburetor of downdraft design Its simplicity in construction makes it easy to service yet its versatility and principles of operation make it adaptable from small to very large engines The Quadrajet carburetor has two stages of operation The primary fuel inlet side has small 1 3 8 bores with a triple venturi set up equipped with plain tube nozzles Operation is similar to most carburetors using the venturi principle The triple venturi stack up plus the small primary bores result in more stable and finer fuel control during idle and part throttle operation During off idle and part throttle operation fuel metering is accomplished with tapered metering rods operating in specially designed jets positioned by a manifold vacuum responsive piston An air valve is used in the secondary side for metering control and supplements the primary bores to meet air and fuel requirements of the engine The secondary air valve mechanically operates tapered metering rods which move in orifice plates thereby controlling fuel flow from the secondary nozzles in di
196. erminal replace the ignition coil as the pri mary windings have most likely melted open because of a shorted tach lead If spark is still not present remove the distributor cap and check the pickup coil for resist ance and short to grounds Resistance across the green and white leads must be 500 1500 ohms 750 850 preferred and the reading must be steady Resistance be tween the green lead and the distributor frame must be infinity and resistance between the white lead and the distributor frame must be infinity If any of these readings differ from specifications replace the pickup coil Verify that the timer core is still magnetic This is the part that rotates above the pickup coil If spark is still not present you will need to false trigger the module to determine if it is opening and closing the primary circuit Proceed as follows a If still isolated reconnect the tach lead to the ignition coil Connect a voltmeter to the gray tachometer lead bullet connector near the ignition coil Set the meter to read DC volts Connect an air gap tester from the coil s secondary terminal to ground b Remove one of the ignition module mounting screws and loosen the other Rotate the module out from the distributor frame then retighten the loose screw Connect the positive lead from a 1 5 volt AA or similar battery to the ignition module s P terminal pickup coil terminal c With the key in the ON position note the voltmeter
197. es required for power operation A hole 1 drilled from the carburetor air horn to the bore of the power piston cavity to break any vacuum that might leak around the sides of the power piston The purpose of the vacuum break hole is to prevent the transfer of vacuum from the piston to the top of the fuel in the float bowl Any vacuum acting on the fuel in the float bowl will affect carburetor calibration The power valve installed in the bottom of the float bowl consists of a plunger and a closing spring When manifold vacuum drops to a predetermined point called power cut in dependant upon engine load and throttle opening the power piston moves downward under spring tension to force the power valve plunger off its seat Then fuel flows through the valve on into separate fuel channels passing through calibrated restrictions by passing the main metering jets and then on into the main well 3A 16 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 MerCarb Pump System 3 pe D DESCRIPTION 90 883145 3 10 03 During quick acceleration when the throttle is opened rapidly the air flow and manifold vacuum change almost instantaneously while the heavier fuel tends to lag behind causing a momentary leanness The accelerator pump is used to provide the fuel necessary for smooth operation during this time Fuel for acceleration is supplied by a double spring loaded pump plunger 1 operated by a pump shaft
198. esel Cylinder Head Gaskets and Overhaul Gasket Kits 00 2 Oil Filters For D7 3L D Tronics 00 3 Mercury Diesel Engine Oil 00 4 MerCruiser Diesel Engine Harnesses Adapters 90 883145 4 0804 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 4 9 2001 MERCRUISER PARTS BULLETIN INDEX 01 1 Distribution Channel for MerCruiser Diesel Engines and Parts USA only 01 2 4 3L 5 0L and 5 7L Replacement Parts 01 3 454 502 cid Replacement Parts 01 4 Power Trim Pump Reservoir Mounting Change 01 5 Alpha Replacement Shift Cable 01 6 Improved Replacement Engine Circulating Water Pumps 01 7 Pump Installation on VM Diesel Engines 01 8 Fire Ring Exhaust Elbow Gaskets 2002 MERCRUISER PARTS BULLETIN INDEX None as of print date 4 10 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 90 883145 4 0804 90 883145 4 0804 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 4 11 WHO TO CALL LIST NOTE 800 Numbers Cannot Be Transferred to Other Departments amp Are for Dealer Use Only Dealer Sales Outboard MerCruiser Inflatable MotorGuide Phone Fax 800 962 0927 920 929 5017 Dealer Sales Parts amp Accessories Parts Assistance Fax Ordering Obsolete Parts Locator Government Sales Engine and Parts Sales Mercury Hi Performance Sales amp Marketing Sales amp Marketing Fax Dealer Technical Service Warranty Pre Authorization Technical Service QuickFax 800 487 6372 800 457 8736 800 558 6300 888
199. ether Knock Sensor Wire Ground Wire For Knock Module Knock Module Signal Wire Battery Positive Wire To Knock Module Battery Positive Wire To Ignition Module Pin C Audio Warning System Wire Pin D Shift System Interrupt Switch If Equipped Pin E NI OD AUN 2D 14 IGNITION SYSTEMS 8 Water Temperature Switch For Audio Warning Pin H 9 Distributor Wire Pin G 10 Distributor Wire Pin 1 11 Ignition Module Grd Wire Pin J 12 Ignition control trigger wire Pin L 13 Timing Lead for setting timing and other tests 90 883145 4 0804 Thunderbolt V Service Procedures Following is a list of some of the basic procedures that differ from the Thunderbolt IV system e Seiting Base Ignition Timing e Adjusting Idle Mixture e Adjusting Engine Idle Speed Setting Base Ignition Timing 1 Connect timing light to number 1 spark plug Connect timing light power supply leads if applicable to 12 volt source 2 Connect a shop tachometer to engine Using a jumper wire connect the ignition system timing lead 13 PUR WHT wire to a good engine ground This locks the ignition module into the Base Timing Mode 4 Start engine and run at normal idle speed Allow engine to reach normal operating tem perature 5 Aim timing light at timing tab located on the timing gear cover and crankshaft torsional dampener 6 Adjust timing using the conventional
200. ewdrivers must be used for removal Readily accessible Capable of being reached quickly and safely for effective use under emergency conditions without the use of tools Static floating position The attitude in which a boat floats in calm fresh water with fuel tanks filled to rated capacity but with no person or item of portable equipment aboard The boat should include all permanently installed factory supplied equipment and options such as but not limited to the engine or engines batteries seats engine oil railings fishing towers etc but not portable gear such as flags searchlights movable cushions mattresses portable fire extinguishers lines fenders chairs tables anchors chain or PFDs Other tanks such as water holding and live bait well tanks are to be empty Water separator A device to separate water from the fuel 24 5 REQUIREMENTS IN GENERAL 24 5 1 installed fuel system shall be designed so that a fuel temperature rise of 60 F 33 shall not cause liquid fuel to spill into the boat or the environment when 24 5 1 1 the fuel tank is filled to its rated capacity according to the boat manufacturers instructions and 1996 American Boat amp Yacht Council Inc 1 FUEL DELIVERY SYSTEM AND CARBURETION 47 24 12 96 Corrected 7 99 24 5 1 2 the boat is in static floating position NOTE A fuel system designed to contain 5 fuel expansion will meet this requirem
201. f contacts shown closed would ground the EST IC line signal PICK UP COIL MODULE RELAY ADVANCE B P _PN x pei 2 7 j ignition Control IC 5 BRN ep Dist Reference 25 TAN BLK By Pass BL Not Activated Dist Reference LOW Distributor Module Mode 2D 30 IGNITION SYSTEMS 90 883145 3 10 03 EST Operation Engine Running ECM Control Mode When the engine RPM reaches a predetermined value for this example 300 RPM the ECM considers the engine running and applies five volts on the bypass line to the EST module This energizes the relay and causes the points from the pickup coil as well as the grounding points for the IC Ignition Control line to open see figure ECM Control Mode This connects the IC Ignition Control line to the base of the power transistor and bypasses the ignition module timing control The EST system is now controlled by the IC Ignition Control signal from the ECM and the time at which the spark occurs can be determined by a variable time circuit in the ECM This is called the ECM Control mode PICK UP 55 COIL MODULE aA m om a E cn bik PNK can Sena Ignition Control IC i Battery lgnition Coil Trigger Signal BRN PUR AWHT Dist Reference m TAI N L K ap By F
202. f the 12 volt power source is not present the Knock module cannot send an 8 10 volt signal to the Ignition Control Module and a false constant spark retard will result B 12VOLTS 8 10 VOLTS KNOCK SENSOR Knock Sensor System Terminal of the Knock module is the signal line from the knock sensor If this circuit opens or shorts to ground the Knock module will never remove the 8 10 volt signal from terminal to and no spark retard will occur The ground circuit for the Knock module is connected to terminal D If the ground circuit opens the Knock module will not be able to remove the 8 10 volt signal and spark knock cannot be controlled IMPORTANT If knock sensor wire is routed too close to secondary ignition wires the Knock module may see the interference as a knock signal resulting in false timing re tard IMPORTANT If there is abnormal mechanical engine noise rattles or knocks they may give a false knock retard signal If fuel octane is too high or too low a false signal can also be sent 2D 18 IGNITION SYSTEMS 90 883145 3 10 03 Testing Knock Module and Sensor 90 883145 3 10 03 NOTE A digital volt ohmmeter DVOM and an unpowered test light low power test light 300mA or less are needed to conduct the following test Avoid fire or explosion Ensure that engine compartment is well ventilated and gaso line vapors are not present when performing electrical tests inside the engine compa
203. fications 93 26 Required EFI VST Fuel Filter Replacement 93 27 Engine Control Module ECM Recall 93 28 DHB Power Steering Valve 806034A1 93 29 MIE 350 EFI Magnum Tournament Ski Inboard Specifications 93 30 Incorrect Aneroid Adjustments 1994 MERCRUISER SERVICE BULLETIN INDEX 94 1 Bravo Trim In Limit Spacer Kit See SB 98 16 94 2 Thunderbolt V Ignition System 94 3 A Cylinder Head Bolt Change B Cylinder Head Torque Sequence Change C Thru Hull Water Pickup Eliminated On MCM D4 2L 94 4 Gasoline Recommendation For All MerCruiser Models 94 5 Drive Unit Trim Tab New Anodic Plate 94 6 DHB Power Steering Control Valve 94 7 Sterndrive Rear Engine Mount Bolt Torque 94 8 Required Fuel Injector Pod And ECM Replacement 94 9 Battery Requirements For MerCruiser Products 94 10 Required Engine Grounding Stud Replacement 94 11 Seawater Hose Power Steering Line Interference 94 12 Gasoline Recommendation Changes Number 1 And 2 94 13 Universal Joint amp Gimbal Bearing Grease 94 14 Wiring Modification 94 15 Required Engine Fuel Filter Replacement 94 16 Bravo Three Trim In Limit Blocks See SB 98 16 94 17 Bodensee Owners Manuals Ordering 1995 MERCRUISER SERVICE BULLETIN INDEX 95 1 Alpha One Generation Upper Gears 95 2 Trim Pump Adaptor Connectors 95 3 MCM 3 0L LX Starter Motor Bolt Breakage 95 4 Hino Diesel Excessive Black Smoke Emission 95 5 MerCruiser GM Engine Identification See SB 2002
204. field is interrupted The ignition coil sends high voltage to the distributor any time the magnetic field is interrupted Robert Bosch 2D 4 IGNITION SYSTEMS 90 883145 3 10 03 Testing Thunderbolt IV HEI System TROUBLESHOOTING THUNDERBOLT IV IGNITION SYSTEM The ignition system consists of four components and a 12 volt source to operate it The four components are ignition coil ignition module ignition sensor and sensor wheel To troubleshoot the ignition system all that is needed is a voltmeter and Spark Gap Tester 91 63998 1 Before testing ignition system operate bilge blower for at least 5 minutes to remove any explosive fumes from engine compartment If boat is not equipped with a bilge blower open engine hatch Check to ensure that tachometer GRY lead is not shorted to ground at the tachometer or within the harness No Spark Isolate shift cut out switch on Alpha models Check all Terminal Connections at Distributor Ignition Module and Ignition Coil Battery OK Distributor Clamping Screw Tight No Spark Check Engine and With Key in RUN Position Check for i he Less than Instrument Wiring Battery Volts at Positive Terminal battery volts Harness Battery on Ignition Coil Cables Key Switch Unplug WHT RED bullet connector from Voltage drop of Distributor 2 or more Check voltage on lead volts below bat coming from module tery voltage Typically 1 2 volts less than ba
205. from the engine 2 Self draining fill and vent pipes located in a separate compartment from the engine compartment 3 Fill and vent external fittings 4 Clips and straps not essential for anti siphon protection required by this standard 24 6 FLEXIBLE FUEL HOSE 24 6 1 Hose shall comply with the requirements of the UL 1114 or with the requirements of SAE J1527 1996 American Boat amp Yacht Council Inc 2 3A 48 FUEL DELIVERY SYSTEM AND CARBURETION 24 6 2 Hose shall be marked the outermost cover with the manufacturer s name or trademark year of manufacture the applicable hose marking in TABLE I and UL 1114 or SAE J1527 24 6 3 required marking shall be legible and permanent on the hose itself at least every 12 inches 305mm in block capitals and numerals at least 1 8 inch 3 16mm high NOTE Hoses less than 12 inches 305mm in length may be tagged with the required marking 24 7 FUEL LINE SUPPORTS 24 7 1 Clips straps or other means used for securing fuel lines shall be of corrosion resistant material and of a design to eliminate cutting or abrading action where in contact with the fuel line 24 7 2 Clips and straps used to hold fuel lines in position to maintain anti siphon protection shall be capable of withstanding a 2 minute fire test 24 8 VALVES 24 8 1 Valves shall pass 2 minute fire test as specified in Title 33 CFR Section CFR 183 590 and 24 5 7 24 8 1 1 Electricall
206. g Fuel Pump Check Valves S B 98 4 Gasoline Additive Problems S B 98 5 1 Key Switch L 1 Ground Shift Cut Out J CIRCUIT CA BREAKER 2 4 lt e KORTI 2 FE i 0654 GROUND MRN 4 TUD 9c 50 17 OIL PRESSURE M BLK Black ELECTRIC CHOKE 2 BARREL ONLY ORN PUR RED YEL Orange Purple Red Yellow SWITCH AS NY S FUEL PUMP _ ee ee e _ _ ee ee ee UAR 90 883145 4 0804 BATTERIES WIRING 2 13 Shift Switch Operation PUR 3 0 Litre with EST Run Position Normally Open No Continuity Thunderbolt IV Run Position Normally Open No Continuity 2A 14 BATTERIES WIRING Thunderbolt V Run Position Normally Open No Continuity Alpha EFI Models MEFI 1 Shown Run Position Normally Closed Continuity MEFI 1 Switch is in EST circuit MEFI 2 3 Switch wired directly to the ECM 90 883145 4 0804 ECM 555 Gear Indicator Shift Interrupt a Gear Indicator b Gear Indicator Switch Closed in Neutral Open in Gear Normally Closed Switch c Shift Interrupt Switch 90 883145 4 0804 H o x e a d Shift Interrupt Switch Alpha Models A to C Normally Closed Ato C Open When Activated A to B 10K Rekeased AtoB
207. ge pump is operating before beginning procedure Excess water in bilge can damage engine or cause boat to sink Do not operate engine with drain system open Excess water in bilge can damage en gine or cause boat to sink IMPORTANT Boat must be as level as possible to ensure complete draining of cooling system Your power package 15 equipped with one of three drain systems Refer to Identification on the following page to determine which instructions apply to your power package The power package should be drained before flushing or prior to extended or cold weather storage IMPORTANT The boat must not be operating at any point during this procedure 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 11 Identification MANUAL SINGLE POINT DRAIN SYSTEM a Blue Handle b Blue Drain Plug Location AIR ACTUATED SINGLE POINT DRAIN SYSTEM CRM T F a il L7 CU 7 S 77955 Closed Cooled Models a Blue Drain Plug Location b Blue Air Pump c Air Manifold d Green Indicators 3 POINT MANUAL DRAIN SYSTEM SZ PL y MIT Ep AL sA wa 77917 Blue Drain Plug 1G 12 WINTERIZATION AND RECOMMISSIONING Seawater Cooled odels 90 883145 3 10 03 Boat In The Water MANUAL SINGLE POINT DRAIN SYSTEM 1 2 4 Close the seacock Rotate the blue handle COUN
208. gine intake manifold air velocity increases in the carburetor venturi Since the low pressure vacuum is now in the smallest boost venturi 5 fuel flows from the main discharge nozzle 4 as follows Fuel from the float bowl flows through the main metering jets into the main fuel wells 9 It passes upward in the main well and is bled with air by an air bleed 3 located at the top of the well The fuel is further bled air through calibrated air bleeds located near the top of the well in the carburetor bores The fuel mixture then passes from the main well through the main discharge nozzles 4 into the boost venturi At the boost venturi the fuel mixture then combines with the air entering the engine through the carburetor bores It then passes as a combustible mixture through the intake manifold and on into the engine cylinders The main metering system is calibrated by tapered and stepped metering rods 2 operating in the main metering jet and also through the main well air bleeds FUEL DELIVERY SYSTEM AND CARBURETION 3A 27 Rochester Quadrajet Power System The power system in the Quadrajet carburetor provides extra mixture enrichment to meet power requirements under heavy engine loads and high speed operation The richer mixtures are supplied through the main metering systems in the primary and secondary sides of the carburetor The fuel mixture is enrichened in the two primary bores through the power system This consists of a v
209. gs and fuel fill openings shall be at least 15 inches 381mm 24 12 2 Deck plates shall carry a permanent fuel type identification e g GAS GASOLINE or the ISO symbol 24 12 3 The minimum inside diameter of the fill system shall be 1 1 4 inch 31 75mm NOTE To maintain the minimum diameter using standard fittings the minimum hose ID will be 1 14 inch _ 38 1 24 12 4 Fuel fill lines shall be hose or metal pipe 24 12 4 1 Flexibie fuel fill hose installed in engine compartments shall be USCG Type 1 or A2 See Table I 24 12 4 2 Fill hose installed outside of engine compartments shall be any of the hose types specified in 24 6 24 12 5 Fuel fill lines shall be self draining and run as directly as practicable from the deck plate to the fuel tank connection 24 12 6 All components of the fuel fill system shall be accessible 24 13 TANK VENT SYSTEMS 24 13 1 The fuel vent system shall be designed to prevent spilling liquid fuel into the boat or the environment while fueling the boat in accordance with the boat manufacturer s instructions NOTE There may be EPA or state regulations that limit the discharge of hydrocarbon emissions into the atmosphere from gasoline fuel systems The latest versions of these regulations should be consulted 24 13 2 Minimum inside diameter of vent line shall be 7 16 inch 11 11mm NOTE To maintain the minimum diameter using standard fittings the minimum hose ID will be
210. he intake manifold as a combustible mixture The idle mixture screw controls the amount of fuel mixture which enters each carburetor bore If the idle mixture screw or needle is backed out more mixture is admitted to the intake manifold and the engine runs rich If the screw is turned in the engine runs lean In this manner the idle mixture is varied for best idle NOTE Engines built after Jan 1 2003 have sealed idle mixture screws OFF IDLE OPERATION As the throttle valves are opened and more air is entering the engine to increase engine speed additional fuel is needed to combine with the extra air This is accomplished by the off idle discharge slots As the throttle valves move past the off idle slots they become progressively exposed to high vacuum below the throttle valves and the extra fuel needed is supplied by these holes The idle holes and off idle slots supply sufficient fuel for engine requirements until air velocity is high enough in the venturi area to obtain fuel flow from the main metering system 3A 14 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 MerCarb Main Metering System DESCRIPTION 90 883145 3 10 03 The main metering system supplies fuel to the engine from off idle to wide open throttle The main metering system provides efficient fuel metering during the cruising range Its operation is dependant upon air flow through the carburetor venturi 8 which in turn creates a low press
211. hould be stored in full down position Universal Joint bellows may develop a set If unit is stored in raised position and may fail when unit Is returned to service 90 883145 3 10 03 PREDELIVERY PREPARATION 1F 9 Predelivery Inspection Not Check Applicable Adjust CHECK BEFORE RUNNING Drain plug in and petcocks closed Seawater inlet valve open Engine mounts tight Engine alignment Drive unit fasteners torqued Power trim cylinders fasteners tight Battery fully charged and secured All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct rotation propeller installed and torqued Throttle shift and steering system fasteners tightened properly Throttle plates open and close completely Crankcase oil level Power trim oil level Sterndrive unit oil level Power steering fluid level Closed cooling level Transmission fluid level Alternator belt tension Seawater pickup pump belt tension Power steering pump belt tension Audio warning system operation 2 If registered to a CA resident Not Applicable Check N THE WATER TEST Engine alignment Inboards only Starter neutral safety switch operation Water pump operation Instruments s operation Fuel leaks Oil leaks Water leaks
212. how full DOWN IN position on dashboard instrument as shown 71671 a Trim Gauge Needle 1F 2 PREDELIVERY PREPARATION 90 883145 3 10 03 5 Tighten retaining screws and turn ignition key to the OFF position 71220 a Retaining Screws b Trim Position Sender Small Block and V6 Transom with ECM 555 equipped engines Connect trim position sender wires from transom assembly to engine harness One lead will go to wire marked ground The other will connect to the orange gray wire for analog gauges or the orange white wire for digital gauges Connect the trim limit switch wires to power trim harness at the pump Trim lead with blue sleeve connects to blue white wire in harness Trim lead with purple sleeve connects to purple white wire in harness 496 Mechanical with Smart transom Connect the three wire sensor from transom assembly to the plug on the aft port side of the engine Connect the trim sender wires from transom assembly to the individual wires on aft starboard side of engine Power Steering IMPORTANT Use only Quicksilver Power Trim and Steering Fluid or Dexron lll auto matic transmission fluid ATF in power steering system NOT RUN POWER STEERING DRY pump will damaged 1 Position drive unit so that it is straight back 2 Remove fill cap from power steering pump reservoir and check fluid level 3 Add fluid as required 90 883145 3 10 03 PREDELIVERY PREPARATION
213. igher speed more air and fuel are needed to meet engine demands The secondary side of the carburetor is used to provide extra air and fuel through the secondary throttle bores The secondary section of the Quadrajet has a separate and independent metering system consists of two large throttle valves 17 connected by a shaft and linkage to the primary throttle shaft Fuel metering is controlled by spring loaded air valves 5 metering orifice plates 13 secondary metering rods 14 main fuel wells with bleed tubes fuel discharge nozzles 9 accelerating wells and tubes The secondary metering system supplements fuel flow from the primary side and operates as follows When the engine reaches a point where the primary bores cannot meet the engine air and fuel demands a lever on the primary throttle shaft through a connecting link to the secondary throttle shaft begins to open the secondary throttle valves As the secondary throttle valves are opened engine manifold vacuum low pressure is applied directly beneath the air valves Atmospheric pressure on top of the air valves forces the air valves open against spring tension and allows metered air to pass through the secondary bores of the carburetor In most models accelerating wells are used to supply fuel immediately to the secondary bores This prevents a momentary leanness until fuel begins to feed from the secondary discharge nozzles When the air valves begin to open the upper edg
214. ightly pull on remote control shift cable end guide to remove slack from remote control and cable and adjust brass barrel as necessary to align attaching points with shift lever clevis pin hole and stud Be sure to maintain light pressure on drive unit shift cable 2 as E 4 Ws CRY 50309 a End Guide b Brass Barrel c Shift Lever Clevis Pin Hole d Stud 16 12 STERNDRIVE INSTALLATION 90 883145 3 10 03 6 If the shift plate is equipped with Shift Assist Assembly then skip this step and go to step 7 If the shift plate does not have a Shift Assist Assembly then follow these isntructions NOTE Two different size threaded ends have been used on the remote control shift cable After cable has been aligned turn brass barrel 2 turns away from cable end guide on 1 4 28 threaded ends and 4 turns away from cable end guide on 1 4 40 threaded ends AN om 50308 a End Guide b Brass Barrel 7 Temporarily install remote control shift cable on stud and install clevis pin dn 50308 Remote Control Shift Cable b Clevis Pin 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 13 8 Shift remote control as stated in or b following a Right Hand RH Rotation Drive Unit reverse gear past detent into wide open throttle position b Left Hand LH Rotation Drive Unit forward gear past detent into wide open throttle position
215. ill give about 1 0 cc less fuel 73131 a Full Accelerator Pump Stroke b 0 5 cc Less Fuel per Stroke c 1 0 cc Less Fuel per Stroke The technician should be able to correct most bogging problems with this 3 holed lever providing the bogging is caused by the carburetor When installing the 3 holed lever remove any metal ball that someone may have put in the accelerator pump well to limit pump travel Also make sure that the duration spring on the accelerator pump is stock and hasn t had several coils cut off Make sure the venturi cluster is the correct one as outlined in the correct Service Manual 3A 18 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 MerCarb Choke System DESCRIPTION 90 883145 3 10 03 The choke system consists of a thermostatic coil assembly electric heater coil offset choke valve and linkage Its operation is controlled by a combination of intake manifold vacuum the off set choke valve and temperature When the engine is cold the thermostatic coil is calibrated to hold the choke valve closed As the engine is started air velocity against the offset choke valve causes it to open slightly against the torque of the thermostatic coil The choke valve assumes a position where the torque of the thermostatic coil is balanced against the air velocity past the offset choke valve The vacuum break position is when the choke valve is in this position and results in a regulated air fl
216. ime since considerable heat accumulates and can cause serious damage For this reason the cranking motor must never be used for more than 30 seconds at any one time Cranking should not be repeated without a pause of at least 2 minutes to permit the heat to escape 90 883145 3 10 03 STARTING SYSTEM 2B 7 Identification 74041 Delco PG260 Starter Motor 75820 Delco PG260F1 Starter Motor Replacement Parts 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 2B 8 STARTING SYSTEM 90 883145 3 10 03 NOTES 90 883145 3 10 03 STARTING SYSTEM 2B 9 Testing Starter Motors NOTE See Information from Service Bulletin 2001 11 or appropriate service manual No Trouble Found or Water in Starter Motors Starter motors are returned for warranty that function properly when tested The first test that should be done on an engine with a starter motor problem is to check the condition of the engine s cranking battery If the fault is not with the battery test the starter motor voltage as outlined in this bulletin There has also been either water or corrosion found inside starter motors
217. ine operation STARTING MODE With the ignition switch in the start position the ECM will turn on the fuel pump relay The elec tric fuel pump runs and pressurizes the fuel in the fuel rail The ECM then checks the Engine Coolant Temperature Sensor ECT and Throttle Position Sensor TP to determine the prop er air fuel ratio for starting The ECM controls the fuel delivered to the engine by changing the pulse width of the injectors RUNNING MODE When the engine is running the ECM checks the inputs from the following sensors to calculate the required air fuel ratio 1 Distributor Reference Signal for engine RPM 2 Manifold Absolute Pressure Sensor MAP 3 Intake Air Temperature Sensor IAT 4 Engine Coolant Temperature Sensor ECT Higher RPM or higher Manifold Absolute Pressure equals lower vacuum in the manifold or Lower Intake Air Temperature or Lower Engine Coolant Temperature signals the ECM to pro vide a richer fuel air ratio for the engine Lower RPM or lower Manifold Absolute Pressure equals higher vacuum in the manifold or higher Intake Air Temperature or higher Engine Coolant Temperature signals from these sen sors would cause the ECM to provide a leaner fuel air ratio to the engine ACCELERATION MODE Rapid changes in Throttle Position Sensor TP and Manifold Absolute Pressure Sensor MAP signals to the ECM will cause the ECM to provide extra fuel to the engine The ECM achieves this by holding the fuel inject
218. ing signal for ignition timing and pulsing the fuel injectors as well as the RPM counter for the ECM ENGINE COOLANT TEMPERATURE SENSOR ECT 10 The Engine Coolant Temperature Sensor ECT is located on the port side of the thermostat housing It sends a signal to the ECM letting it know if the engine is warm or cold THROTTLE POSITION SENSOR TP 9 The Throttle Position Sensor TP is mounted on the underside of the throttle body assembly As the throttle is opened the TP sends out a changing voltage signal to the ECM so that it can adjust the fuel delivery The TP also signals the ECM when the throttle is opened rapidly so it can add extra fuel for acceleration MANIFOLD INTAKE AIR TEMPERATURE SENSOR MAT or IAT 19 The Intake Air Temperature Sensor IAT is a two wire sensor mounted on the under side of the intake air plenum It measures the temperature of the incoming air 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 21 IDLE AIR CONTROL VALVE IAC 8 The Idle Air Control Valve is mounted into the side of the throttle body assembly and controlled by the ECM This valve controls engine idle speed by controlling the amount of air that bypasses the throttle valves through the idle air passage in the throttle body It also prevents stalls due to a change in engine RPM The valve moves in and out of the idle air passage to decrease or increase air flow as required KNOCK SENSOR 7 The Knoc
219. inkage assembly in the stern drive 10 Place Remote Control in neutral position 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 27 NOTE As Bell Housing shift cable enters the shift linkage assembly it pushes the assembly back into the stern drive housing and the Jaw closes securing the cable as shown in Steps 27 77 27 72467 IMPORTANT If Bell Housing Shift Cable b does not line up to properly enter Jaws of shift linkage assembly a cable will have to be aligned manually AV 21 V es 72457 11 Place drive shaft housing in position bell housing and install drive unit as follows a Position trim cylinders so they point straight backwards b Position drive unit so that universal joint shaft aligns with bell housing bore c Guide U joint shaft thru bearing in gimbal housing and into engine coupler Make sure that shift linkage Jaws engage the bell housing shift cable assembly d If necessary rotate propeller shaft counterclockwise slightly using a propeller to align U joint shaft splines with splines in engine coupling then slide drive unit ail the way into bell housing 16 28 STERNDRIVE INSTALLATION 90 883145 3 10 03 12 5 drive unit to bell housing with 5 washers and 6 locknuts Torque to 50 Ib ft 68 N m 22031 a Continuity Washer Do Not Install Flat Washer Here b Elastic Stop Nuts 6 and Flat Washers 5
220. ion sealant to help retard corrosion Power Trim Pump Check oil level with sterndrive unit in the full down position e Use only Quicksilver Power Trim and Steering Fluid SAE 10W 30 or 10W 40 engine oil in power trim system IMPORTANT Older style reservoirs which may not have the vented cap may have a vent hole in the upper side of the reservoir filler neck Never install an un vented cap onto an un vented reservoir or damage to the pump could occur 1 Unscrew fill cap a and remove Caplug c from fill neck then replace fill cap Fill cap is vented and should periodically be checked to ensure vents are clear N 50630 a Fill Cap b Vent Slots c Cap plug Remove and Discard Before Operating Pump d Fill Neck 2 Raise and lower drive unit to the full up position 6 to 10 times to purge air from system Check oil level visually with drive unit in the full down position Oil level should be main tained at bottom lip of fill neck 90 883145 3 10 03 PREDELIVERY PREPARATION 1F 1 Trim Position Sender Adjustment if applicable 1 Loosen both trim position sender retaining screws 71220 Retaining Screws b Trim Position Sender DO NOT start engine in the following step or damage to drive unit and engine could result from lack of cooling water 2 Turn ignition key to the RUN position 3 Trim drive unit to the full DOWN IN position 4 Rotate trim position sender as required to s
221. ithin the 2 minute test 24 18 4 7 3 At the end of the 2 minute test period any continued burning is to be extinguished 24 18 4 7 4 Following the test the fuel tank sample shall be examined for leakage and then drained and pressure checked with 1 4 psi 1 75 of aerostatic pressure This pressure shall be applied gradually by means of a suitable regulator so as not to strain the tank due to pressure surge The tank fails the test if leakage is detected in the tank shell using a means other than the pressure drop method 24 18 5 Tank Mechanical Strength Tests 24 18 5 1 Static Pressure Test Representative samples of the fuel tanks shall be tested by the tank manufacturer at 1 times the maximum test pressure indicated on the tank label with gauge or sending unit installed See 24 18 3 The fuel tank shall not exhibit any leakage using a leak detection method other than the pressure drop method 24 18 5 2 Shock Test Representative samples for fuel tanks of less than 25 gallons 95 liters capacity shail not leak or show signs of permanent deformation or other signs of failure following 1000 cycles of vertical shocks with an acceleration of 25g with a duration measured at the base of the shock envelope of 6 14 milliseconds 1996 American Boat amp Yacht Council Inc 9 FUEL DELIVERY SYSTEM AND CARBURETION 3A 55 24 12 96 Corrected 7 98 24 18 5 2 1 Shock tests for non metallic fuel tanks shall be conducte
222. k Sensor is mounted in the lower side of the engine block When abnormal engine vibrations occur because of spark knock the sensor produces a signal that is sent to the ECM DISCRETE SWITCH INPUTS 4 17 Two discrete switch inputs are used to identify abnormal conditions that may effect engine operation a low oil pressure switch and low drive unit fluid level switch are wired to the ECM They signal the module of low oil pressure or low drive unit fluid Both discrete switches are in a normal open mode when the engine is running The warning horn will sound if there is a problem Inboard models use a transmission temperature switch instead of the low drive unit fluid level switch If the transmission temperature gets too high the switch will signal the ECM of this condition The following are additional sensors used on the PCM 555 EFI System EXHAUST MANIFOLD COOLANT TEMPERATURE SENSORS EMCT There are two Exhaust Manifold Coolant Temperature Sensors EMCT one in each exhaust manifold port and starboard They are located at the mounting flange between each manifold and its elbow Both EMCT sensors are two wire sensors and their primary purpose is to tell the Guardian program the temperature of the coolant in each exhaust manifold Both EMCT sensors are thermistors and operate in the same manner as the ECT sensor A failure in either EMCT will set a specific fault for that sensor CRANKSHAFT POSITION SENSOR CPS The Crankshaft
223. k is full If thermostat housing was removed reinstall and tighten cover bolts securely Store boat with drive unit in full DOWN IN position 16 20 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 Recommissioning NOTICE Refer to Cold Weather or Extended Storage Precautions in this section BEFORE proceeding To prevent possible injury or damage to equipment not install battery until all maintenance has been performed on engine 1 2 Check that all cooling system hoses are connected properly and hose clamps are tight Check that all drain plugs are installed and tightened securely Inspect drive belts When installing battery be sure to connect NEGATIVE battery cable to NEGATIVE battery terminal and POSITIVE battery cable to POSITIVE battery terminal If battery cables are reversed electrical system damage will result Install fully charged battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting p Refer to FLUSHING COOLING SYSTEM before starting engine ro 8 9 Coat terminal connections with a battery terminal anti corrosion agent Perform all maintenance tasks listed in the MAINTENANCE SCHEDULES except those performed during the power package lay up procedure Perform all checks in the BEFORE STARTING column of the Operation and Maintenance Manual OPERATION
224. l PSI F Sea Pump PSI TPS 1 Volts TPS MAT F FPC Total oz PCM only Serial Number Test RPM conditions Prop type and pitch Calibration Sea Lake River Temperature Current Reading Comments 3B 60 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 PFERCURY MerCruiser service bulletin No 2001 1 WARRANTY INFORMATION v SERVICE INFORMATION This bulletin replaces bulletins 96 9 and 93 23 Destroy these older bulletins MerCruiser Rinda Scan Tool Models MCM MIE EFI TBI and MPI Gasoline Models All MCM MIE 496 8 1L PCM 555 MPI Gasoline Models All 1997 and Newer MCM MIE Carburetor Models with Thunderbolt V Ignition System All MCM MIE D Tronic Diesel Models 2001 Scan Tool Version 4 0 This hand held Scan Tool has been updated for 2001 It can be used on all gasoline MCM MIE engines equipped with either the Delco MEFI ECM or the new Mercury PCM 555 The tool will also monitor the MCM MIE D Tronic system used on diesel models On carburetor en gines with Thunderbolt V Ignition 1997 and newer this Scan Tool can read rpm history stored in the ignition module The tool is not able to troubleshoot the Thunderbolt V ignition system Dealers that already own an earlier version of this scan tool can purchase the 2001 4 0 ver sion update kit Technicians will also need a special 4 pin PCM 555 Adapter to connect the tool to the engine harness This Adapter c
225. lastic on its outer case If the case is melted the tachometer lead gray or white is shorted to ground somewhere Isolate and repair before replacing the ignition coil 2 Make sure that battery voltage is present at the purple power lead carbureted or red power lead at the ignition coil If not isolate and repair the problem in the engine or boat harness 3 Isolate the gray carbureted or white EFI tach lead at the negative side of the ignition coil as described in the previous section step 4 If spark is now present the tach lead is shorted to ground in the engine harness boat harness or in the tach itself 4 Disconnect the 4 pin connector from the ignition module Carbureted models if spark is now present the shift cut out switch is stuck on or shorted closed Replace the switch and retest EFI models if spark is now present the ECM is sending bypass voltage to pin B of the igni tion module and it is not supposed to The EFI system will have to be diagnosed at this time as there is not a problem with the EST system 2D 26 IGNITION SYSTEMS 90 883145 3 10 03 90 883145 3 10 03 Disconnect the 2 pin connector from the ignition module With the Key ON check for bat tery voltage at both the pink and brown terminals of the harness a If there is not battery voltage at the pink terminal replace the 2 wire harness as the filter is most likely blown open b there is not battery voltage at the brown t
226. le Power Sensor Power VDC Battery Volts Port Exhst Temp F otbd Exhst Temp F Sea Pump Pres psi Spark Advance deg Oil Pressure psi IAC Duty Cycle TPS 1 Position TPS 1 Volts Manifold Air Temp F Barometric Pressure psi Manifold Pressure psi Coolant Temp F Not used on ECM555 models a default value will be displayed 3B 68 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 PFERCURY O rvice Bulletin Warranty Information Service Information Bulletin No 2004 04 Parts Information OEM No 2004 02 Circulate to Sales Manager Accounting V service Manager Technician Vf Parts Manager Computer Diagnostic System Models Affected MerCruiser Models Covered Serial Number Or Year MCM MIE MEFI EFI TBI and MPI Gasoline Models All Models MCM MIE PCM ECM 555 or PCM 03 Gasoline Models All Models Mercury Mariner Outboards Models Covered Serial Number Or Year 200 DFI All Models 240 EFI with PCM 555 All Models Mercury Racing Jet Drives Future software releases will include other models with digital processors 2004 04R MAY 2004 2004 Mercury Marine 1 4 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 69 Computer Diagnostic System Situation Mercury Marine has partnered with SPX Corporation to develop a PC based system designed to aid the dealership technician by reducing the diag
227. le will be programmed with the correct fuel injector information for every rpm and density reading The programming engineer has to come up with these figures because the ECM is not actually calculating the Mass Air Flow The speed density system depends on the engine being unmodified from its original production state If we change the volumetric efficiency of the engine in any manner the amount of air flow for a given rpm and air density will change causing the ECM to deliver the incorrect amount of fuel Any modification to the following components will influence the air flow through the engine throwing the speed density system out of calibration 1 Pistons and combustion chambers anything that changes the compression ratio Camshaft changes effecting the valve timing lift and duration Changes to intake and exhaust valve size as well as porting and polishing Installing different intake and or exhaust manifolds gov Installing a different size throttle body and or flame arrestor ELECTRONIC FUEL INJECTION INTRODUCTION 3B 1 Speed Density Operation The engine s RPM is easily determined from the REF HIGH signal on systems with EST ignition or the timing signal from the Thunderbolt Distributor s hall effect sensor small block MEFI 3 models To determine the density of the air in the intake manifold we need to know the intake manifold vacuum which we measure with the MAP Manifold Absolute Pressure sensor It i
228. lead to the battery cable itself that is inside the crimped bat tery cable ring terminal d Test each battery cable connection in this manner all the way back to the battery post If a battery switch is used check between the battery cable ring terminal and the switch s terminal STARTING SYSTEM 2B 11 9 Check for voltage drop on battery negative cable Connect voltmeter lead directly to the battery post not the battery cable ring terminal Connect voltmeter lead to an unpainted surface of the starter housing NOTE Remove one voltmeter lead before starter motor is turned off or voltmeter damage may occur The starter may produce a voltage spike that can damage a voltmeter a Crank engine over while looking at the voltmeter The maximum allowed drop is 0 25v b To find the point where the resistance is highest leave voltmeter lead on battery post and move voltmeter lead to the ground stud where the battery cable is connected c Then move the voltmeter lead to the battery cable ring terminal that is on the ground stud d Next move voltmeter lead to the battery cable itself that is inside the crimped bat tery cable ring terminal e Test each battery cable connection in this manner all the way back to the battery post Testing for Voltage Drop 10 After testing to ensure that the starter motor is getting at least 9 5v test the star
229. limit by stopping the spark This feature has an RPM range that varies from model to model The over speed limit for a particular engine is set slightly higher than the top end of the RPM range for that model For example if the recommended range is 4600 5000 RPM the over speed limit would be set 5100RPM When RPM reaches this limit spark is turned off until engine RPM drops down to a Reset RPM which would be approximately 4750 RPM for this example At this point spark comes back on Knock Retard Spark Control The knock control feature helps provide protection from harmful detonation Knock control is handled by the Knock Control Module This module receives a signal from a sensor that is mounted on the engine block The knock control module works in conjunction with the igni tion module to retard the timing if spark knock is present 90 883145 3 10 03 IGNITION SYSTEMS 2D 9 Thunderbolt Spark Control Graph IMPORTANT The graph below shows the typical advance envelopes for a Thunderbolt V ignition control module The numbers plotted on the graph are not representative of any particular model It is only presented to provide an understanding of how the sys tem functions S 49 4 2 95 22 WSN WV TOTAL SPARK ADVANCE MINUS INITIAL TIMING 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 ENGINE R P M Base Timing Advance Curve Idle Speed Advance Envelope Knock Retard Envelope If knock mod
230. ll move in direction A when shift handle is placed in the forward position LEFT HAND ROTATION Install the control cable in remote control so that cable end will move in direction when shift handle is placed in the forward position A f B 23242 IMPORTANT Drive unit must be installed IMPORTANT DO NOT run engine NOTE The illustrations on the following pages show models that have a shift plate that is mounted on the exhaust elbow The shift mechanism components on the 3 0L model are lo cated on the top of the valve cover as shown in the following illustration The procedure for making the adjustments is exactly the same HN See gt A OCT A 5 5 ER 50626 3 0L Model With Components Mounted On Valve Cover a Shift Assist Assembly b Remote Control Shift Cable 1C 8 STERNDRIVE INSTALLATION 90 883145 3 10 03 1 Remove remote control shift cable and shift assist assembly if installed With Shift Assist Assembly a Shift Assist Assembly b Remote Control Shift Cable 90310 Without Shift Assist Assembly a Remote Control Shift Cable 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 9 IMPORTANT If boat is being equipped with REMOTE CONTROL THAT HAS SEP ARATE SHIFT AND THROTTLE LEVERS the shift assist assembly that is shipped with the engine should NOT be used The use of the shift assist assembly with this type of remote contr
231. long term recording there 15 still a battery draw on the system and it will go dead This is a normal condition and must be turned off manually each time Q What sizes are the fuses and what are the part numbers A There are 2 fuses The small fuse is a 2 amp MT586 2 and the large fuse is a 10 amp MT586 3 Q The display starts loosing segments and has unusual figures cold weather what could be wrong A Check your operating temperature It s common for an LCD to freeze below 32 degrees F Q The meter reads Ouch is it broken A No On Ohms the meter will reach Ouch to signify infinite Ohms On the temperature selection it means the thermocouple is not inserted or has an open circuit on the thermocouple Also when in the manual ranging mode the meter will read Ouch to indicate the range needs to be increased e Q The temperature reads Ouch and just replaced the thermocouple is there a field fix A Yes Since the temperature and mA range share the 2 amp fuse check for this fuse failure Also check for thermocouple continuity 0 What is the location of the fuses A The rubber boot should be removed and the 3 screws taken off the back cover Next split the case and remove the back cover Gently pry the circuit board out of the front case As you are looking at the circuit board selector facing you the 10 amp fuse is on the left side and the 2 amp is on the right Q Can you check the fuses with
232. m Put 2 drops of Loctite 27131 into the rotor so it lands on the locating key Put 2 drops of Loctite 27131 in keyway on upper portion of distributor shaft Immediately 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 the shaft until it stops with the palm of your hand Let Loctite cure overnight with distributor in inverted position 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 Reinstall distributor cap on distributor Install spark plug wires if removed Refer to Spark Plug Wires in this section IGNITION SECONDARY 2E 3 Spark Plug Wires Checking Replacing 1 Visually inspect spark plug wires for damage such as being cracked cut or oil soaked 2 Visually inspect spark plug boots for damage NOTE Use care when removing spark plug wires and boots from spark plugs Twist the boot 1 2 turn before removing Firmly grasp and pull on the boot to remove the wire end 3 Check spark plug wires for continuity using a Multi Meter Digital Volt Ohm Meter or simi lar Replace any plug wires that do not show continuity from end to end 4 Replace any damaged plug wires IMPORTANT Wire routing must be kept intact during service an
233. mber PCM Pinout Cyl Number 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 45 P N 91 805747A2 Timing Tool for MerCruiser EFI Engines WSR S Timing Tool b DLC Connector CODEMATE Marine Code Reader CodeMate serves as both an EFI problem indicator and a spark timing service tool The de vice connects to the DLC in a matter of seconds and alerts the boat owner or technician when EFI problems are detected CodeMate allows diagnostic trouble codes DTC s to be read and when used with a timing light allows the technician to verify set the base ignition timing Rinda 94008 Available from Rinda Technologies Inc Chicago IL Telephone 773 736 6633 Fax 773 736 2950 Scan Tools Older Software and Newer EFI Systems Older scan tool software for the Quicksilver Digital Diagnostic Terminal DDT and MerCruis er Rinda scan tools will not be able to read the information coming out of the newer ECM s If you try to use the older software you will get an error message on the display of the DDT scan tool and you will get incorrect information from a MerCruiser Rinda scan tool 3B 46 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 Test Tool Data Link Connector DLC Locations MEFI Systems 1 Electrical Bracket 2 Relay 3 Relay 4 Screw 5 Knock Sensor KS Sensor 6 Screw 7 Slave Solenoid 8 Nut 9 Circuit Breaker 10 Screw 11 Scre
234. n The 4MV has a manifold mounted choke thermostat housing and a link rod attaching the thermostat spring to the carburetor choke linkage The 4MC has the choke thermostat housing mounted directly on the airhorn of the carburetor The thermostat spring is hooked directly to the carbu retor choke linkage 22 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Rochester Quadrajet 4MV Carburetor Exploded Parts View 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 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 23 Rochester Quadrajet Float System The float system operates in the following manner Fuel from the engine fuel pump enters the carburetor fuel inlet p
235. n often called waste spark instead of every other revolution The fuel injectors will also operate in sequential mode where they all fire individually OIL PRESSURE SENSOR The Oil Pressure Sensor is a three wire sensor and is mounted just above the remote oil filter adapter on the port side of crankcase It is a pressure transducer and its primary purpose is to supply oil pressure information to the Guardian program A failure in the Oil Pressure sensor or its circuit will set a fault SEA PUMP PRESSURE SENSOR The Sea Pump Pressure Sensor is also a three wire sensor and it is mounted in the sea pump body on the front starboard lower corner of the engine It is a pressure transducer and its primary purpose is to supply sea pump pressure information to the Guardian program A failure in the Sea Pump Pressure sensor or its circuit will set a fault OTHER COMPONENTS ASSOCIATED WITH THE ECM The provision for communicating with the ECM is the Data Link Connector DLC 5 Connector It is part of the EFI engine wiring harness and is electrically connected to the ECM The codes stored in the ECM can be read through the DLC connector There are three fuses 14 located in a holder near the ECM One 15 amp fuse is for the fuel pump and relay A 10 amp fuse for the ECM Injectors and a 15 amp fuse for the ECM Battery 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 23 There are different modes of eng
236. n 24 18 4 and 24 18 5 NOTE Fuel tanks meeting the requirements of ANSI UL 1102 Non integral Marine Fuel Tanks comply with these requirements of 24 18 2 through 24 18 2 13 24 18 3 Tank Labels 24 18 3 1 All fuel tanks shall bear a label with at least the following information 24 18 3 1 1 manufacturer s name or trademark and address 24 18 3 1 2 month or lot number and year of manufacture 24 18 3 1 3 capacity in US gallons liters 24 18 3 1 4 material specification and thickness 24 18 3 1 5 fuel for which tank is suitable 24 18 3 1 6 maximum test pressure 24 18 3 1 7 model designation and 24 18 3 1 8 the statement This tank has been tested under Title 33 CFR Section 183 510 a 24 18 3 2 Each letter and each number on a label shall 24 18 3 2 1 be at least 1 16 inch 1 6mm high and 24 18 3 2 2 contrast with the basic color of the label or be embossed on the label 24 18 3 3 Each label shall 24 18 3 3 1 withstand the combined effects of exposure to water oil sea spray direct sun light heat cold and wear expected in normal operation of the boat without loss of legibility and 1996 American Boat amp Yacht Council Inc 8 3A 54 FUEL DELIVERY SYSTEM AND CARBURETION 24 18 3 3 2 resist efforts to remove or alter information on the label without leaving some obvious sign of such efforts 24 18 4 Tank Fire Resistance Tests 24 18 4 1 Representative samples of the fuel tanks
237. n Coil No Spark at Coil Replace Ignition Module R1000 IMPORTANT The WHT GRN lead must be touched against ground 2 3 times per second to simulate a running engine Repeat this test several times to ensure that spark is present 2D 20 IGNITION SYSTEMS 90 883145 3 10 03 Test Equipment Electrical Test Equipment Service If you need any of your Quicksilver electrical test equipment serviced check Service Bulletin 97 13 for the vendor repair addresses 3 0L EST Ignition System Operation EST Ignition 3 0L 3 0LX To provide primary current for the ignition coil EST uses a magnetic pulse generator and an electronic module The pulse generator consists of a timer core on the main distributor shaft and pole piece around the outside The magnetic pole piece is designed with the same num ber of internal teeth as engine cylinders 4 cylinder engines 4 teeth The timer core rotates inside of the pole piece and has an equal number of external teeth As the internal and exter nal teeth start to align voltage output from the magnetic pickup coil increases as the teeth align and pass each other the voltage reverses polarity and decreases As the distributor shaft rotates the pickup assembly produces AC voltage Timer Core Electronic Module 2 Wire Connection from Pickup Coil to Module 70105 Distributor Assembly 4 cyl shown 90 883145 3 10 03 IGNITION SYSTEMS 2D 21 3 0L EST Circuits To help understan
238. n propeller MUST match direction of rotation of propeller shaft Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller Place a block of wood between anti ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when tightening propeller nut 1 FRESH WATER SALT WATER To aid in future removal of the propeller liberally coat the propeller shaft spline with one of the following Quicksilver lubricants then install propeller as shown Anti Corrosion Grease 92 802867 1 Special Lubricant 101 92 802865 1 2 4 C Marine Lubricant 92 802859 1 Anti Corrosion Grease 92 802867A1 IMPORTANT Installation is correct when at least 2 threads of propeller shaft are ex posed thru propeller nut after torquing it Install propeller with attaching hardware as shown Tighten nut until a minimum of 55 lb ft 75 is attained he a Apply Lubricant to Exposed Area of Propshaft b Forward Thrust Washer c Drive Sleeve d Propeller e Drive Sleeve Aft Adaptor f Locking Tab Washer g Propeller Nut 1F 6 PREDELIVERY PREPARATION 90 883145 3 10 03 Test Running Engine i If engine is to be tested with boat out of water the propeller must be removed to avoid injury IMPORTANT If using a test tank ensure water level is above water intake holes a
239. n the manual release valve Verify that the green indicators are no longer extended 7 638 a Green Indicators 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 19 3 POINT MANUAL DRAIN SYSTEM NOTE Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails 1 Remove three blue drain plugs One from the distribution housing lower front port side and two from the seawater pickup pump front starboard side a Blue Drain Plug 2 Verify that water is draining from each opening 3 Allow the system to drain for a minimum of 5 minutes Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained 4 Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump Do NOT allow engine to start 5 Prior to launching boat or starting the engine close the drain system by re installing the three blue drain plugs All Models 1 For additional assurance against freezing and corrosion fill the cooling system with a mixture of propylene glycol antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage a Remove thermostat housing or hose and fill with propylene glycol coolant until engine bloc
240. nd minimums simultaneously Give your service personnel the latest in innovative marine technology the DMT 2000A Digital Tachometer Mul ti meter from Mercury Marine Order today Complete the order form below and we guarantee that your marine service life will get just a little easier DESCRIPTION PART NUMBER DMT 2000A Complete Kit 91 854009A 3 DMT 2004 Complete Kit Replacement Components HEN P N 91 892647A01 8 ft 2 4m inductive pick up ODE 91 854011 1 DMT 2004 similar to DMT 2000A Replacement ferrite core 91 854012 Interface module 91 854013 1 Hard carrying case Users gue Optional Accessories Po 84 854016 T 8 ft 2 4m inductive pick up extension Clamp on Current Probe 91 802650 1 Direct Voltage Adaptor 91 89045 1 It has a serial port for connecting meter to a CDS unit Order on MIDAS or contact Quicksilver Sales at In USA Phone 920 929 5589 Fax 800 457 8736 Quicksilver Marine Parts and Accessories Products of Mercury Marine Fond du Lac WI 54936 1939 USA 90 883145 4 0804 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 2G 1 Mercury DMT 2000A FAQ S What battery does the DMT 2000A take and where is it located A The DMM requires a 9 volt alkaline battery and is located inside the meter at the bottom of the case inside e Q The DMT 2000A keeps using up batteries A The instrument has a sleep mode and not auto power off Since you may do
241. nd possible severe engine damage 1 Start engine and allow to reach operating temperature 2 With engine running install a jumper wire b across the two 2 white leads a on the distributor using P N 91 818812A1 or fabricate one using a 6 in 150mm section of 16 gauge wire with two 2 male bullet terminal ends connected With engine running install a jumper wire b across the two 2 white leads a on the distributor using P N 91 818812 1 or fabri cate one using a 6 in 150mm section of 16 gauge wire with two 2 male bullet termi nal ends connected 70103 3 Bypass the shift interrupt switch by disconnecting wires at shift interrupt switch and tem porarily joining together IMPORTANT Do not fail to reconnect these two wires to the shift interrupt switch when timing procedures are complete 4 With timing light connected check timing Timing should be S N 0L096999 and below 1 degree BTDC S N 0L097000 0L340999 1 degree ATDC S N 0L341000 and above 2 degrees ATDC 5 If required loosen distributor hold down clamp and rotate distributor to obtain specified timing Secure distributor hold down clamp and recheck timing as above Reconnect the two wires to the shift interrupt switch Remove jumper wire at distributor white leads IMPORTANT Be sure to remove jumper wire before returning engine to service other wise timing will not advance 8 With timing light still connected and engine
242. ne as a combustible mixture As the throttle valves are opened further and engine speeds increase air flow through the secondary side increases and opens the air valves to a greater degree which in turn lifts the secondary metering rods further out of the orifice plates The metering rods are tapered so that fuel flow through the secondary metering orifice plates is directly proportional to air flow through the secondary carburetor bores In this manner correct air fuel mixtures through the secondary bores are controlled by the depth of the metering rods in the orifice plates The depth of the metering rods on the orifice plates in relation to the air valve position are factory adjusted to meet air fuel requirements for each specific engine model cont 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 29 There are other features incorporated in the secondary metering system as follows 1 The secondary main well air bleeds tubes extend downward into the main fuel well below normal fuel level These bleed air into the fuel in the secondary wells to quickly emulsify the fuel with air for good atomization and improved fuel flow from the secondary nozzles 2 There are two baffle plates in each secondary bore located just below the air valves They extend up and around the secondary discharge nozzles their purpose is to provide good fuel distribution at lower air flows by providing as near as possible equal fuel distribution t
243. nector seals are not deformed or crushed when mating the connectors together BATTERIES WIRING 2A 9 Wiring Diagrams Quicksilver Instrumentation Wiring Diagrams MCM Gasoline Engine SINGLE STATION INSTALLATIONS TYPICAL a Audio Warning Buzzer b Tachometer c Oil Pressure d Water Temperature e Battery Meter f Ignition Switch g Trim Indicator h Read Observe NOTE 1 and 2 Read Observe NOTE 3 j To Engine Wiring Harness 2 2 lt p 2 A tanet T7950 L PUR BLK BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT OR LT LIGHT DRK DARK YEL RED Refer to gauge manufacturer s instructions for specific connections 74583 NOTE 1 Connect Wires Together with Screw and Hex Nut Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection NOTE 2 Power for a Fused Accessory Panel May Be Taken from This Connection Load Must Not Exceed 40 Amps Panel Ground Wire Must Be Connected to Instrument Terminal That Has an 8 Gauge Black Ground Harness Wire Connected to it NOTE 3 Lanyard stop switch lead and neutral safety switch leads must be soldered and covered with shrink tube for a water proof connection If an alternate method of connection is made verify connection is secure and sealed for a water proof connection 2A 10 BATTERIES WIR
244. nition timing The module monitors the amperage required by the ignition coil and alters the ground path Cel ui 2 m mna pem Battery FARRER d d 1 Filter z 1 i Ignition WHT Td Trigger Signal Y To 12V Shi Interrupter Switch Not Activated Ignition Control Module Engine Running 2D 22 IGNITION SYSTEMS 90 883145 3 10 03 90 883145 3 10 03 Advance will occur below 1000 rpm to set initial timing the advance must be disabled the 3 0 3 0LX bypassing the interrupter switch energizes the relay causing the points from the pickup coil as well as the grounding points to open By connecting a jumper between the white wires from the distributor a pulse is pulled from the signal converter and routed to the transistor This bypasses the timer circuit and disables the advance PICK UP COIL MODULE RELAY ss ADVANGE rE SIGNAL pe TX CONVERTER 1 F i 1 referee aac TT k PNK ri Timing Battery EEE Jumper Filter 1 LE Ignition Coil g BRN E J Trigger Signal Ad shit Interrupter witch Activate Ignition Control Module Timing Bypass IGNITION SYSTEMS 2D 23 TIMING PROCEDURE 3 0L 3 0LX WITH EST IGNITION IMPORTANT Failure to follow the timing procedure instructions will result in improper timing causing performance problems a
245. njector Test Harnesses 1986 and up 2 4L 2 5L 3 0L Outboards Use with 84 822560A 7 1982 and up Hi Performance 2 0L 2 4L 2 5L 3 4L Outboards Use with 84 830043A 2 1982 and up Hi Performance 2 0L 2 4L 2 5L 3 4L Outboards including Offshore models Use with 84 830043A 1 v2 0 For MEFI 1 2 3 ECM models Can also read RPM history on 1997 and up Thunderbolt V ignition modules v1 1 For PCM 555 models Used on Outboards also ELECTRONIC FUEL INJECTION INTRODUCTION 3B 49 MerCruiser Adapter Harnesses 84 822560A 2 84 822560T12 84 822560A13 84 861540A 1 DDT Accessories 84 825003A 1 91 804805 For MEFI 1 2 3 ECM models For PCM 555 models adapts 4 pin MerCruiser connector to 2 pin 84 822560A 5 Outboard harness OR For PCM 555 models 4 pin connectors no additional harness required 1997 and up V6 and V8 Carb Engines with Thunderbolt V Ignition Allows rpm history stored in Ignition Module to be read Use with 84 822560A 7 Replacement 10 ft 3 m 25 pin Harness for DDT Heavy Duty Carrying Case for DDT Not sold by Mercury Marine Order these parts from Owantonna Tool Company USA And Canada International Website www spx com OTC P N 3305 30 OTC P N 3285 OTC P N 212535 P N 212536 3B 50 ELECTRONIC FUEL INJECTION INTRODUCTION Phone 800 328 6657 Fax 800 578 7375 Phone 810 578 7247 Fax 810 578 7321 Replacement Rubber Protector Boot f
246. nk breather pipe must have an inner diameter of at least 1 2 in 13 mm and must be fitted with a swan neck to prevent water from entering the tank is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine All fuel lines must be well secured The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets This prevents damage to the lines from abrasion The following but not limited to the following additional fuel connection related points applying to all engines unless otherwise stated must be considered Refer to boating standards NMMA ABYC etc and Coast Guard regulations for complete guidelines 1 On Gasoline Engines Fuel tank should be mounted below carburetor level if possible or gravity feed may cause carburetor fuel inlet needle to unseat and flooding may result 2 Fuel pickup should be at least 1 in 25 mm from the bottom of fuel tank to prevent picking up impurities 3 On Gasoline Engines The maximum measured vacuum at the engine s fuel inlet must not exceed 2 in Hg or 1 psi 6 9 kPa at 600 3000 full throttle rpm and idle rpm IMPORTANT Vacuum reading higher than specified can cause vapor locking with some of today s fuels It can also cause poor engine performance because of fuel starvation 4 On Gasoline Engines Fuel lines us
247. noid Trailer Switch Neutral Switch To Instrument Wiring Harness Trim Limit Switch Trim Buttons SO 0ao0 RED PUR GRN WHT e es a eS we BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN wr ow PNK PINK e PUR PURPLE e 7 S RED RED e TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK 73962 90 883145 3 10 03 POWER TRIM ELECTRICAL 2F 5 Trim Position Sender Adjustment 1 Reconnect trim position sender wires to engine harness and trim limit switch leads to trim pump harness 2 Reinstall battery cables 1 WS BS m Gye 22031 a Positive Battery Lead b Negative Battery Lead 3 Turn ignition key to the RUN position DO NOT START ENGINE with the drive unit in the DOWN IN position Rotate sender until needle is at bottom mark on the gauge Retighten screws when adjustment is correct 22175 2F 6 POWER TRIM ELECTRICAL 90 883145 3 10 03 Trim Limit Switch Adjustment 2 90 883145 3 10 03 When adjusting trim limit switch use extreme care engine is not started and keep clear of area near propeller Use care to prevent placing hands in an area where injury could occur because of drive unit movement CAUTION Trim limit switch MUST BE adjusted exactly as outlined If switch is adjusted incorrectly drive unit could move out beyond the gimbal ring s
248. nostic times required to identify the root cause of electrical and electronic fuel controlled system problems The software consists of a user friendly menu driven interface engine data screens step by step pinpoint guided diagnostics for certain models internet connectivity for timely software updates and integrated service manuals The basic Computer Diagnostic System CDS is offered in three different configurations The first will consist of diagnostic software SmartComms Interface Box storage case Dell D500 laptop and Quick Setup Guide The second configuration includes all of the items listed above and includes a Rugged Panasonic CF 18 laptop computer in place of the Dell D500 laptop The third configuration is designed for our partners who have recently purchased a computer and do not wish to purchase another The diagnostic software and SmartComms Interface Box is offered to those who have a computer that meets the minimum system requirements Optional kit accessories available include an Electrical Harness Break Out Box Harness Pin Probes 12 Volt DC Adapters and the DMT 2004 VOM Meter with communications interface Additionally Mercury Precision Parts is developing an Electronic Dual Pressure Tester with communications interface These communications interfaces will reduce required technician key strokes remove entry errors and decrease troubleshooting times when using the pinpoint guided diagnostics Version in English is avail
249. not be used 24 9 5 3 A gasket or O ring shall be retained by the body or cover when the part is removed 24 9 6 Marking 24 9 6 1 Each unit shall be permanently and plainly marked with the following a manufacturer s or private labeler s name or identifying symbol b type of unit filter strainer or separator c replacement element part designation d direction of fuel flow e test pressure f types of fuel for which the unit is intended g installation and use instructions These may be a separate sheet and shall contain a component parts replacement list h date of manufacture NOTE Filters separators and strainers meeting the requirements of ANSYUL 1105 Marine Use Filters and Separators comply with the requirements of 24 9 through 24 9 6 1 2410 INSTALLATION FUEL TANK 24 10 1 Fuel tank s shall be permanently installed so that the tanks s do not support decks bulkheads or other structures 24 10 2 The tank s shall be installed so that means for maintenance or replacement is provided or indicated so it can be accomplished with a minimum disturbance of the boat structure 24 10 3 Tank connections and fittings shall be accessible 90 883145 3 10 03 H 24 12 96 24 10 4 As installed in the boat tank labels shall be accessible and located so they can be read 24 10 5 Fuel tanks shall be installed and restrained so that the fuel tank does not move at the mounting surface more
250. nt Tool may cause improper alignment and damage to gim bal bearing and or engine coupler To avoid damage to gimbal bearing engine coupler or alignment tool e DO NOT attempt to force alignment tool DO NOT raise or lower engine with alignment tool inserted or partially inserted in gimbal bearing or engine coupler 22029 a Alignment Tool use only recommended alignment tool b This End Of Alignment Tool Inserts Through Gimbal Housing Assembly 47 lt 5 a 5 gt AAR Css waits otv 2 E PLE M Aa fot AE AEN v 5 H Macr gt vu ep a VS te 69 i fut MIS 22 a 27647 Alignment Tool b Gimbal Bearing c Engine Coupler NOTE Dimension refers to point on boat transom that is extension of engine crank shaft centerline 1B 6 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 Final Engine Mount Height Adjustment 90 883145 3 10 03 IMPORTANT Finished boat stringer must position engine so that a minimum mount adjustment exists after front mount is adjusted down to stringer This allows for future adjustments IMPORTANT Turn both front engine mount adjustment nuts an equal amount in direction required to align engine During final engine mount adjustment the mounts are temporarily adjusted until they rest on the stringers Hoist tension is relieved so that
251. nto bore of trim cylinders e Install the flat washers f Install the E ring clips into narrow grooves NOTE The inboard grooves of the aft anchor pin are for E ring clips and wider outboard grooves are for securing plastic caps g Push plastic caps onto ends of aft anchor pin 70027 a Aft Anchor Pin b Bushings c Flat Washers d E Ring Clips e Plastic Caps 17 drive unit serial number decal as described in General Information 1C 6 STERNDRIVE INSTALLATION 90 883145 3 10 03 ATTACHING SPEEDOMETER WATER TUBE GIMBAL HOUSING TO ALPHA STERNDRIVE 1 Raise drive to gain access to area between gimbal housing and sterndrive immediately above the transom end of the anti ventilation plate 2 Align plastic slots on male and female portions and insert 3 Push down to secure 75486 75508 End of Speedometer Tube Fitting b Female Portion 455 a Tube Fitting Male End b Topside Portion Female End 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 7 Alpha Drive Unit Remote Control and Drive Unit Shift Cables Adjustment Drive Unit Installed IMPORTANT Shift cable adjustment for a right hand RH rotation drive unit is different than the procedure for adjusting a left hand LH rotation drive unit Be sure to refer to the appropriate procedure when performing the following steps RIGHT HAND ROTATION Install control cable in remote control so that cable end wi
252. o all engine cylinders An air horn baffle is used on some models to prevent incoming air from the flame arrestor reacting on the secondary main well bleed tubes The baffle is located adjacent to the sec ondary well bleed tubes and extends above the air horn between the primary and secon dary bores This prevents incoming air from forcing the fuel down in the secondary wells through the bleed tubes and prevents secondary nozzle lag on heavy acceleration Rochester Quadrajet Air Valve Dashpots The primary purpose is to control the opening rate of the air valves and prevent secondary discharge nozzle lag The valve dashpot operates off of the choke vacuum break diaphragm unit The secondary air valve is connected to the choke vacuum break unit by a rod to control the opening rate of the air valve Whenever manifold vacuum is above approximately 5 6 of Mercury Hg the vacuum break diaphragm is seated plunger fully inward against spring tension At this point the vacuum break rod is in the forward end of the slot in the air valve lever or in the rear of the slot in the vacuum break plunger and the air valves are closed During acceleration or heavy engine loads when the secondary throttle valves are opened the manifold vacuum drops The spring located in the vacuum break diaphragm overcomes the vacuum pull and forces the plunger and link outward which in turn allows the air valves to open The opening rate of the air valves
253. o float systems both systems function identical The float system operates as follows Fuel from the engine fuel pump is forced through the fuel inlet filter 1 and on through the float needle seat 2 past the float needle 3 into the float bowl 4 Fuel flow continues until the fuel raises the float pontoon to a position where it forces the float needle against the needle seat and shuts off fuel flow As fuel is used from the carburetor bowl during engine operation the float again drops downward moving the float needle off its seat allowing more fuel to flow into the float bowl thereby keeping the fuel level constant The float drop tang located at the rear of the float arm prevents the float from moving too far downward The maximum float drop must be maintained so that the float assembly will drop sufficiently to allow maximum fuel flow under heavy engine demands cont FUEL DELIVERY SYSTEM AND CARBURETION 3A 35 The bowl vent is internal inside the air horn just below the flame arrestor The amount of fuel metered by the carburetor is dependant upon the pressure inside the float bowl causing the fuel to flow The vent system assures that any pressure build up in the float chamber during hot engine operation caused by fuel vapors will be relieved into the flame arrestor During normal engine operation when the engine is running manifold vacuum pulls the fuel vapors into the engine Weber Carburetor Idle System
254. o wide open throttle The main metering system provides efficient fuel metering during the cruising range Its operation is dependant upon air flow through the carburetor venturi 8 which in turn creates a low pressure in the venturi area causing fuel to flow As the throttle valves 2 are opened beyond the off idle discharge slots allowing more air to enter the intake manifold and engine speed to increase the vacuum decreases below the throttle valves and the off idle slots gradually diminishes With the increases throttle opening there is an increased air velocity in the venturi system This causes a drop in pressure in the main venturi which is increased many times in the boost venturi fuel will flow in the following manner The main discharge nozzle 5 is located in the low pressure area inside the boost venturi 7 Atmospheric pressure which is greater forces fuel from the float bowl through the main metering jets 1 around the primary metering rods and into the main well 3 As the fuel passes through the main well tubes 4 it is mixed with air from the calibrated main well bleeds 6 The fuel mixture then passes from the tip of the discharge nozzle 5 to the boost venturi 7 and on into the intake manifold As the throttle valve opening is increased and more fuel is drawn through the main well tubes the fuel in the main well drops The calibrated holes in the main well tubes are proportionately exposed to the air in the
255. ocuments United States Government Information POB 371 954 Pittsburgh PA 15250 7954 Phone 202 512 1800 Fax 202 512 2250 Military Specifications Military specifications may be obtained from the Naval Publications and Forms Center 5801 Tabor Avenue Philadelphia PA 19120 SAE Society of Automotive Engineers 400 Commonwealth Drive Warrendale PA 15096 0001 90 883145 3 10 03 H 24 12 96 Corrected 7 00 7 01 7 02 7 03 Phone 724 776 4841 Fax 724 776 5760 Website WWW Sae org UL Underwriters Laboratories Inc 12 Laboratory Drive PO Box 13995 Research Triangle Park NC 27709 3995 Phone 919 549 1400 Fax 919 547 6000 Web site www ul com 24 4 DEFINITIONS Accessible Capable of being reached for inspection removal or maintenance without removal of permanent boat structure Anti siphon valve A valve preventing a siphon action created by a break in the fuel distribution system below the topmost level of the fuel tank Fuel filter A filtering device with a micron rating less than 500 Fuel strainer rock screen A screening device to remove coarse debris from the fuel supply and still permit the passage of water Gasoline Includes all gasoline based fuels The Federal Hazardous Substance Act classifies gasoline as extremely flammable having a flash point at or below 20 F 7 C Permanently installed Securely fastened so that tools such as wrenches and scr
256. of cooling system e Engine must be as level as possible wire should be repeatedly inserted into all drain holes to ensure there are no ob structions in passages Remove petcock if necessary to insert wire completely into drain hole IMPORTANT To prevent threads in manifolds elbows and cylinder blocks from rusting out during storage reinstall plugs using Quicksilver Perfect Seal on threads Never leave drain plugs out during storage NOTE If possible place a container under drains and hoses to prevent water from draining into boat WINTERIZATION AND RECOMMISSIONING 1G 1 If engine is equipped with Closed Cooling System Closed Cooling section must be kept filled with a solution of ethylene glycol antifreeze and water mix antifreeze to manufacturer s recommended proportions to protect engine to lowest temperature to which it will be exposed DO NOT USE PROPYLENE GLYCOL antifreeze in closed cooling section Seawater section however must be drained completely A discharged battery be damaged by freezing IMPORTANT MerCruiser recommends that propylene glycol antifreeze a nontoxic and environmentally safe antifreeze be used in seawater section of the cooling sys tem for cold weather or extended storage Make sure that the propylene glycol anti freeze contains a rust inhibitor and is recommended for use in marine engines Be cer tain to follow the propylene glycol manufacturer s recommendations
257. ol can cause the shift lever to move out of gear unexpectedly The following kit will have to be ordered to connect remote control shift cable when shift assist assembly is not used Spacer Kit 23 11284A1 a Clevis Pin b Washer Spacer d Cotter Pin 2 Ensure shift lever adjustable stud is at bottom of slot If necessary loosen stud and move it to end of slot toward pivot point and retighten stud fo A Kee A 50309 a Adjustable Stud 1C 10 STERNDRIVE INSTALLATION 90 883145 3 10 03 17 7 3 Shift remote control as stated in or following a Right Hand RH Rotation Drive Unit forward gear past detent into wide open throttle position b Left Hand LH Rotation Drive Unit reverse gear past detent into wide open throttle position 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 11 4 Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel this removes all slack from the cable IMPORTANT Do not use excessive force when holding pressure on the drive unit shift cable Excessive force would be indicated by movement of the shift cutout switch a Drive Unit Shift Cable Push In b Propeller Shaft Rotate Counterclockwise 9 L
258. ond Normally Closed Normally Open Propulsion Control Module Programmable Read Only Memory Random Access Memory Reference High Reference Low Read Only Memory olave Switch Tachometer Terminal Throttle Position Sensor Volts Vacuum Wide Open Throttle 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 19 MerCruiser System Electronic Components MEFI 3 MCM Sterndrive 7 4L MPI Bravo and MIE Inboard 7 4L Inboard NOTE All BLACK wires with a ground symbol are interconnected within the system harness NOTE Component position and orientation shown is arranged for visual clarity and ease of circuit identification lt gt 75993 1 Fuel Pump 13 Ignition System Relay 2 Distributor 14 Fuse 15 Amp Fuel Pump 3 Fuse 15 Amp ECM DLC Battery 4 Gear Lube Monitor Bottle Not Used On MIE Fuse 10 Amp Injector Ignition 5 Data Link Connector DLC Knock Module 6 Manifold Absolute Pressure MAP Sensor 15 2 Connector To Starting Charging arness 16 Positive Power Wire To Engine Circuit 7 Knock Sensor 8 Idle Air Control IAC Breaker 17 Oil Pressure Audio Warnin g Switch 10 Engine Coolant Temperature ECT Sensor Load Anticipation Circuit Not Used 11 Electronic Control Module ECM _ 12 Fuel Pump Relay 19 Intake Air Temperature IAT Sensor
259. or DDT Hard Copy Printer 12v use with P N 212536 cable PC Adaptor Cable 9 pin PC Adaptor Cable 25 pin 90 883145 4 0804 7 688 06 080 9 96 NOLLO3PNI 13603 OINOYLOA 13 00 6 99 weyy LAA OI DDT MerCruiser 2 0 3 502 Mag MARINE DIAGNOSTICS 1 GM Single 2 GM Twin 3 Thunderbolt V 4 Injector test GM 5 Tool Setup Go to page 4 Go to page 4 Go to page 5 Data Link harness 84 805696A 2 must be connected between dual engine installations to be able to use this function Otherwise scan each engine individually Is the engine s equipped with a mani air temp sensor 1 Yes 2 No SELECT FUNCTION 1 Display Sys Info 2 Trouble Codes 3 Data Monitor 4 Service mode 9 Set Outputs See next page Is the engine s equipped with a mani air temp sensor 1 Yes 2 No GM TWIN SELECT 1 Port Master 2 Starboard master 3 Qwery ECMs SELECT ENGINE 1 Port Engine 2 Starboard Engine 3 Both Engines SELECT DUAL FUNCTION 1 Display Sys Info 2 Display Codes 3 Dual Data Monitor Operation similar 5 to single engine operation Page 1 NOILONGOYLNI NOILOSPNI 19154 OINOYLOSA TA 9 9 V SVLE88 06 080 5 Set Outputs Cont from page 1 SELECT FUNCTION 1 Display Sys Info 2 Trouble Codes 3 Data Monitor 4
260. or returned for warranty that has a no trouble found condition will have the warranty claim rejected and the part returned to the dealer CHARGING SYSTEM 2C 7 Alternator Charging Voltage RPM Alternators will not put out 13 5 volts until they reach 800 After that they will put out charg ing voltage at any rom Half of the alternators returned for warranty operate correctly 25 of the returned units have water in them 25 of the returned units have actually failed 42701 Charging System Testing and Repair Consult appropriate service manual for testing and repair information Also see Service Bulle tin 2001 12 MANDO ALTERNATOR SERVICE MANUAL 24 DELCO ALTERNATOR SERVICE MANUAL 31 Several service manuals have alternator testing and repair information These particular manuals are given only as examples 2C 8 CHARGING SYSTEM 90 883145 3 10 03 MERCRUISER ELECTRICAL SYSTEMS LEVEL I PF IGNITION SYSTEMS Table of Contents Conventional Ignition System Delco Remy and Prestolite Thunderbolt IV Ignition System Exploded View Typical Thunderbolt IV Distributor Identification Thunderbolt IV Module Identification Distributor Mounted Module Exhaust Elbow Mounted Module Hall Effect Sensor Testing Thunderbolt IV HEI System Thunderbolt IV Ignition System Wiring Diagram Thunde
261. or sensor wheel assembly removed inspect the locating key inside the rotor Inspection 2 The locating key will appear as a clean edged 1 8 in 8 mm wide sloped ramp at the bottom of the splined hole 72980 a Locating Key b Screws Hex Head c Sensor Wheel d Locating Pin 3 there is any doubt if sensor wheel is located properly lay sensor wheel on top of the figure above with sensor fingers facing up toward you Line up three screw holes and locating pin hole on sensor wheel with the figure If wheel is indexed properly all the fingers on wheel will line up with those in the figure 4 lf there are pieces of material shaved off the 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 2E 2 IGNITION SECONDARY 90 883145 3 10 03 Installation 90 883145 3 10 03 rotor is damaged replace rotor by removing three hex bolts 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 three hex bolts securely Bend carbon brush tang upward slightly until a distance of 1 4 in 6 4 mm is obtained between rotor and tang 72979 a 1 4 in 6 5 m
262. ors OPEN for a longer period of time CLEAR FLOOD MODE If an engine floods it can be cleared by positioning the throttle one half to three quarters open When the TP sensor reads between 50 and 75 at cranking rpm the ECM will not fire the fuel injectors at all This will allow air to be drawn into the engine but no fuel injected As soon as the engine starts and exceeds 300 rpm the ECM cancels the clear flood mode and enters running mode Not active on ECM PCM 555 equipped engines 3B 24 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 FUEL CUTOFF MODE The ECM cuts off fuel delivery to the engine when the key is off to prevent dieseling when no distributor reference pulses are sent means the engine is not running and at high engine RPM overspeed protection DECELERATION MODE The Idle Air Control Valve IAC is similar to a carburetor dashpot It provides additional air when the throttle is rapidly moved to the idle position to prevent the engine from stalling POWER REDUCTION MODE 1995 AND EARLIER EFI ENGINES EARLY MEFI 1 The two discrete switch inputs and the ECT engine coolant temperature sensor are used by the EFI system to identify abnormal conditions that affect engine operations If engine oil pressure drops too low or if drive unit fluid level in the reservoir bottle becomes too low or if the engine coolant temperature becomes too high the ECM will engage the power reduc tion mode
263. oting Parts Bulletins 98 6 Fuel System Replacement Parts 3A 68 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 4 0804 FUEL SYSTEMS LEVEL I ELECTRONIC FUEL INJECTION INTRODUCTION Table of Contents Speed Density Theory and Operation 3B 1 EST Ignition Source of Ref Signal 3B 5 Engines with Mercury Marine Thunderbolt V Distributor and MEFI 3 ECM 1999 V 6 and Small Block V 8 Engines 3B 6 ECM PCM 555 RPM Input 3B 7 Multi Port Fuel Injection System Fuel Flow 3B 8 Throttle Body Injection System 3B 9 Early 350 Mag MPI Induction System 3B 10 350 MPI Magnum Gen Tournament Ski Black Scorpion Induction System 3B 11 Later Model 350 Mag MPI Induction System Model MEFI 1 amp 2 Similar 3B 12 Later Model 350 Mag MPI Throttle Body Assembly MEFI 3B 13 Throttle Body Assembly TBI EFI Models 3B 14 7 4L L29 MPI Induction System 3B 15 496 8 1L MPI Induction System Typical 3B 16 Small Block V 8 Induction System V 6 Similar GM EFI 3B 16 MEFI 1 and 2 ECM Input and Sensor Descriptions MEFI 3 Similar 3B 17 PCM 555 Input and Sensor Descriptions ECM 555 3B 18 EFI System Abbreviations
264. ough a fuel line f back to the water separating fuel filter b WATER SEPARATING FUEL FILTER B Fuel not used by the engine is returned to the water separating fuel filter where it mixes with fuel coming in from the fuel tank This fuel is then sent back to the engine This system does not require a return fuel line to the boat s fuel tank Fuel Line from boat s fuel tank Water Separating Fuel Filter Electric Fuel Pump i LL Fuel Cooler d Lr Fuel Pressure Regulator Return Line to Fuel Filter Water Flow through Cooler 9 Vacuum Line to Intake Manifold Fuel Rail Fuel Injectors 8 Dummy Regulator some MEFI 1 amp L A 20 0o0QG 0099w 2 models O 74871R2 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 29 Cool Fuel System Fuel Pressure Regulators There are 3 different Cool Fuel fuel pressure regulators that are used in production If the wrong regulator is used on an engine that engine can have a problem with its fuel supply to the injectors When checking regulator pressure on MPI engines always remove the small black hose that goes to the regulator before the test This hose goes to the intake manifold or plenum and it has vacuum on it which causes the pressure to read lower at idle RPM By removing the hose the regulator s true pressure will be shown a Filter b Fuel Cooler Orifice c Pressure Regulator d Screw and Wash
265. out taking the case apart A Yes check the 10 amp fuse turn the selector to the temperature setting and use one test lead to bridge the common and temperature terminals The display should read close to room tempera ture To check the 2 amp fuse set the selector to the diode setting and bridge the common and Ohms terminals The display should read very close to zero Ohms if the 2 amp fuse is good e Does the DMT 2000A have Auto Power Off and Auto ranging A Yes The meter will shut off after approximately 30 minutes this is only a sleep mode there is still a power draw It is automatically in auto ranging The manual ranges can be selected using the Range button otherwise it is always in auto ranging While using the Inductive RPM mode on small engines the display hunts or reads higher than actual RPM or even locks up the display What can be done A Use the RPM 1 signal conditioning module 2G 2 QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 90 883145 3 10 03 Q Using the RPM mode the RPM s seem to be doubled why A On some late model ignition systems with a waste spark system the plug fires twice per cycle Simply switch to 2 Stroke to obtain the correct readings While using the Ohms range the display is not stable A Make sure the test leads are tight in the meter Also clean the probe ends with a mild abrasive for best contact With the test lea
266. ow into the carburetor This regulated air flow provides the richer mixture needed during the warm up period a Scribed Mark b More Choke Less Choke As the engine warms up electrical current is supplied to the heater coil located next to the thermostatic coil The electric current passing through the coils generates heat inside the thermostatic coils housing This heat causes the thermostatic coil to relax its tension Thus the choke valve is allowed to move gradually to the full open position During the warm up period the air flow past the choke valve also serves to modify the choke action to compensate for varying engine loads on acceleration Any acceleration or increased load decreases the vacuum pull on the choke valve This allows the thermostatic coil to momentarily increase choke valve closure to provide the engine with a richer mixture for acceleration FUEL DELIVERY SYSTEM AND CARBURETION 19 When the automatic choke is in operation operator may wish to advance the throttle to wide open position Since this would decrease pull upon the choke valve thereby closing the choke valve it is necessary to provide increased carburetor air flow by opening the choke valve mechanically To accomplish this a tang on the fast cam is made to contact the throttle lever at wide open throttle to sufficiently open the choke valve This is called a choke unloader and also serves to de choke a flooded engine during starting wnenev
267. ow the Inner Transom Plate Engine Supports on Alpha One Gen Transom Assembly 31 35988A12 Bearing Set 90 19 Possible Difficulty Shifting Out Of Gear on Bravo 1 36 1 and 1 81 1 1991 MERCRUISER SERVICE BULLETIN INDEX 91 9 91 10 New Battery and Battery Cable Recommendations for MerCruiser Products Engine Specification Corrections to Number 9 MerCruiser Service Manual 90 14499 1 887 MCM 502 Magnum MIE 8 2L Inboard GM Mk IV Engine Specifications 815471A3 Bravo Shift Cable Replacement Kit Seawater Fuel Pump Maintenance 7 4L Bravo MIE 7 4L Inboard GM Gen V Engine Specifications New Engine Break In Procedure For Diesel Engines MCM 350 Magnum Alpha MCM 5 7L Bravo MIE 350 Magnum Tournament Ski Inboard Specifications Oil Leaking from Water Pickup Holes in Gear Housing on Alpha One Gen II Drive otarter Relay Chatter On Diesel Engines 91 11 Warranty Fraud 91 12 91 13 91 14 90 883145 4 0804 Ignition System Advance Curve Specifications Priming 4 Cycle Engines with Oil Replacement Trim Pump for the Prestolite Style Pump MERCRUISER APPLICABLE SERVICE BULLETIN LIST 4 1 91 15 Alpha II Stern Drive Special Tools List 91 16 MCM 454 Magnum Bravo GM Gen V Engine Specifications 91 17 4 3L 4 3LX Alpha GM Gen II Engine specifications 91 18 MerCruiser Instructional Video Tapes 91 19 Anode Material Change 91 20 Bravo Drive Unit Housing Comparison and Identification 91 21 Drive Unit Gear Ratio Id
268. oys normally used for fuel fittings and lines are considered acceptable for direct coupling with all fuel tank materials listed in TABLE IV except aluminum 90 883145 3 10 03 H 24 12 96 Corrected 7 99 7 02 7 03 24 18 1 6 Copper base alloy components shall be separated from contact with aluminum tanks or fitting plates by means of a galvanic barrier such as 300 series stainless steel 24 18 1 7 Fastenings used to couple fittings such as fuel senders to aluminum tanks shall be of 300 series stainless steel or its equivalent in corrosion resistance 24 18 2 Design and Construction 24 18 2 1 Fuel tanks shall not be integral with the hull 24 18 2 2 Stainless steel tanks shall be cylindrical with domed heads and a capacity of less than 20 gallons 75 liters 24 18 2 3 Each opening into the fuel tank shall be at or above the topmost surface of the tank 24 18 2 4 The tank design shall be such that no exterior metallic part of the tank will trap water as the tank is intended to be installed when the boat is in the static floating position 24 18 2 5 The exterior shape of the tank s shall provide smooth bearing surfaces to support and secure the tank s 24 18 2 6 Spuds and other tank fittings shall be attached so as to maintain the liquid and vapor tight integrity of the tank without reducing the strength of the tank wall 24 18 2 7 If baffles are provided the total open area provided in the baffles shall be a m
269. p Nut and Flat Washer e Throttle Lever 1E 2 THROTTLE CABLE ADJUSTMENT 90 883145 3 10 03 EFI Models 1 Place remote control handle s in neutral idle position IMPORTANT Be sure that cable is routed to avoid sharp bends and or contact with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated 2 Install cable end guide on throttle lever then push cable barrel end lightly toward throttle lever end This will place a slight preload on shift cable to avoid slack in cable when mov ing remote control lever Adjust barrel on throttle cable to align with hole in anchor plate Ensure hole in barrel positions cable as shown R 52 ae 2 AC 7 2 C 4 42 ZL 76899 Typical a Flat Washer and Locknut b Cable Barrel Flat Washer And Locknut 3 Secure throttle cable with hardware as shown and tighten securely Loosen locknut a 1 2 turn 4 Place remote control throttle level in the wide open throttle WOT position Ensure that throttle plates are completely open 5 Return remote control throttle lever to idle position and ensure that throttle lever is com pletely closed 90 883145 3 10 03 THROTTLE CABLE ADJUSTMENT 1E 3 Bravo Throttle Cable Installation amp Adjustment 1 Place remote control handle s in neutral idle position IMPORTANT Be sure that cable is routed in such a way to avoid sh
270. r Identification a Identification Number See Specifications NOTE The MerCarb carburetor will not backfit MerCruiser 120 140 engines which utilize the Rochester 2GC carburetor The MerCarb may be distinguished from the Rochester 2GV carburetor as follows MerCarb Single Idle Mixture Needle Rochester 2GV Two Idle Mixture Needles 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 bleeds to properly meter the correct fuel air mixture to the engine MerCarb Repair Kit Part Numbers 90 883145 3 10 03 The following part numbers are difficult to locate but can be found in the 2003 Parts Guide MerCarb with large accelerator pump repair kit 3302 804844 MerCarb with small accelerator pump repair kit 3302 804845 These kits do not contain the power valve or float which may be ordered with MIDAS MercNet FUEL DELIVERY SYSTEM AND CARBURETION 11 MerCarb Two Barrel MerCruiser Carburetor Exploded Parts View T 1 Rod Accelerator Pump 2 Accelerator Pump Shaft and Lever Assembly 3 Washer Outer 4 Washer Inner 5 Screw 6 Washer 7 Screw 8 Spring 9 Filter 10 Gasket
271. r bank of bat teries through the Model 32023A battery isolator Any other manufacturer s battery isolator that is the same type as the Sure Power Inc Model 32023A could also be used Generators The generator s battery should be considered in the same manner as another en gine s battery 2A 18 BATTERIES WIRING 90 883145 4 0804 p enu merCruizer TO SERVICE MANAGER TECHNICIANS No 97 13 PARTS MANAGER Service Repair Of Electrical Test Equipment All electrical test equipment must be returned to the vendor or repair facility for service repair and or re placement parts Please contact the business prior to shipping the unit to obtain shipping estimates and repair details Any test equipment received in Fond du Lac or Stillwater will be returned to the sender The addresses and phone numbers are as follows Test Equipment 1 Digital Diagnostic Tester DDT 91 823686A2 Vendor SPX Service Repair 2300 Park Drive Owatonna MN 55060 Phone 800 344 4013 2 Tach Dwell Meter 91 59339 Ignition Analyzer 91 76032 Vendor Merc O Tronic Service Dept 215 Branch Almont MI 48003 Phone 810 798 8555 Fax 810 798 2222 3 Timing Light self contained 91 99379 Multi Meter DVA 91 99750 Merctach Digital Tachometer 79 17391A1 EFI 91 11001 2 a EFI Tester Digital Volt Meter is not Vendor Electronic Specialtie
272. r output circuit first Loose or corroded connections in the alternator output circuit can cause charging system problems a Discharge the battery by grounding the ignition coil high tension wire and crank the engines over for 10 15 seconds b Turn off all accessories c Connect voltmeter lead directly to the alternator output terminal not the ORN wire ring terminal Connect voltmeter lead directly to the battery post d Start engine increase rpm to 1300 and observe voltmeter reading The maximum allowed is 0 5v find the point where the resistance is highest leave the voltmeter lead on the battery post and move the voltmeter lead to the alternator ORN wire ring terminal f Next move voltmeter lead to the ORN wire itself that is inside the crimped ring terminal 90 883145 3 10 03 CHARGING SYSTEM 2C 5 g Test each alternator output wire connection in this manner all the way back to the battery post If a battery switch is used check between the battery cable ring terminal and the switch s terminal Testing For Charging Circuit Hesistance 0 5v Max 11 Test for resistance on the alternator ground next a Repeat a and b in step 10 b Connect voltmeter lead to ground terminal on the alternator not the BLK wire ring terminal Connect voltmeter lead directly to the battery post NOTE If alternator does not have
273. r source can be used 1 Remove the blue air pump from the engine 2 Ensure that lever on top of pump is flush with the handle horizontal 3 Install the air pump on the fitting in the air manifold 77638 Green Indicators 4 Pull the lever on the air pump up vertical to lock the pump on the fitting 5 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side TS j CT 77995 Closed Cooled Models Seawater Cooled Models a Blue Drain Plug Location b Blue Air Pump c Air Manifold d Green Indicators 1G 18 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 6 Verify that water is draining from each opening If not use the 3 Point Manual Drain System a Port Side Drain Location b Starboard Side Drain Location 7 Allow the system to drain for a minimum of 5 minutes Add air as necessary to keep the green indicators extended 8 Crank engine over slightly with starter motor to purge any water trapped in seawater pump Do NOT allow engine to start 9 Remove the air pump from the air manifold and return it to the mounting bracket 10 MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained 11 Before launching boat pull up o
274. r than the Schrader type Adaptors are used to attach the fuel pressure test gauge to each size of test port They are shown on the next page 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 31 Fuel Pressure Test Gauge Adaptor Fittings The following information is contained in revised Service Bulletin 97 24 1998 2000 MCM MIE 7 4L MPI L29 uses a different size and type of test port valve on it for checking the fuel pressure at the fuel rail The older Fuel Pressure Gauge Kit P N 91 16850A 2 will not attach to this valve A new kit has superseded this kit and it contains 2 fittings so it will fit both types of test ports and a TBI pressure valve to allow the gauge to connect to TBI engines Quicksilver will also sell an Adapter Kit that can be purchased to update the older 91 16850A 2 kit This kit comes with both size test port valve adapters and instructions on how to fit it to the older gauge kit 91 16850A 7 Fuel Pressure Gauge Kit Kit contains Adapter Kit and TBI Pressure Valve To update older 91 16850A 1 2 orA 3 Fuel Pressure Gauge Kits order the following 91 806901 TBI Pressure Valve Allows older Gauge Kits to connect to engines 91 803135 Adapter Kit Allows older Gauge Kits to connect to either type of test port valve Available after May 1998 3B 32 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 NOTES 90 883145 4 0804 ELECTRONIC FUEL INJE
275. ra hose clips may be required to secure hose to transom 71984 181 CID 3 0L Model Shown Similar a Hose b Hose Clip c Sta Strap 1B 10 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 GIMBAL HOUSING CONNECTION 90 883145 3 10 03 The gear lube monitor hose is connected to a quick release 90 fitting This fitting is then con nected to the gimbal housing IMPORTANT Hose must not come in contact with steering system components or the engine coupler U joint shaft or drive shaft We 1 M N 74235 x 75874 75313 a Hose b 90 Hose Fitting c Gimbal Housing Fitting d Gear Lube Monitor On Bravo sterndrive units the quick release button on hose fitting must be positioned away from water inlet fitting or block off plate if equipped Release button must not contact water fitting or block off plate if equipped Avoid sterndrive unit damage Quick release button on gear lube monitor 90 hose fitting may not lock on gimbal housing if touching or depressed by water inlet fitting or block off plate if equipped Ensure quick release button does not contact block off plate or water inlet fitting if equipped Failure to do so could result in a loose 90 fitting causing a loss of gear lube and damage to drive unit INN VAM 4 lt j 998 Block Off Plate Installation Shown Similar For Models With Water Fitting a Block Off Plate Or Water Inlet Fitting If Equippe
276. ransmissions 96 12 Changes To The 1997 Operation And Maintenance Manuals 96 13 Commander 3000 Remote Control Recall 96 14 Aftercooler Torque Specifications 96 15 Required ECM Replacement 96 16 Hurth V Drive Output Flange Torque 1997 MERCRUISER SERVICE BULLETIN INDEX 97 1 Torquing Intake Manifold on Gen Engines 97 2 MerCruiser MCM MIE Inline Diesel Heat Exchanger End Cover Torque 97 3 Required Flame Arrestor Replacement 97 4 MCI Alpha One Alpha One Gen II Gear Case and Bearing Bore Differences 97 5 Multiple EFI Engine Battery Precautions 97 6 MerCruiser GM Engine Identification See SB 2002 08 97 7 Bravo Drives and Transoms See SB 98 16 97 8 MerCarb 2 Carburetor 97 9 Weber 4 bbl Carburetor 97 10 Alternate Gear Ratio Sterndrive Units for High Altitude 97 11 AC Spark Plug Replacement 97 12 Battery and Battery Cable Requirements for MerCruiser D tronic Diesels 97 13 Service Repair of Electrical Test Equipment 97 14 1998 Gasoline Engine Specifications 97 15 Timing 1998 350 Mag MPI and 7 4L MPI Models 97 16 Engine Specifications 97 17 Engine Dieseling and Running On 4 4 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 90 883145 3 10 03 97 18 1997 1 2 Shift Changes for Bravo One Two Three and BlackHawk 97 19 Extended Life Coolant Antifreeze in Gasoline Engines 97 20 Required EFI and MPI Fuel Line Replacement 97 21 Required ECM Replacement 97 22 Engine Oil Level D2 8L D Tronic
277. rbolt V Ignition General Description Idle Speed Spark Control Acceleration Spark Advance Mean Best Timing MBT Spark Advance Over Speed Control Knock Retard Spark Control Thunderbolt V Spark Control Graph Ignition Systems Thunderbolt V Circuit Description Ignition Control Module Knock Control Module Ignition Control System Timing LOG ode ee pees ead Thunderbolt V Ignition System Wiring Diagram 1997 and Older Models with Distributor Mounted Module Bravo shown 2D i IGNITION SYSTEMS Page Thunderbolt V 1998 and Newer Models with Exhaust Elbow Mounted Module Alpha and Bravo Models see Note 1 Ignition System Wiring Diagram 20 14 Thunderbolt V Service Procedures 2D 15 Setting Base Ignition Timing 2D 15 Adjusting Idle Mixture 2D 15 Adjusting Engine Idle Speed 2D 16 Thunderbolt V Engine Wiring Harness Diagram 20 17 Troubleshooting Thunderbolt V Ignition 20 20 Test Equipment 2D 21 Electrical Test Equipment Service 2D 21 3 0L EST Ignition System Operation 2D 21 EST Ignition 3 0L 3 0LX 2D 21 3 0L EST Circuits 2D 22 Timing Procedure 3 0 3 0 With Est Ignition
278. re checking or adjusting timing Also throttle must be advanced before con necting timing tool to avoid engine stalling The idle air control IAC valve closes air passage when engine is placed in the Service Mode when timing tool is installed 1 Connect timing light to 1 ignition wire 2 Adjust engine throttle to 1800 RPM 200 Necessary on MEFI 1 ECM s only 3 Connect timing tool to the Assembly Line Data Link ALDL connector which is located in the engine electrical box 4 Check and adjust timing in the normal manner Remove timing tool when finished timing engine a Timing Tool b ALDL Connector IGNITION SYSTEMS 2D 33 NOTES 2D 34 IGNITION SYSTEMS 90 883145 3 10 03 MERCRUISER ELECTRICAL SYSTEMS LEVEL I PF IGNITION SECONDARY Table of Contents Page Distributor 2E 1 Removal 2E 1 Inspection 2E 1 Rotor Sensor Wheel 2E 2 Removal 2E 2 Inspection 2E 2 Installation 2E 3 Spark Plug Wires 2E 4 Checking 2E 4 Replacing 2E 4 Distributor 2E 5 Checking 2E 5 Spark PIUS eee eae 2E 6 Checking 2E 6 Replacing 2E 7 2E i
279. rect proportion to air flowing through the secondary bores The float bowl is centrally located to avoid problems of fuel spillage causing engine cut out and delayed fuel flow to the carburetor bores The float bowl reservoir is smaller in design than most earlier 4 barrel carburetors to reduce fuel evaporation loss during engine shut down hot The float system has a single pontoon float and fuel valve for simplification and ease in servicing An integral fuel filter located in the float bowl ahead of the float needle valve is easily removed for cleaning or replacement The throttle body is aluminum to reduce overall weight and improve heat conduction to prevent icing A heat insulator gasket is used between the throttle body and bowl to prevent fuel percolation in the float bowl Many Quadrajet applications use a shim between the throttle body and flange gasket The shim is used to protect the carburetor aluminum throttle body from exhaust gasses flowing through the heat crossover passage in the intake manifold The primary side of the carburetor has six operating systems They are float idle main metering power pump and choke The secondary side has one main metering system plus accelerating wells on some models All metering systems receive fuel from the one float chamber NOTE The 4MV and 4MC Quaarajets are 4 barrel 2 stage carburetors Both the 4MV and 4MC are of the same design the only real difference being in the choke operatio
280. retor Exploded Parts View 3A 23 Rochester Quadrajet 3A 24 Float System 24 Rochester Quadrajet 25 Idle System 3A 25 Rochester Quadrajet 3A 26 Main Metering System 3A 26 Rochester Quadrajet 3A 28 Power System 3A 28 Rochester Quadrajet 3A 30 Air Valve Dashpots 3A 30 Rochester Quadrajet 31 Accelerating Pump System 3A 31 Rochester Quadrajet 3A 32 Choke System 3A 32 Weber Four Barrel Carburetor Exploded Parts View 34 Fuel Systems Carburetors 3A 35 Weber Carburetor 3A 35 Float System 35 Description 35 Weber Carburetor 3A 36 Idle 3A 36 Description 3A 36 Off idle operation 37 Weber Carburetor 3A 38 Main Metering System Primary Side 3A 38 Description 3A 38 Weber Carburetor 3A 39 High Speed Circuit Power 3A 39 Description 3A 39 Weber Carburetor 3A 40 Secondary Initial Discharge 3A 40 Descrip
281. returned for warranty Condensation will not cause the amount of damage found Inspect all starter motor failures for signs of water damage before sending it in for warranty Testing the Starter Motor with a Voltmeter Other than water damage low voltage is the number one cause of shortening the expected life of a starter motor Low voltage causes excessive heat to build up in the starter motor It can also cause starter motor solenoid contact problems Perform these tests before removing starter from the engine 1 An analog or digital voltmeter can be used but the digital meter is best NOTE Be sure to 0 meter before making the test and that the boat s battery is fully charged 2 Remove the coil wire from distributor cap and ground it so engine does not start 3 Connect voltmeter positive lead directly to the large threaded starter motor terminal that the battery positive cable is connected to 4 Connect voltmeter negative lead directly to an unpainted metal surface on starter housing 5 Crank engine over with key switch for about 10 15 seconds and watch the voltmeter 2B 10 STARTING SYSTEM 90 883145 3 10 03 90 883145 3 10 03 6 voltmeter reading of 9 5 volts more indicates that there is sufficient voltage being sup plied to the starter to operate properly a Ifthe starter does not function like it should there could be a problem with the starter or the engine Remove the spark plugs and tr
282. rim indicator e Raise and lower drive unit s several times to ensure that the trim limit point is properly marked POWER TRIM ELECTRICAL 2F 9 NOTES 2F 10 POWER TRIM ELECTRICAL 90 883145 3 10 03 MERCRUISER ELECTRICAL SYSTEMS LEVEL I PF QUICKSILVER DMT 2000A and DMT 2004 DIGITAL TACHOMETER MULTI METER INFORMATION Table of Contents Page QuickSilver Marine Parts amp Accessories 20 1 Mercury DMT2000A FAQ S 2G 2 DMT2000A Digital Tachometer Multi Meter Kit 2G 4 Meter Connections and Hook up 2G 5 Interface Module Battery Check 20 5 Tachometer Secondary Inductive lies 1o 20 6 Direct Voltage Adapter DVA Optional Accessory P N 91 89045 2G 7 Temperature Probe 20 8 Clamp On Current Probe Optional P N 91 802650 2G 9 2G i QUICKSILVER DMT 2000A DIGITAL TACHOMETER MULTI METER INFORMATION 90 883145 3 10 03 QUICKSILVZA Marine Parts amp Accessories Attention Dealers You know from your own marine service experience that outboard ignition systems are very noisy with lots of RFI interference Our new DMT 2000A Digital Tachometer Multi meter represents real breakthrough technology in the marine service industry It s the only meter on the marine market today designed to read accurately in high RFI environments The only meter that measures RPM on both 2 and 4 cycle marine engines while recording maximums a
283. rk plugs and torque to specifications Refer to Torque Specifications in this section 4 Install spark plug wires in proper order Refer to Engine Rotation and Firing Order and or Spark Plug Wires following IGNITION SECONDARY 2bE 7 NOTES 2E 8 IGNITION SECONDARY 90 883145 3 10 03 MERCRUISER ELECTRICAL SYSTEMS LEVEL I PF POWER TRIM ELECTRICAL Table of Contents Power Trim Electrical System Series V 1986 and UD aue mda parce mr tt es Power Trim Wiring Diagram Trim Pump Wiring Diagrams Model With Three Button Trim Trailer Panel Model With Trim In Handle and Trailer Switch Separate Trim Position Sender Adjustment Trim Limit Switch Adjustment High Performance Transom Assembly Without Electrical Trim Sender and Trim Limit Switch 2F i POWER TRIM ELECTRICAL 90 883145 3 10 03 NOTES 90 883145 3 10 03 POWER TRIM ELECTRICAL 2F 1 Power Trim Electrical System Series 1986 and Up The Oildyne pump is fitted with two solenoids as standard equipment Without the use of solenoids the smaller gauge wire in the control handle or the additional length of wire harness would cause too great a voltage drop for the pump motor to operate properly Current is supplied to the control panel or handle from the battery via the red lead and is protected
284. rogen gases that escape from the battery during charging are explosive When charging batteries be sure battery compartment or area where battery is located is well vented Battery electrolyte is a corrosive acid and should be handled with 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 prevent damage to electrical system be sure to adhere to following e When installing battery be sure to connect the POSITIVE battery cable to POS ITIVE battery terminal first and then the NEGATIVE battery cable to NEG ATIVE battery terminal Never disconnect the battery cables while the engine is running If a charger or booster is to be used be sure to connect it in parallel with existing battery positive to positive and negative to negative When applying a booster charge to battery disconnect both cables from battery to prevent damage to voltage regulator Check battery condition periodically Make sure that battery leads are kept clean and tight 90 883145 3 10 03 STARTING SYSTEM 2B 1 Typical Starting System Components YEL RED RE 72930 a Ignition Switch b 20 Amp Fuse c Starter Slave Solenoid d Circuit Breaker e Starter Motor f Neutral Safety Switch g 90 Amp Fuse h Engine Ground 2B 2 STARTING SYSTEM 90 883145 3 1
285. rom the pump discharge passage Rochester Quadrajet Choke System The Quadrajet choke valve is located in the primary side of the carburetor The closed choke valve provides the correct air fuel mixture enrichment to the engine for quick cold engine starting and partially open during the warm up period The thermostatic coil is located in the engine manifold and is connected by a rod to the intermediate choke shaft and lever assembly Choke operation is controlled by the combination of intake manifold vacuum the off set choke valve temperature and throttle position The thermostatic coil located in the engine manifold is calibrated to hold the choke valve closed when the engine is cold cont 34 32 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 During engine cranking the choke valve is held closed by the tension of the thermostatic coil This restricts air flow through the carburetor to provide a richer starting mixture When the engine starts and is running the engine manifold becomes heated it relaxes its tension and allows the choke valve to open further because of intake air pushing on the off set choke valve Choke valve opening continues until the thermostatic coil is completely relaxed at which point the choke valve is wide open 90 883145 3 10 03 FUEL DELIVERY SYSTEM AND CARBURETION 33 Weber Four Barrel Carburetor Exploded Parts View The Weber carburetor is a square bore design with eq
286. rs D7 3L 270 TURBO MOT NO 3000 3400 RPM PROPPING RANGE 123452123 6 1 Model amp Serial Number Plate 1B Serial Number Plate 2 Transom Serial Number 3 Drive Serial Number 4 Propeller Part Number 5 Propeller Pitch 6 Vessel Serial Number 7 Exhaust Gas Emissions Certificate Number 90 883145 3 10 03 USE OF SERVICE LITERATURE 14 3 Dealer Service Publications Dealer Publications and Starting Serial Number Guide 830571 Mercury Precision Parts and Quicksilver Accessories Guide dealer version 42000 XX US 814817 XX Canada consumer version 18379 XX US MerCruiser Special Tools Catalog 806737003 Installation Instruction Sheets 1A 4 USE OF SERVICE LITERATURE 90 883145 3 10 03 Dealer Operations Guide 827690 Dealer Propeller Guide 859429 XX Service Manuals Service Bulletins Parts Bulletins 90 883145 3 10 03 USE OF SERVICE LITERATURE 1A 5 Product Line Familiarization Sterndrives Ski Inboard 6 USE OF SERVICE LITERATURE 90 883145 3 10 03 MerCruiser Power Package Components Engines 496 MAGNUM 8 1 SIMILAR D N E F M G H L K 7 635 90 883145 3 10 03 USE OF SERVICE LITERATURE 1A 7 Exhaust Systems Typical Sterndrive Exhaust Components i m 1 SCA 726 72737
287. rtment Sparks generated by electrical tests could ignite gasoline vapors caus ing fire or explosion 1 Start engine and warm it up to normal operating temperature 2 Connect the positive lead from the DVOM to the PURPLE WHITE timing terminal that comes from the engine harness see previous wiring diagram Connect the negative lead from the DVOM to a good engine ground With the engine running there should be 8 10 volts on this circuit If voltage is not present check to ensure that there is 12 volts to the knock module PURPLE wire Terminal B 3 Advance the throttle to approximately 1500 RPM 4 Disconnect the harness connector BLUE wire from the knock sensor Connect the un powered test light to a positive 12 volt source To simulate an AC voltage rapidly tap the knock sensor harness terminal with the test light If knock module and wiring is func tioning properly you should see a voltage drop on the DVOM If a voltage drop is not seen check the BLUE wire from the sensor to the knock module for a short or open circuit If the circuit is functioning properly to this point the knock sensor may not be functioning Proceed to the following step the knock sensor harness connector to the sensor 6 While still watching the DVOM lightly and rapidly tap on the engine block near the knock sensor with a small hammer If the knock sensor is functioning properly you should see the voltage decrease If
288. s 93 5 Replacement Ignition Resistor Wires 93 6 Replacement Pistons 93 7 Crankcase Breather Kit 1994 MERCRUISER PARTS BULLETIN INDEX 94 1 Parts Manuals 94 2 Mark IV to Gen V Change Over Kits For 454 and 502 CID Engines 94 3 MOM 888 Holley Carburetor Replacement 94 4 V6 185 amp 205 Long Block Ordering Information 94 5 Replacement Weber Carburetors amp Components 1995 MERCRUISER PARTS BULLETIN INDEX 95 1 Delco PG260 Starter Motor Parts 95 2 V6 amp V8 Replacement Cylinder Heads 95 3 Trim Pump Supersession Super Speedmaster Drives 95 4 Bearing Kit For 55 Amp Mando Model AR150 Alternator 95 5 Prestolite Distributor Parts 95 6 Velvet Drive Borg Warner Transmissions 95 7 D7 3L 270 Turbocharger Rebuild Kit 95 8 Availability Of Water In Fuel Module 95 9 Modification Of The Piston And Piston Pin 95 10 MCM MIE D7 3L Turbocharger Waste Gate Rebuild Kit 95 11 Shift Spool for Aloha One Alpha One Generation 4 8 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 90 883145 4 0804 1996 MERCRUISER PARTS BULLETIN INDEX 96 1 Hino Turbocharger 96 2 Hino Cylinder Head Gasket 96 3 MCM MIE D4 2L Intercooler 96 4 Crankcase Breather Kit 96 5 Power Trim Valve Body Gear Assembly 392 7734 96 6 Black Max Alpha Performance Series Propellers 96 7 Zero Effort Control Quadrant Lever Re fitting Non Trim Switch Levers To Trim Switch Levers 96 8 Belt Driven Seawater Pump With Plastic Body Changes
289. s Inc pairable Buy a new digital volt meter lo 2449 Pierce Drive cally Meter must be of good quality with Spring Grove IL 60081 at least 10 meg ohms input impedance Phone 815 675 1812 or it may not allow the EFI Tester to Fax 815 675 2905 normalize 4 Thunderbolt Ignition Analyzer 91 62563A1 Meter 91 62562 Mark Tester 91 64645A1 Vendor Not Repairable Replacement parts are not available 90 883145 4 0804 BATTERIES WIRING 2 19 NOTES 2A 20 BATTERIES WIRING 90 883145 4 0804 MERCRUISER ELECTRICAL SYSTEMS LEVEL I 75818 STARTING SYSTEM Table of Contents Replacement Parts Warning Maintenance Typical Starting System Components orm Positive Current Flow 55 Amp Fuse Replaces Circuit Breaker Slave Solenoid Identification ate ede e eee Standard Type Slave Solenoid Switch Type Slave Solenoid Testing Replacement Solenoid Switch Periodic Inspection Delco PG260 Starter Motor Starter Specifications Torque Specification Lubricants Sealants Adhesives Description Identification Replacement Parts Warning Testing Starter Motors No Trouble Found or Wat
290. s The vacuum which results is exposed to various ports inside the carburetor as the throttle position changes Float System DESCRIPTION The carburetor float system controls the fuel level in the carburetor bowl Fuel level is very important be cause it must be maintained to give proper carburetor metering throughout all ranges of engine operation If the fuel level is to high in the float bowl problems such as rich mixtures affecting fuel consumption fuel spillage from the main discharge nozzles on turns and engine loading can result If the fuel level is lower than the specified setting it can cause lean mixtures hesitation on acceleration engine surge plus engine cut out during heavy fuel demands The float system operates as follows Fuel from the engine fuel pump is forced through the fuel inlet fitting 1 inlet filter 2 and on through the float needle seat 3 past the float needle 4 into the 90 883145 3 10 03 float bowl 6 Fuel flow continues until the fuel raises the float pontoon 5 to a position where it forces the float needle against the needle seat and shuts off fuel flow As fuel is used from the carburetor bowl during engine operation the float again drops downward moving the float needle off its seat allowing more fuel to flow into the float bowl thereby keeping the fuel level constant The float drop tang located at the rear of the float arm prevents the float from moving too far downw
291. s important to remember that a MAP sensor measures the manifold pressure above absolute zero like a barometer while a conventional vacuum gauge measures the manifold pressure below the current atmospheric pressure The use of the Manifold Absolute Pressure Sensor allows us to compensate for variations in atmospheric pressure due to weather and altitude changes A conventional vacuum gauge would not provide us with this needed information NOTE While the temperature of the air does affect its density not all engines use an IAT in take air temperature sensor If no IAT is present then the ECM assumes 75 degree Fahren heit for all density calculations If an IAT is present then the ECM can more accurately deter mine the air s density However the amount of correction the IAT adds is a relatively small amount approximately 1096 maximum change in fuel flow In review our standard unmodified production engines flow a repeatable and therefore known amount of air at any specific engine rpm and manifold pressure With this knowledge the ECM can be programmed to deliver the correct amount of fuel from the combination of the speed sensor distributor signal and density information from the MAP sensor It is often said that the speed density system runs in theory alone since the ECM doesn t really know how much air is flowing through the engine it is just assuming it knows how much based on the repeatability of airflow theory In r
292. s of fuel distribution and return lines above the level of the tank top from the tank to the carburetor inlet or its equivalent e g throttle body port fuel injection or a location where fuel leakage cannot enter the boat when the boat is in its static floating position 24 14 10 2 installing an anti siphon device at the tank withdrawal fitting or along the line with a rated siphon protection head and flow rate greater than required for the installation 24 14 10 3 installing an electrically operated valve at the tank withdrawal fitting or along the line connected to be energized open only when the engine ignition switch is on and the engine is running NOTE to 24 14 10 3 momentary type override 15 acceptable for starting 24 14 10 4 installing a manual shut off valve directly at the fuel tank connection arranged to be readily accessible for operation from outside the compartment if the fuel tank top is located below the level of the carburetor inlet and the fuel line is rigid metal or USCG Type 1 hose 24 14 10 4 1 Ifthe length of fuel line from the tank outlet to the engine inlet is greater than 12 feet 3 6m a second manual shut off valve shall be installed at the fuel inlet connection to the engine NOTE Readily accessible from outside the compartment includes a shut off valve installed at the tank close to and directly below an access port in the deck through which the valve can be operated 24 14 11 In
293. shall be subjected to the test described herein The tank to be tested shall be a complete assembly and include the fuel pick up tube fuel fill pipe and fuel gauge sender specified for the fuel tank 24 18 4 2 A single fuel tank design shown to be representative of a series of fuel tanks of similar design size and construction may be tested as representative of that series of fuel tanks 24 18 4 3 fuel tank shall be capable of withstanding exposure to a test fire without contributing to the fire due to leakage of the fuel contained therein NOTE For the purpose of this test slight vapor leakage will be permitted except in the tank shell if it can be shown that the path of leakage will not permit a fire outside the tank to ignite vapors within the tank 24 18 4 4 The fuel tank sample to be tested shall be provided with all the attachments specified by the manufacturer 24 18 4 5 As Installed Fire Test 24 18 4 5 1 This test shall be conducted to qualify fuel tanks intended to be installed in a particular model boat or series of boats where the construction of the tank is known and the installation of the tank is specified or otherwise controlled 24 18 4 5 2 fuel tank sample shall be installed in an actual or simulated hull section of sufficient size to simulate fire conditions aboard the boat bulkheads supports floors and other surfaces in the simulated fuel tank compartment shall be of the same material
294. shift cables 1 Install shift cable into remote control Refer to appropriate remote control instructions 3 90 883145 3 10 03 Loosen stud and move it to dimension as shown Retighten stud 71657 a Stud b 3 inches 76mm Center of Pivot Bolt to Center of Stud Install drive unit shift cable STERNDRIVE INSTALLATION 1C 33 Gua 71658 Washers 2 b Lock Nut Tighten Until Contact Then Back Off 1 2 Turn c Cotter Pin Insert from Top and Spread Both Ends 4 Place adjustment tool over drive unit shift cable as shown Hold tool in place using a piece of tape over the barrel retainer 71659 5 Locate center of remote control and control cable play backlash a Shift remote control to neutral b Push in on control cable end with enough pressure to remove play and mark position a on tube c Pull out on control cable end with enough pressure to remove play and mark position b on tube d Measure distance between marks a and b and mark position c half way between marks a and b 71656 IMPORTANT Be sure to keep center mark c aligned with control cable end guide edge when making the following adjustment 10 34 STERNDRIVE INSTALLATION 90 883145 3 10 03 6 Adjust control cable as follows a Temporarily install control cable end guide into shift lever and insert
295. shooting procedures visually inspect any questionable mating connector Mating surfaces should be properly formed clean and likely to make proper contact Some typical causes of connector problems are listed below 1 Improperly formed contacts and or connector housing 2 Damaged contacts or housing due to improper engagement 3 Corrosion sealer or other contaminants on the contact mating surfaces 4 Incomplete mating of the connector halves during initial assembly or during subsequent troubleshooting procedures 5 Tendency for connectors to come apart due to vibration and or temperature cycling 6 Terminals not fully seated in the connector body 7 inadequate terminal crimps to the wire Wire harnesses should be replaced with proper part number harnesses When signal wires are spliced into a harness use the same gauge wire with high temperature insulation only With the low current and voltage levels found in the system it is important that the best possible bond be made at all wire splices by soldering the splices as shown in the following illustrations Use care when probing a connector or replacing connector terminals It is possible to short between opposite terminals If this happens certain components can be damaged Always use jumper wires with the corresponding mating terminals between connectors for circuit checking NEVER probe through connector seals wire insulation secondary ignition wires boots nipples or covers
296. solenoid to energize the starter motor solenoid Some model en gines use the small terminal on the switch type solenoid for ignition by pass during the start ing of the engine Because of this be sure to use correct type of slave solenoid for replace ment Standard Type Slave Solenoid Starting Position Off or Run Position From Key Switch 12 Volts In Start Position To Ground 12 Volts From Battery 12 Volts To Starter Volts From Key Switch To Ground 12 Volts From Battery O Volts To Starter ooo Switch Type Slave Solenoid Starting Position Off or Run Position From Key Switch 12 Volts In Start Position Mounting Bracket and Ground 12 Volts From Battery 12 Volts To Starter 12 Volts to Ignition Coil Volts From Key Switch To Ground 12 Volts From Battery Volts To Starter Volts To Coil P20 TD 90 883145 3 10 03 STARTING SYSTEM 2B 5 Testing Replacement 1 Using continuity meter connect test leads as shown and connect 12 volt battery with jumper leads as shown 72630 2 f no meter movement is present replace solenoid Solenoid Switch The solenoid switch along with plunger return spring and shift lever are completely sealed and permanently mount ed in the drive housing If solenoid is defective entire drive housing must be replaced Periodic Inspection Cranking motor and solenoid are completely enclosed in the drive housing to prevent
297. sor Fuel Rate Gph Inj Pulse Width ms Spark Advance KS System Enabled KS Signal Knock Retard Knock 1 Knock 2 IAC Position Base IAC Position Shift Interrupt Troll Mode Not used by MC Troll RPM Limit Not used by MC IAC Follower Closed Throttle Vessel Speed MPH Not used by MC Battery V Voltage Warning Fuel Pump Relay Cause Power Reduction Not used by MC Power Reduction Overheat Detection Low Oil Pressure Switch Low Oil Level Switch Not used by MC Low Oil Lamp Not used by MC 3B 58 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 MEFI 3 Data Log Sheet DDT cont Data english units 13 Current Reading Comments General Warning 1 General Warning 2 General Warning 1 Lamp Not used by MC General Warning 2 Lamp Not used by MC Buzzer Lanyard Stop Check Gauge Lamp Not used by MC RPM Base Out Not used by MC ECM Status Fuel System Not used by MC Engine Hours total Run Time current run event 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 59 PCM 555 03 and ECM 555 Data Log Sheet DDT Engine Model Customer RO Type exhaust Altitude Ambient Temperature Data Item english units Engine RPM Battery Volts PWR 1 Volts PWR 2 Volts MAP PSI Fuel Level Available PWR Shift ECM 555 only Trim Pitot Paddle Wheel Lake Sea Temp F IAC PWM Spark Ang B ATDC Baro PSI STB EMCT F PCM only Port EMCT F PCM only Oi
298. st or corrosion is found after steps 1 3 place all loose parts in a sealed plastic bag Return starter motor and bagged parts with warranty claim 74041 All Delco Starter Motors a Short Screws PG260 Models Only b Long Screws STARTING SYSTEM 2B 13 Replacing Starter Motors When a starter motor is replaced retest the voltage at the starter motor to ensure that it is getting a minimum of 9 5 volts If a complete starter motor is needed for warranty replacement it must be ordered from Mer cury Parts The use of any other company s starter motor as a warranty replacement is not allowed Warranty Any starter motor returned for warranty that has either a no trouble found condition or signs of water being on the inside of it will have the warranty claim rejected and the part returned to the dealer 2B 14 STARTING SYSTEM 90 883145 3 10 03 MERCRUISER ELECTRICAL SYSTEMS LEVEL I P CHARGING SYSTEM Table of Contents Page Electrical Systems Charging System 2C 1 Identification 2C 1 System Components 2C 2 Alternator Block Diagram with Regulator Detail Typical 2 3 Alternator Block Diagram Typical 2C 3 Testing Alternator Output with a 2 4 5 2 4 No Trouble Found 2C 4 Testing the Charging System 2C
299. stem Models Test coolant to ensure that it will protect against freez ing to the lowest temperature expected during storage 12 Lubricate all items outlined in Lubrication 13 Service batteries Refer to manufacturer s instructions 14 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 ll or wipe down with Quicksilver Storage Seal or SAE 20W engine oil 15 For drive unit layup information refer to appropriate Sterndrive Manual Sterndrive unit should be stored in full down position Universal Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service WINTERIZATION AND RECOMMISSIONING 1G 3 Draining Instructions Typically consult service manual for a particular engine Single Point Drain System Some models are equipped with a single point drain system consisting of 2 hoses with hard ware and T handle retrieval tool shown below This system drains the seawater section of the engine only 76242 a T handle Retrieval Tool b Hoses If your engine is equipped with this device follow this procedure 1 Detach the hoses from the top fittings 76243 a Fittings 1G 4 WINTERIZATION AND RECOMMISSIONING 90 883145 3 10 03 2 Lower hoses into bilge If hoses have developed a set T handle retrieval tool can be 90
300. sting Follow equipment manufacturer s instructions regarding test period and meter readings Cranking Discharge Method With a Voltmeter attached to the battery Crank the engine for 15 seconds the battery voltage must be 9 6 Volts or higher at the end of the 15 second period Lower ambient temperature readings below 70 Fahrenheit will result in lower voltage readings 10 20 F 30 F 40 F 50 F 60 F 8 5V 8 V 8 9V 9 1v 9 3v 9 4v 9 5v 2A 4 BATTERIES WIRING 90 883145 3 10 03 Charging Guide 12 Volt Battery Recommended Rate and Time for Fully Discharged Condition Twenty Hour 5 10 20 30 40 50 Rating Amperes Amperes Amperes Amperes Amperes Amperes 2 2 1 2 Ampere Hours or 10 Hours 5 Hours H 2 Hours ours Above 50 to 75 7 1 2 3 1 2 2 1 2 1 1 2 Above 75 10 100 20 Hours 10 Hours 5 Hours 3Hous 21 2 2 2 Hours Ampere Hours Hours Above 100 to 150 30 Hours 15 Hours th d 5 Hours E 3 Hours Ampere Hours Above 150 20 Hours 10 Hours 6 12 5 Hours 4 Ampere Hours Hours Initial rate for constant voltage taper rate charger To avoid damage charging rate must be reduced or temporarily halted if 1 Electrolyte temperature exceeds 125 F 52 2 Violent gassing or spewing of electrolyte occurs Battery is fully charged when over a two hour period at a low charging rate in amperes all cells are gassing freely and no change in specific gravity occurs For the most sa
301. t Hole d Trim Tab Cavity Drain Passage e Gear Housing Water Drain Hole One Each Port and Starboard f Gear Housing Cavity Vent Hole Li a 5 g 70134 6 Crank engine over SLIGHTLY with starter motor to purge any water trapped in seawater pickup pump DO NOT ALLOW ENGINE TO START If boat is in the water is to remain in water seacock if equipped must remain closed until engine is to be restarted to prevent water from flowing back into cooling system If boat is not fitted with a seacock seawater inlet hose must remain disconnected and plugged to prevent water from flowing into cooling system and or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the seawater inlet hose reconnected prior to starting the engine 7 After cooling system has been drained completely coat threads of drain plugs with Quick silver Perfect Seal and reinstall Tighten drain plugs securely Reconnect hoses and tight en all hose clamps securely If NOT equipped with seacock seawater inlet hose must remain disconnected and plugged until engine is to be restarted IMPORTANT MerCruiser recommends that propylene glycol antifreeze nontoxic and biodegradable which makes it friendly to lakes and rivers be used in seawater section of the cooling system for cold weather or extended storage Make
302. t will not slide all the way into bell housing ensure that the shift shaft and couplers are positioned properly Do not force drive unit into position O 75199 le la 70010 Gasket b Shift Slide c Shift Slide Stabilizer Tool e If necessary rotate propeller shaft counterclockwise slightly to help align U joint shaft splines with engine coupler splines Then slide drive unit all the way into bell housing f Secure drive unit to bell housings using fasteners as shown Torque to 50 lb ft 68 Nm 22062 Locknut and Flat Washers b Locknut and Continuity Circuit Washer No flat washer at this location 15 Return remote control shift lever to the neutral position 90 883145 3 10 03 STERNDRIVE INSTALLATION 1C 5 16 Install trim cylinders end of drive unit NOTE Upon installation of hardware apply Quicksilver 2 4 C Marine Lubricant with Teflon to all components except plastic caps a Insert one bushing in each inboard hole of both trim cylinders b Align the bores of trim cylinders with that of the drive unit c Insert the aft anchor pin through the port trim cylinder drive unit bore and starboard trim cylinder until it protrudes equally 70026 a Aft Anchor Pin b Bushings NOTE Distance between trim cylinders and drive unit anchor pin bore is exaggerated for visual clarity d Install the two remaining bushings onto the aft anchor pin ends and fit i
303. ter motor solenoid to see if it is getting at least 9 5v from the slave solenoid during cranking Low voltage at the starter solenoid can cause intermittent operation of the solenoid contacts and shorten the life of it a Connect the voltmeter lead to the terminal on the starter solenoid that has the YEL HED wire from the slave solenoid connected to it Connect the voltmeter lead to unpainted surface of the starter housing b Crank engine over and watch the voltmeter If the starter solenoid is not getting 9 5v the YEL RED wire or the slave solenoid could be the cause of the low voltage 2B 12 STARTING SYSTEM 90 883145 3 10 03 Water or Corrosion Inspection 90 883145 3 10 03 1 Delco PG260 models only remove 2 short screws from the end cap and look at the threads a If they are clean and gold color the starter motor did not have water inside of it b Ifthey are dirty and black or gray in color the starter motor may have had water on the inside of it go to step 2 Remove the 2 long bolts to disassemble and inspect the inside of the starter motor a Heavy rust and corrosion inside the starter motor indicates water damage b If starter motor has little or no signs of rust or corrosion on the inside go to step 3 Remove starter solenoid Look at condition of solenoid plunger grease a Brown or red rust colored grease or if the plunger is rusty solenoid has been under water If no signs of ru
304. th 84 822560A 6 84 822560A 7 All Hi Performance 2 0L 2 5L Outboards with 11350A ECM only Use with 84 822560A 7 84 822560A 8 25 40 hp 4 cycle Outboards Use with 84 822560A 7 84 822560 10 Extension Harness 2 pin 4 57 m 15 ft Use with 84 822560A 5 84 822560T 11 2000 Digital OptiMax Outboards only This T Harness allows the DDT 84 8752327 1 to be connected under the dash at the 5 pin tachometer harness outlet For Verado 200 275 hp adapts flat 4 pin connector to 2 pin 84 822560A5 harness 200 275 hp 4 Cycle Outboards 4 pin connectors no additional 84 822560A13 harness required 225 EFI FourStroke Not for use with the DDT 84 822560A14 CAN 1 diagnostics cable Connects into a junction box or male to male adapter cable for Command Module configuration Not for use with the 84 892663 DDT Male to male adapter cable Allows connection between CAN 1 communications cable and Command Module harness in applications 84 892452A01 where a junction box is not used Mercury Mariner Outboard Injector Test Harnesses 1986 and up 2 4L 2 5L 3 0L EFI Outboards Use with 84 822560A 7 1982 and up Hi Performance 2 0L 2 4L 2 5L 3 4L EFI Outboards Use 84 830043A 1 with 84 830043A 2 1982 and up Hi Performance 2 0L 2 4L 2 5L 3 4L EFI Outboards 84 830043A 2 including Offshore models Use with 84 830043A 1 MerCruiser Adapter Harnesses Harnesses are purchased from Mercury Precision Parts 2004
305. th corrosion resistant metallic clamps NOTE Some hose that meets the requirements of UL 1114 is not designed to be clamped 24 11 2 The ID of a hose and the OD of a connecting spud or fitting must meet the specification in Table II 24 11 3 Hose shall not be installed on helical threading or knurling that provides a path for fuel leakage 24 11 4 Clamps depending solely on the spring tension of the metal shall not be used 24 11 5 Clamps shall be installed to impinge directly on the hose and shall not overlap each other 24 11 6 Clamps shall be beyond the flare or bead or fully on serrations where provided and at least 1 4 inch 6mm from the end of the hose 24 11 7 Hose used in the fuel tank fill system shall be secured to pipes smooth pipes acceptable spuds or other fittings at each connection by at least two metallic clamps with nominal band widths of at least 1 2 inch 12mm 24 11 8 Hose used in the fuel tank vent system or the fuel distribution and return line system shall be secured to a mating spud pipe or fitting that 15 formed or machined to provide serrations at least 0 015 inch 0 38mm depth or a 1996 American Boat amp Yacht Council Inc 4 3A 50 FUEL DELIVERY SYSTEM AND CARBURETION bead At least one corrosion resistant metallic clamp shall be used with a minimum nominal band width as indicated in Table III 2412 FUEL FILL SYSTEMS 24 12 1 Separation between compartment ventilation openin
306. the engine s speed and the intake manifold s air density in order to calculate the correct amount of fuel to inject The engine requires an air fuel mixture of approximately 14 7 to 1 in the combustion cham bers Since the EFI system doesn t control air flow it must determine how much air is flowing through the engine in order to calculate the correct amount of time to fire the fuel injectors The net result is that there must be 1 part of fuel for every 14 7 parts of air going through the engine Since the engine is basically an air pump we know that an engine is capable of pumping certain maximum amount of air at any specific rpm The actual amount of air it pumps at a specific rpm depends on the density of the air in the intake manifold The air density in the intake manifold will vary depending on rpm throttle plate position and barometric pressure If the air density in the intake manifold is known the actual amount of air flowing through the engine the Air Mass or Mass Air Flow could be calculated This calculated and the actual air flow is a repeatable function meaning that at a specific and a specific manifold absolute pressure reading the air flow through the engine will always be the same However in the speed density system we do not actually calculate the actual air flow Instead the ECM measures the rpm and the air density then refers to a programmed lookup table in the ECM s EEPROM This lookup tab
307. the inside of the cup into the bottom of the pump well This also vents any vapors which may be in the bottom of the pump well so that a solid charge of fuel can be maintained in the fuel well beneath the plunger head When the primary throttle valves are opened the connecting linkage forces the pump plunger downward The pump cup seats instantly and fuel is forced through the pump discharge passage where it unseats the pump discharge check ball 13 and passes on through the passage 8 to the pump jets 5 located in the air horn where it sprays into the venturi area of each primary bore cont FUEL DELIVERY SYSTEM AND CARBURETION 3A 31 should be noted the pump plunger is spring loaded The upper duration spring 6 is balanced with the bottom pump return spring 12 so that a smooth sustained charge of fuel is delivered during acceleration The pump discharge check ball seats in the pump discharge passage during upward motion of the pump plunger so that air will not be drawn into the passage otherwise a momentary lag in acceleration could result During high speed operation a vacuum exists at the pump jets A cavity just beyond the pump jets 3 is vented to the top of the air horn outside the carburetor bores This acts as a suction breaker so that when the pump is not in operation fuel will not be pulled out of the pump jets into the venturi area This insures a full pump stream when needed and prevents fuel pull over f
308. tification 02 9 Lack of Serpentine Belt Adjustment 02 10 SmartCraft Communication Problem 02 11 Uneven or Increased Handle Effort After Control Installation Commander 3000 Classic Panel Mount Remote Control 02 12 New Minimum EFI and MPI Cranking Battery Requirements 02 13 MerCruiser Product Changes Related to SmartCraft 4 6 MERCRUISER APPLICABLE SERVICE BULLETIN LIST 90 883145 3 10 03 03 01 03 02 03 03 03 04 03 05 03 06 03 07 03 08 03 09 2003 MERCRUISER DEALER SERVICE BULLETIN INDEX Required MCM and MIE Water Inlet Hose Replacement Aftermarket Replacement Aluminum Anodes Cracked or Broken Brass Trim Pump Adapter Fittings Serpentine Belt Shredding on Inboard Models Replacement Quick Oil Drain Components V6 and V8 GMEFI with No Start Engine Miss Fire or Engine Shut off Conditions Required MCM Power Steering Return Hose Replacement 4000 4500 GEN II Control Box Official Notification U S Federal Boat Safety Act MCM Shift Plate Cable Attaching Hardware 03 10 1 Hairpin Cotter 18 859746 is NLA 03 11 03 12 03 13 03 14 04 01 04 02 04 03 04 04 90 883145 4 0804 MCM Rear Engine Mount Design Change Propeller Failures and Guidelines Outboards 2 5 through 250 Alpha Bravo One Bravo Two Bravo Three Sterndrives Propellers 3 0L LX Service Replacement Crankshaft Change Service Repair of Electrical Test Equipment replaces Service Bulletin 97 13 2004 MERCRUISER DEALER SERVICE BULLETIN INDEX
309. tion 40 Weber Carburetor 3A 41 Auxiliary Valve Operation 41 Description 41 Weber Carburetor 3A 42 Accelerator Pump 42 Description 42 Weber Carburetor 3A 43 EMISSIONS 3A 43 Idle circuit 43 Emissions high speed circuit 3A 44 ANSI ABYC Standard H 24 3A 45 Turn Key Start TKS System 3A 63 Service and Parts Bulletins 3A 68 Service Bulletins 68 Parts Bulletins 3A 68 90 883145 4 0804 Fuel Recommendations FUEL RATINGS IMPORTANT Use of improper gasoline can damage your engine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and damage caused thereby will not be covered under the limited warranty USA and Canada MerCruiser engines with the exception of the early Black Scorpions specified below in the USA and Canada will operate satisfactorily when using a major brand of unleaded gasoline having a MINIMUM pump posted Octane Rating of 87 AKI anti knock index which is the average of the RON research octane number and the MON motor octane number Federal regulations mandate that you DO NOT use leaded gasoline in the USA and Canada Higher octane fuels can be used on all mod
310. tion TKS Carburetor w mounting gasket Oil pressure switch with fittings Coolant temperature switch with fittings New thermostat housing Engine harness jumper Flexible fuel line Installation Instructions 90 883145 4 0804 FUEL DELIVERY SYSTEM AND CARBURETION 3A 67 Service and Parts Bulletins For subjects covered in the Fuel Delivery System and Carburetion Section Service Bulletins 91 28 Required Water Separating Fuel Filter Replacement 92 5 Required Warning Decal Installation 92 15 Official Notification under the U S Federal Boat Safety Act Required Fuel Pump RFI Filter Replacement 93 5 Required Fuel Pump Push Rod Replacement 93 15 Rochester 4 Barrel Quadrajet Carburetor 94 12 Gasoline Recommendation Changes Number 1 and 2 94 15 Official Notification under the U S Federal Boat Safety Act Required Engine Fuel Filter Replacement 97 8 MerCarb 2 Barrel Carburetor 97 9 Weber 4 Barrel Carburetor 97 17 Engine Dieseling and Running On 98 4 Electric Fuel Pump Check Valve Sticking 98 5 USA Gasoline Additive Causing Fuel System Component Problems 99 7 Gasoline Engine Vapor Locking Rev 1 01 99 8 EFI MPI Fuel Pumps with Low Pressure 00 5 Official Notification under the U S Federal Boat Safety Act Stainless Steel Fuel Pumps 01 4 Priming Fuel System 01 5 496 8 1 Fuel Line etc 02 2 Inline Fuel Filter Kit 02 3 Required Boost Pump Installation 04 01 Electric Fuel Pump Troublesho
311. tion Sensor CPS ff Cam Position Sensor CMP gg Inputs hh PCM 555 Controller ii Outputs jj Input Output 90 883145 3 10 03 Abbreviations Amp Amperes C BARO Battery Positive B n ho CA Camshaft cond cont P V 2 I We NU ME Crank Crankshaft K C C CM 5 C Cylinder D Digital Diagnostic Tester IAT KS mA MP MA MA MI N N PC A O Dist Biagio Distributorless Ignition System PCM A A C G N R Battery Positive Terminal Battery or System Voltage Distributor PROM JJ TI DVOM Digital Volt Ohm Meter DM Digital Multimeter DM Digital Multimeter amp Tachometer E Engine Control Module E E ENGT EM Ec Electronic Electronic Throttle Control High Energy Ignition High Voltage Switch Engine Coolant Temperature TACH t N 5 J a AN T R P T S L yl Data Link Connector TC Diagnostic Trouble Code REF HI T 5 p C C S M T 15 GND HVS Idle Air Control Intake Air Temperature Ignition Control Ignition Inches of Mercury Injection Kilopascal Knock Sensor System Kilovolts Milliamperes Main Power Relay Manifold Absolute Pressure Manifold Air Temperature Malfunction Indicator Lamp Milliohms Millisec
312. tions are not known 24 18 4 6 2 The fuel tank sample is to be supported in a test enclosure as shown by Figure 1 if the fuel tank is intended for below deck installation or in a test enclosure as shown in Figure 2 if the tank is intended for above deck installation 24 18 4 6 3 The side supports of the fuel tank sample are to be spaced to support the fuel tank ends and at each fuel tank baffle and are to be formed to maintain the fuel tank sample 2 inches 50 8mm away from the inside surface of the simulated hull side panel 24 18 4 6 4 supports for the bottom of the fuel tank sample are to be located in the same manner as the side supports and are to be formed to maintain the fuel tank sample 3 inches 76 2mm above the inside surface of the enclosure 24 18 4 6 5 The fuel tank sample is to be secured to the test enclosure by steel straps The top of the test enclosure shall be formed so that the maximum fuel tank s sample set back does not exceed 2 inches 50 8mm and the clearance between the top of the test enclosure and the top of the fuel tank sample is not less than 7 inches 177 8mm nor more than 34 inches 863 6mm 24 18 4 6 6 The area of the enclosure beneath the fuel tank sample is to serve as the fuel reservoir and shall be formed so that the surface of the test fuel extends 6 inches 152 4mm beyond the fuel tank sample ends and 2 inches 50 8mm beyond the exposed front surface of the fuel tank sample
313. tisfactory charging the lower charging rates in amperes are recommended Full charge specific gravity is 1 260 1 280 corrected for temperature with electrolyte level at split ring Battery Power as Affected by Temperature 80 F 27 C 100 32 F 0 C 0 18 20 45 29 74310 Power Watts Available Power Watts Required 90 883145 3 10 03 BATTERIES WIRING 2A 5 NOTES 2A 6 BATTERIES WIRING 90 883145 3 10 03 Wiring Colors for MerCruiser 90 883145 3 10 03 NOTE Color codes listed below DO NOT apply to fuel injection system harnesses ABBREVIATIONS Reference Electrode MerCathode Trim Up Switch Trim Down Switch Trim Trailer Switch YELLOW RED YEL RED Sel Switch to Starter Solenoid to Neutral Start TAN BLUE TAN BLU Audio Warning System Also Electric Chokes on models so equipped NOTE Yellow used as GROUND wire color in Europe and by some North American Boat builders NOTES BATTERIES WIRING 2A 7 Wiring Harness Service Wire Repair Marine engine control circuits contain many special design features not found in standard land vehicle wiring Environmental protection is used extensively to protect electrical contacts and proper splicing methods must be used The proper operation of low amperage input output circuits depends upon good continuity between circuit connectors Before component replacement and or during normal trouble
314. tle are factory mounted However proper hose routing and connection are required for the system to operate The following information is provided to assist in understanding the system Refer to the Installation Manual packaged with the power package for more information 1B 8 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 TYPICAL MONITOR CONNECTIONS IMPORTANT Avoid using excessive hose when routing to gear lube monitor Hose should be routed directly to gear lube monitor in as straight a line as possible to avoid low spots traps in the system Ensure that hose is not kinked when connected If hose is kinked gear lube monitor will not function properly and damage to sterndrive unit could occur Secure with hose clamp after properly routing the hose SS ee 71982 181 cid 3 0L Model a Gear Lube Monitor b Hose c Clamp N 17 E 2 D N x 7 jj if ay A m A 195 75847 262cid 4 3L With Single Piece Manifolds a Gear Lube Monitor 90 883145 3 10 03 ENGINE INSTALLATION AND ALIGNMENT 1B 9 76230 305 cid 5 0L and 350 cid 5 7L a Gear Lube Monitor On 454 cid 7 4L and 502 cid 8 2L Models also secure hose with J Clip that is attached to the valve cover 71991 75444 454 cid 7 4L and 502 cid 8 2L Models a Gear Lube Monitor b Hose c J Clip on Valve Cover Depending upon application ext
315. to provide source of known quality fuel or to bypass boat fuel system required Should be used only by trained Marine Technicians and only for short term diagnostic purposes Used for both pressure and vacuum tests Gauge Guard is not necessary Reads from absolute zero to 199 9 PSI 3 Can be used to apply slight pressure to test fuel systems for leaks 4 Must have a minimum of 100 milliamps draw but not more than 300 milliamps 5 Contains six tools for removal of terminal pins from harness blocks 6 7 8 1 Such the Ferret 80 series from Stevens Instruments OTC and other suppliers euch as Snap On MT14GS15SV Used to listen to fuel injectors air leaks fuel pump s and IAC operation Used to check fuel pressure regulators for leakage and to attach vacuum gauge Used to check the VST vent line for the presence of raw fuel Tool Manufacturers Cole Parmer Instrument Co Rinda Technologies OTC Tools SPX Corporation Fluke Corp 800 323 4340 4563 N Elston Ave 655 Eisenhower Drive P O Box 9090 847 549 7600 Chicago IL 60630 Owatonna Minnesota 55060 Everett WA 98206 9090 847 247 2929 FAX 773 736 6633 800 533 0492 800 443 5853 847 549 1700 International FAX Fax 773 736 2950 Fax 800 283 5665 Kent More Tools SPX Corporation Stevens Instruments SPX Service Repair J tools 111 Greenwood Avenue 2800 Park Drive 29784 Little Mack Waukegan Illinois 60079 9375 Owatonna MN 55060 Roseville MI 48066 847 336
316. tored while the engine is running to aid in diagnosis and will display any stored trouble codes On MerCruiser engines the DDT is used to set the base engine timing on MEFI 1 2 3 ECM models 75722 3B 48 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 Ordering DDT Scan Tool 91 823686A 2 Digital Diagnostic Terminal DDT Mercury Mariner Outboard Cartridges 91 822608 6 91 880118 1 v5 0 For non PCM 555 Outboards v1 1 For PCM 555 Outboards Used on MerCruiser also Mercury Mariner Outboard Adapter Harnesses 84 822560A 1 84 822560A 5 84 822560A 6 84 822560A 7 84 822560A 8 84 822560A10 84 822560T11 84 8752321 1 Mercury Mariner Outboard 84 830043A 1 84 830043A 2 MerCruiser Cartridges 91 803999 91 880118 1 90 883145 4 0804 1994 3 0L Carb Engines 1994 1 2 and up 2 5L EFI with 824003 ECM only 1994 1 2 Pro Max Super Max Super Magnum 1997 and up DFl OptiMax Outboards 1995 and up 3 0L EFI and Carb Outboards Use with 84 822560A 7 1995 and up 3 0L EFI and Carb Outboards Use with 84 822560A 6 All Hi Performance 2 0L 2 5L EFI Outboards with 11350A ECM only Use with 84 822560A 7 25 40 hp 4 cycle Outboards Use with 84 822560A 7 Extension Harness 2 pin 15 ft 4 57 m long Use with 84 822560A 5 2000 Digital OptiMax Outboards only This T Harness allows the DDT to be connected under the dash at the 5 pin tachometer harness outlet
317. ts one side of the oil pressure switch to the electrical harness The purple wires in the harness are supplied current when the key switch is in the run position When the engine is running oil pressure 4 psi holds the contacts inside the oil pressure switch closed Current will pass through the closed contacts and on to the purple yellow wire connecting to the fuel pump During starting the oil pressure switch is open due to little or no oil pressure To engage the starter the starter solenoid is activated by current through the yellow red wire With the solenoid activated a metal disk inside the solenoid connects the positive battery terminal to the purple yellow wire This connection bypasses the oil pressure switch and supplies current to the fuel pump Fuel Pressure 3 9 psi Electric Fuel Pump RFI Filter Replacement S B 92 15 oticking Fuel Pump Check Valves S B 98 4 Gasoline Additive Problems S B 98 5 1 To Key Switch gt Rey STARTER SLAVE SOLENOIDS CIRCUIT CA BREAKER 3 i b OIL 7 PRESSURE SWITCH KiS lt FUEL PUMP BLK Black ORN Orange PUR Purple RED Red YEL Yellow ELECTRIC CHOKE 2 BARREL ONLY SW 3A 8 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 MerCruiser Carburetor Adjustments 1 Float level affects air fuel ratios at all engine speeds and loads 2 Float drop ensures
318. ts per cell 7 2 volts on a standard 12 volt battery The higher the number the more amps it can deliver to crank the engine CCA x 1 3 MCA Marine Cranking Amps MCA This figure is similar to the CCA test figure except that the test is run at 32 Fahrenheit instead of 0 MCA x 77 CCA This is more in line with actual boat operating conditions Reserve Capacity This figure represents the time in minutes that a fully charged battery at 80 Fahrenheit can deliver 25 amps without dropping below 1 75 volts per cell 10 5 volts on a standard 12 volt battery The reserve capacity rating defines the length of time that a typical vehicle can be driven after the charging system fails The 25 amp figure takes into account the power required by the ignition lighting and other accessories The higher the reserve capacity rating the longer the vehicle could be driven after a charging system failure Amp Hour Rating 90 883145 3 10 03 The ampere hour rating method is also called the 20 hour rating method This rating repre sents the steady current flow that the battery will deliver for 20 hours while at 80 Fahrenheit without dropping below 1 75 volts per cell 10 5 volts on a standard 12 volt battery The rating is actually the steady current flow times the 20 hours Example A 60 amp hour battery will deliver 3 amps continuously for 20 hours BATTERIES WIRING 2A 1 The following battery charts list the minimum cca m
319. ttery voltage 12 Volts 1 2 volts less than battery voltage Reconnect WHT RED bullet connectors Remove High Tension Lead from Dis tributor to Coil Insert a Spark Gap Tester from Coil Tower to Ground Dis Replace Ignition connect WHT GRN Lead from Distrib Spark Sensor in utor Place Ignition Key in RUN Posi at Coll tion Rapidly strike the Terminal of the WHT GRN Lead that comes from mod ule against Ground See IMPORTANT below No Spark at Coil Substitute a New Ignition Coil Spark Install New Repeat Above Test at Coil Ignition Coil No Spark at Coil Replace Ignition Module R1000 IMPORTANT The WHT GRN lead must be touched against ground 2 3 times per second to simu late a running engine Repeat this test several times to ensure that spark is present Distributor 90 883145 3 10 03 IGNITION SYSTEMS 2D 5 Thunderbolt Ignition System Wiring Diagram IGNITION SWITCH FE SAFETY J VOLTMETER SWT GH WIRING HARNESS WATER TEMPERATURE 4 S M gt 3 26d43g3c lt e CISEIZT OIL 2 p PRESSURE SHIFT halons aah CUTOUT SWITCH IGNITION AMPLIFIER OIL PRESSURE SENDER TRIM SENDER IGNITION COIL BLK TEMPERATURE SENDER ALTERNATOR STARTER SLAVE CIRCUIT BREAKER _ GROUND STUD 2 BARREL ONLY 4221
320. turn it to the mounting bracket 13 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 14 Before launching boat pull up on manual release valve Verify that green indicators are no longer extended 77638 a Green Indicators 15 Open the seacock prior to operating the engine 90 883145 3 10 03 WINTERIZATION AND RECOMMISSIONING 1G 15 3 POINT MANUAL DRAIN SYSTEM NOTE Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails 1 Close the seacock 2 Remove three blue drain plugs One from the distribution housing lower front port side and two from the seawater pickup pump front starboard side a Blue Drain Plugs 3 Immediately remove the blue drain plug from the side of the thermostat housing This must be removed within 30 seconds to properly vent the cooling system 77949 Blue Drain Plug Location 4 Verify that water is draining from each opening 5 Allow the system to drain for a minimum of 5 minutes Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance 6 Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump Do NOT allow the engine to start 7 Prior to launching bo
321. ual size primaries and secondaries The square bore design provides better air fuel distribution for improved low end and mid range response The mid range transition is controlled by a weighted air valve and is not adjustable eo nm of v a 9 NN Ge 000 Air Deflector 2 Screw 2 Cover Metering Rod 2 Metering Rod Assembly 2 Spring Metering Rod 2 Fuel Inlet Fitting Sealing Washer Screw Linkage Rod Choke Pull Off 10 Screw 11 Air Horn Carburetor Top 12 Filter Fuel Inlet 2 13 Gasket 2 14 Seat Fuel Inlet 2 15 Needle Valve Fuel Inlet 2 16 Pin 2 17 Float 2 18 Secondary Venturi Cluster 2 19 Baffle Plate Float Bowl 2 20 Screw 4 21 Primary Venturi Cluster 2 22 Gasket 2 23 Jet Primary Fuel 2 24 Screw 2 25 Fuel Pump Injector Housing 26 Gasket 27 Check Weight or Check Spring if So Equipped 28 Check Ball 29 Screw 30 Diaphragm Choke Pull Off 31 Vacuum Hose 32 Idle Mixture Screw 2 33 Spring Idle Mixture Screw 2 34 Gasket Carburetor Base 35 Linkage Rod Choke Plate 36 S Link 37 Accelerator Pump Lever 38 Screw 39 Linkage Rod Accelerator Pump 40 Wire Clip 41 Wire Clip 42 Gasket 43 Screw 4 44 Gasket 2 45 Jet Secondary Fuel 2 46 Secondary Air Valve
322. ule is on engine Acceleration Advance Envelope Advance Envelope Not on Tournament Ski engines 2D 10 IGNITION SYSTEMS 90 883145 3 10 03 NOTES 90 883145 3 10 03 IGNITION SYSTEMS 2D 11 Ignition Systems Thunderbolt V Circuit Description Refer to the circuit wiring diagram on the following page for reference to this circuit descrip tion Ignition Control Module The ignition module receives its power thru the PURPLE wire 9 Ignition module ground is accomplished thru the BLACK wire 10 There is also a Case Ground wire 12 that is connected to one of the ignition module attaching screws Later versions are grounded through the module mounting tabs The 12 volt signal from the ignition module to the distributor is carried thru the WHITE RED wire 8 to the distributor sensor and back to the ignition module thru the WHITE GREEN wire 7 The tachometer signal is carried to the instrument panel thru the GRAY wire 11 The PURPLE WHITE wire 3 carries the signal from the knock contro module to the igni tion control module There are two BLACK wires 5 that have bullet connectors This circuit is reserved for future options On current models the two BLACK wires must be connected for the system to function properly The TAN BLU wire 6 carries a signal from the Audio Warning circuit to the ignition module Knock Control Module The knock
323. und stud to prevent a possibility of a spark from the disconnected spark plug wires IMPORTANT When using a Remote Starter tool to crank the engine over some engines may have the ignition coil energized by the R terminal in the starter solenoid even though the key switch and the Lanyard Stop Switch are in the off position Tool Required 71089 Remote Starter Kit 91 52024A1 Fill crankcase to proper level with the recommended engine oil Remove spark plugs Leave ignition key in OFF position A WN gt Connect remote starter switch to large 12 V terminal RED battery cable and small terminal YELLOW RED wire on starter motor a lf remote starter switch is not available disconnect PURPLE wire from ignition coil before using key switch to crank the engine over Tape terminal on PURPLE wire to prevent it from touching ground 5 Crank engine for 15 seconds then allow starter motor to cool down for 1 minute This should prevent starter motor from overheating Repeat this process until a total of 45 seconds of cranking time is achieved 7 Remove remote starter switch a If key switch was used reconnect PURPLE wire to ignition coil 8 Install spark plugs and wires 9 Supply cooling water to seawater pump and start motor 1B 18 ENGINE INSTALLATION AND ALIGNMENT 90 883145 3 10 03 MERCRUISER EN PDI AND MAINTENANCE LEVEL I STERNDRIVE INSTALLATION Table of Contents Alpha Sterndrive
324. upper well area When this occurs they become air bleeds mixing progressively more air with the fuel passing through the main well tubes Therefore although the nozzle suction is increased at higher engine speeds the air fuel mixture to the engine remains constant throughout part throttle range 34 38 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 Weber Carburetor High Speed Circuit Power DESCRIPTION 90 883145 4 0804 The power system in the Weber carburetor provides extra mixture enrichment to meet power requirements under heavy load and high speed operation The richer mixtures are supplied through the main metering system The spring loaded power piston 7 located in the cavity of the air horn directly above the main jet 1 is held in the down position by engine manifold vacuum supplied directly through a connecting passage from the base of the carburetor The power system is exposed to manifold vacuum at all times During idle and cruising ranges the relatively high engine vacuum holds the power piston and metering rod in the down position against tension of a calibrated spring located on the power piston stem During this period the metering rod limits the amount of fuel allowed through the main jet Increases in engine load lower the manifold vacuum When it has dropped sufficiently the power piston spring overcomes the downward vacuum pull and the power piston moves upward lifting
325. upport flanges and cause damage to sterndrive unit 1 Adjust trim limit switch as follows a Loosen screws and turn trim limit switch clockwise to end of slots 71221 Screws b Slots b Ensure drive unit is in the full DOWN IN position c Using the Trim button on the control trim drive unit UP OUT DO NOT USE TRAILER BUTTON POWER TRIM ELECTRICAL 2F 7 9 Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown Refer to illustration below 71221 a Rotate Counterclockwise to Adjust e Retighten screws when adjustment is correct 21 3 4 Max 554mm Figure 1 Earlier R MR Alpha One Models b 20 3 4 in Max 520mm Figure 2 Alpha One Generation II Models d 50464 21 3 4 Max 554mm Figure 3 Bravo Models 2F 8 POWER TRIM ELECTRICAL 90 883145 3 10 03 High Performance Transom Assembly Without Electrical Trim Sender and Trim Limit Switch 90 883145 3 10 03 IMPORTANT The electrical Trim Limit Switch and Trim Position Sender are not present on this transom assembly Without a Trim Limit Switch the drive unit can be trimmed up out beyond the position where the drive unit has side support from the gimbal ring at any throttle setting It is highly recommended that a mechanical cable actuated Trim Position Indicator be installed to provide important drive unit trim angle informa tion to the operator and that the
326. ure in the venturi area causing fuel to flow As the throttle valves 2 are opened beyond the off idle discharge slots allowing more air to enter the intake manifold and engine speed to increase the vacuum decreases below the throttle valves and the off idle gradually diminishes With the increased throttle opening there is an increased air velocity in the venturi system This causes a drop in pressure in the main venturi which is increased many times in the boost venturi 7 fuel will flow in the following manner The low pressure in the boost venturi is transmitted to the tip of the main well tube 9 or main discharge nozzle 5 Atmospheric pressure which is greater forces fuel from the float bowl through the main metering jets 1 and into the main well 3 As the fuel passes through the main well tubes 4 it is mixed with air from the calibrated main well bleeds 6 The fuel mixture then passes from the tip of the discharge nozzle through the mixture passage to the boost venturi and on into the intake manifold As the throttle valve opening is increased and more fuel is drawn through the main well tubes the fuel in the main well drops The calibrated holes in the main well tubes are proportionately exposed to the air in the upper well area When this occurs they become air bleeds mixing progressively more air with the fuel passing through the main well tubes Therefore although the nozzle suction is increased at higher engine sp
327. w 1 Install steering cable and secure with hardware as shown 2 Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical posi tion Torque coupler nut to 35 Ib ft 47 N m Be certain the flat surfaces are still aligned vertically after torque is applied to coupler nut This is done to assure prop er internal alignment of the oil passages Steering Cable Grease Fitting Cable Coupler Nut Cable Guide Tube Steering Cable End Clevis Clevis Pin Cotter Pin i Steering cable outer casing must be free to move back and forth tor steering system to function properly Do not fasten any items to steering cable 90 883145 3 10 03 POWER STEERING INSTALLATION 1D 1 NOTES 1D 2 POWER STEERING INSTALLATION 90 883145 3 10 03 MERCRUISER EN PDI AND MAINTENANCE LEVEL I E THROTTLE CABLE ADJUSTMENT Table of Contents Page Alpha Throttle Cable Installation and Adjustment 1E 1 Bravo Throttle Cable Installation and Adjustment 1E 4 1E i THROTTLE CABLE ADJUSTMENT 90 883145 3 10 03 Alpha Throttle Cable Installation and Adjustment Carbureted Models 1 Place remote control handle s in NEUTRAL IDLE position IMPORTANT Be sure that cable is routed to avoid sharp bends and or contact with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is
328. w 12 MerCathode 13 Data Link Connector DLC 14 Circuit Breaker Fuse 15 Circuit Breaker Fuse 16 Circuit Breaker Fuse 17 Screw 18 Nut 19 Engine Control Module ECM ECM PCM Systems 1 Data Link Connector DLC 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 47 PFERCURY MerCruiser service bulletin No 2001 2 WARRANTY INFORMATION V SERVICE INFORMATION This bulletin replaces bulletin 96 4 Destroy that older bulletin Quicksilver DDT Scan Tool Models Mercury Mariner EFI DFI Optimax 3 0L Carb and 25 40 hp 4 cycle Outboards Mercury Racing EFI Outboards and MerCruisers MerCruiser EFI and MPI Models including PCM 555 MerCruiser 1997 and Newer Carb Models with Thunderbolt V Ignition System Digital Diagnostic Terminal DDT and Cartridge This hand held Scan Tool is easy to use The flexible sealed keypad rubber boot and rugged design will provide many years of service It comes with a 10 foot 3 m cable Adapter cables are used to connect the DDT to Data Link Connector DLC on the engine There are separate Cartridges for Mercury Mariner Outboards and MerCruiser products Instructions with the Cartridges and Service Manuals will tell how to connect the DDT to the engine The DDT when used with the correct cartridge and the product s Service Manual will allow the technician to properly diagnose and repair engine systems Engine functions can be mon i
329. w to avoid the hazard NOTE An example of such a label follows AVOID SERIOUS INJURY OR DEATH FROM FIRE OR EXPLOSION RESULTING FROM LEAKING FUEL INSPECT SYSTEM FOR LEAKS AT LEAST ONCE A YEAR 24 16 2 In systems with multiple engines and or multiple tanks the valves in the system shall have a label that indicates what the valve is controlling and what each valve position means and 24 16 2 1 valves at junctions in the fuel system shall be labeled as to function and position 24 17 INSTALLATION TESTS 24 17 1 There must be no blow back of fuel through the fill fitting when filling at a rate of 9 gpm 34 Ipm from 1 4 to 3 4 of the capacity on the tank label For fuel tanks of 25 gallons 95 liters capacity or less the fill rate may be reduced to 6 gpm 23lpm NOTE test to determine compliance with this requirement may be performed on a representative installation 90 883145 3 10 03 24 17 2 Fuel fills shall be located and oriented so that no fuel can enter the boat when it is in its static floating position and fuel overflows at a rate of 5 gpm 19 lpm for 5 seconds 24 17 3 Overflow from the fuel tank vent at the rate of 2 gpm 7 5 lpm or less shall not enter the boat 24 17 4 After installation the fuel system of every boat shall be pressure checked to at least 3 psi 21kPa orat 1 times the maximum hydrostatic head to which it may be subjected in service whichever 1s greater 24 17 4 1 The fuel s
330. which extend into the wells The fuel is metered at the lower tip of the idle tube and passes up through the tube The fuel is mixed with air at the top of each idle tube through an idle air bleed 1 The air bleed size is controlled either by a drilled hole or a brass insert depending upon the carburetor application Then the fuel mixture crosses over to the idle down channels where it is mixed with air at the side idle bleed located just above the idle channel restriction 2 The mixture continues down through the calibrated idle channel restrictions past the lower idle air bleeds 4 and off idle discharge ports 6 where it is further mixed with air The air fuel mixture moves down to the adjustable idle mixture needle discharge holes 7 where it enters the carburetor bores and blends with the air passing the slightly open throttle valves The combustible air fuel mixture then passes through the intake manifold to the engine cylinders Turning the idle mixture needles inward clockwise decreases the fuel discharge gives a leaner mixture and turning the mixture needles outward counterclockwise enriches the engines idle mixture cont FUEL DELIVERY SYSTEM AND CARBURETION 3A 25 As the primary throttle valves are opened from low idle to increased engine speed additional fuel is needed to combine with the extra air entering the engine This is accomplished by the slotted off idle discharge ports As the primary throttle valves open the
331. witches and other inputs used by the ECM to control its vari ous systems Although we will not cover them all in great detail there will be a brief description of each a System Relay j Serial Data b Distributor For REF rom k Audio Warning Buzzer c Discrete Switches Audio Warning Fuel Injectors d Knock Module m IAC Motor e Knock Sensor n Ignition Control Module f TP Fuel Pump Relay g MAP p Fuel Pump h ECT q Inputs i IAT r Outputs s ECM 90 883145 3 10 03 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 17 PCM 555 Input and Sensor Descriptions ECM 555 Similar The following lists the sensors switches and other inputs used by the PCM 555 to control its various systems Although we will not cover them all in great detail there will be a brief description of each IO CD a MAP b MAT c d ECT e Sea Pump f Oil Pressure g Port EMCT h Starboard EMCT i Lube Oil Bottle Knock 1 k Knock 2 Fuel Level m Paddle Wheel Sea Temp n Transom Harness Pitot p Steering Angle DLC r CAN Line 3B 18 ELECTRONIC FUEL INJECTION INTRODUCTION K fg O wji LA Y S Fuel Injectors 1 8 t Ignition Coils 1 8 u Tach Signal v IAC w Fuel Pump Relay x Boost Fuel Pump y Cool Fuel Pump Main Power Relay MPR Trim UP Relay bb Warning Horn cc Tabs dd Key ee Crank Posi
332. with a maximum delivery hose length of 48 inches 1 22m 24 14 8 1 Electrically operated fuel pump systems shall be connected to be energized only when the engine ignition switch is on and the engine is running momentary type override is acceptable for starting 24 14 8 2 The outlet pressure of electrically operated fuel pumps shall be rated or controlled to the maximum carburetor fuel inlet pressure specified by the engine manufacturer EXCEPTION Electric fuel pumps used to transfer fuel between tanks 24 14 9 On vessels with multiple fuel tanks and a fuel system such as fuel injection that returns unused fuel to the tank the system 24 14 9 1 shall return unused fuel to the same tank from which it was drawn and 24 14 9 2 valves or other means shall ensure simultaneous switching of the fuel supply and return lines by a single operation to prevent fuel overflow 24 14 9 3 Information about the design operation and maintenance of this system shall be provided in the vessel s owner s manual and 24 14 9 3 1 this information shall include a warning about the consequences of modifying this system that may result in a fuel overflow See ABYC T 24 Owner s Manuals 1996 American Boat amp Yacht Council Inc 5 FUEL DELIVERY SYSTEM AND CARBURETION 3A 51 24 12 96 24 14 10 Fuel distribution systems shall be provided with anti siphon protection by at least one of the following 24 14 10 1 Keeping all part
333. with hardware as shown e With Shift Assist Assembly Remote Control Shift Cable Shift Assist Assembly Clevis Pin Cotter Pin Spread Both Prongs Large 1 0 Washer Small 1 0 Washer g Locknut Tighten Until Bottomed Then Back Off 1 2 Turn There should be no pressure on either side of the shift assist assembly attaching point Failure to adjust properly could apply excessive load to the cable and cause the throttle only portion of the control to hang up and malfunction the shift assist assembly requires effort to fit over the anchor stud and clevis pin the shitt cable from the control box is adjusted incorrectly Remove the shift cable and reposition the adjustment barrel as required to allow the shift assist assembly to be attached with no effort Without Shift Assist Assembly Remote Control Shift Cable Pin Cotter Pin Existing Spring Existing Washer Existing Washer Spacer Washer Existing Locknut Existing Tighten Until Bottomed Then Back Off 1 2 Turn IMPORTANT If an extra long remote control shift cable is used or if there are a large number of bends in remote control shift cable or remote control has inadequate out put travel an additional adjustment may be necessary Refer to step 12 or 13 as appli cable 1C 16 STERNDRIVE INSTALLATION 90 883145 3 10 03 12 Remote Control with Single Lever Shift Throttle
334. xceed the cohesive strength of the plastic and 24 10 11 4 the fuel tank must be supported in the boat by means other than plastic foam 24 10 12 Cellular plastic used to encase fuel tanks must 24 10 12 1 Not change volume by more than 5 percent or dissolve after being immersed in any of the following liquids for 24 hours at 84 2 F 29 1996 American Boat amp Yacht Council Inc 3 FUEL DELIVERY SYSTEM AND CARBURETION 3A 49 24 12 96 Corrected 7 01 Reference Fuel B of ASTM D 471 No 2 Reference Oil of ASTM D 471 or Five percent solution of trisodium phosphate in water and must 24 10 12 2 absorb more than 0 12 pound of water per square foot of cut surface measured under Military Specification MIL P 21929B 24 10 13 Non polyurethane cellular plastic if used to encase fuel tanks must have a compressive strength of at least 60 pounds per square inch at 10 percent deflection measured under ASTM D 1622 Apparent Density of Rigid Cellular Plastics 24 10 14 Polyurethane cellular plastic if used to encase fuel tanks must have a density of at least 2 0 pounds per cubic foot measured under ASTM D 1622 Apparent Density of Rigid Cellular Plastics 24 10 15 A means to determine fuel level or quantity shall be provided 24 11 CONNECTIONS FUEL HOSE 24 11 1 Flexible hose not equipped with permanently attached end fittings such as swaged sleeve and threaded insert shall be attached wi
335. y MC Engine Hours total Run Time current run event 3B 56 ELECTRONIC FUEL INJECTION INTRODUCTION 90 883145 4 0804 P EHCUHY MEFI 2 Data Log Sheet DDT Tech Service Education Engine Model Serial Number Customer RO Test RPM conditions Data english units Current Reading Comments Engine Speed Rpm Desired Engine Rom ECT Sensor F IAT Sensor F Map Sensor Hg Map Sensor V Baro Sensor Hg Baro Sensor V TP Sensor V TP Sensor Fuel Rate Gph Inj Pulse Width ms Spark Advance KS System Enabled KS Signal Knock Retard IAC Position Base IAC Position Shift Interrupt IAC Follower Battery V Fuel Pump Relay Power Reduction Not used by MC Overheat Detection Low Oil Pressure Switch Low Oil Level Switch Not used by MC Low Oil Lamp Not used by MC General Warning 1 General Warning 2 General Warning 1 Lamp Not used by MC Buzzer Lanyard Stop Not used by MC Check Gauge Lamp Not used by MC ECM Status Fuel System Not used by MC Engine Hours total Run Time current run event 90 883145 4 0804 ELECTRONIC FUEL INJECTION INTRODUCTION 3B 57 MERCURY MEFI 3 Data Log Sheet DDT Tech Service Education Engine Model Serial Number Customer RO Test RPM conditions Data english units Current Reading Comments Engine Speed Rom Desired Engine Rom ECT Sensor F IAT Sensor F Map Sensor Hg Map Sensor V Baro Sensor Hg Baro Sensor V TP Sensor V TP Sen
336. y operated valves shall meet the requirements of UL 429 Electrically Operated Valves 24 8 2 The unit shall incorporate means for independent mounting designed to relieve strain from connected fuel lines 24 83 Manually operated valves shall be designed with positive stops in the open and closed positions or shall indicate their opened and closed positions 24 8 4 Electrically operated shut off valves shall be connected to be energized to open when the engine ignition switch is on A provision for manual operation shall be incorporated in the design 24 8 5 Tapered plug valves with an external spring shall not be used 24 9 FUEL FILTERS STRAINERS AND WATER SEPARATORS 24 9 1 unit shall incorporate means for independent mounting 2492 The unit shall be designed so that routine servicing and removal for cleaning purposes will minimize as much as practical any spillage of fuel into the bilge 90 883145 3 10 03 24 9 5 Drain openings shall be equipped with tapered pipe plugs The plugs shall not create a galvanic cell with the housing that will accelerate corrosion 24 9 4 fitting threads shall be tapered pipe threads 24 9 4 1 External threads shall be National Pipe Thread Fine NPTF 24 9 4 2 Internal threads shall be Pipe Thread Fine Short PTF SPL SHORT 24 9 5 Gaskets and Seals 24 9 5 1 Gaskets and seals if used shall form a complete ring and shall not be split 24 9 5 2 Cork gaskets shall
337. y pass by the off idle ports gradually exposing them to high engine vacuum below the throttle valves The additional fuel added from the off idle ports mixes with the increasing air flow past the opening throttle valves to meet increased engine air and fuel demands Further opening of the throttle valves increases the air velocity through the carburetor venturi sufficiently to cause low pressure at the lower idle air bleeds As a result fuel begins to discharge from the lower idle air bleed holes and continues to do so throughout operation of the part throttle to wide open throttle ranges supplementing the main discharge nozzle delivery The idle needle holes and off idle discharge ports continue to supply sufficient fuel for engine requirements until air velocity is high enough in the venturi area to obtain efficient fuel flow from the main metering system Rochester Quadrajet Main Metering System The main metering system supplies fuel to the engine from off idle to wide open throttle The primary bores two smaller bores supply fuel and air during this range through plain tube nozzles and the venturi principle The multiple venturi in each primary bore produce excellent fuel metering control due to their sensitivity to air flow cont 3A 26 FUEL DELIVERY SYSTEM AND CARBURETION 90 883145 3 10 03 90 883145 3 10 03 As the primary throttle valves 10 are opened beyond the off idle range allowing more air to enter the en
338. y turning the engine over by hand to rule out the engine itself A meter reading below 9 5v indicate voltage loss between the starter motor and the bat tery Example Voltage measured at the battery posts indicates 12 5v You measure 9v at the starter That means there is a 3 5v drop between the battery posts and the starter Corroded battery cables loose or dirty connections loose battery cable terminal crimps under size battery cable gauge for length used in boat painted surfaces or battery switches could be the cause for this voltage drop Testing Cranking Voltage at the Starter Look for cause of low voltage by using the following test 9 Test the battery positive cable first Connect voltmeter lead directly to the battery post not the battery cable ring terminal Connect voltmeter lead directly to the large threaded starter motor terminal that the battery cable is connected to NOTE Hemove one voltmeter lead before starter motor is turned off or voltmeter damage may occur The starter may produce a voltage spike that can damage a voltmeter a Crank engine over while looking at the voltmeter The maximum allowed drop is 0 25 b To find the point where the resistance is highest leave the voltmeter lead on the battery post and move the voltmeter lead to the battery cable ring terminal that is on the threaded starter terminal c Next move voltmeter
339. ystem shall evidence no leakage under such testing checked at a minimum of 5 minutes after application of the test pressure for systems of 50 gallons 190 liters or less capacity with one additional minute for each increment of 10 gallons 38 liters or fraction thereof above 50 gallons 190 liters 24 17 4 2 leak detection method other than the pressure drop method must be used at every joint except at the deck fill and exterior vent fittings NOTE It is suggested that soapy test solutions be non corrosive and non toxic Ammonia present in some soaps and detergents creates a condition that attacks brass fittings like those used in fuel systems Undetectable at first in a matter of months these fittings may develop cracks creating a very hazardous situation 24 18 GASOLINE FUEL TANKS 24 18 1 Tank Materials 24 18 1 1 Material thickness shall be at least the minimum thickness listed in TABLE IV 24 18 1 1 1 Materials not listed in TABLE IV shall be tested to demonstrate corrosion resistance in a marine environment equivalent to those materials listed 24 18 1 2 Steel sheet tanks when constructed for gasoline shall be galvanized on the inside and out by the hot dip process 24 18 1 3 Fuel tanks shall not be constructed of terneplate steel 24 18 1 4 Non metallic materials are considered acceptable for corrosion resistance however all other requirements of this standard must be met 24 18 1 5 The copper base all

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