merCruvcr SERVICE MANUAL
Contents
1. _ ______ merCruizer SERVICE MANUAL Number 1 Stern Drive Units and Marine Engines Book 1 of 2 Sections 1 thru 5 Brunswick Corp 1986 Printedin U S A 90 68648 286 5 a gt stat bag d Notice to Users of This Manual This service manual has been written and published by the service department of Mercury Marine to aid our dealers mechanics and company service personnel when servicing the products described herein It is assumed that these personnel are familiar with the servicing procedures of these products or like or sim ilar products manufactured and marketed by Mercury Marine That they have been trained in the recom mended servicing procedures of these products which includes the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and or results of each method We have not undertaken any such wide evaluation Therefore anyone who uses a service procedure and or tool which is not recom mended by the manufacturer first must completely satisfy himself that neither his nor the product s safety will be endangered by the service procedure selected All information illustrations and specifications con tained in this manual are based on the latest2. product information available at time of publication It should be kept in mind while working on the pro duct that the electrical system and ignition system is capable of violent and damaging short circuits or severe electrical shocks When performing any work where electrical terminals could possibly be grounded or touched by the mechanic the battery cables should be disconnected at the battery Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started It is important to note that during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed whether metric or customary Numbers on the heads of the metric bolts and on surfaces of metric nuts indi cate their strength Customary bolts use radial lines for this purpose while most customary nuts do not have strength markings Mismatched or incorrect fasteners can result in damage or malfuction or possibly per sonal injury Therefore fasteners removed should be saved for re use in the same locations whenever possi ble Where the fasteners are not satisfactory for re use care should be taken to select a replacement that matches the original Replacement Parts AWARNING Electrical ignition and fuel system components on MerCruiser Engines a
3. ber MCO IE OE ae EE ER BE ME ES MERCRUISER SERVICE MANUAL OUTLINE SECTION NO 1 General Information 2 Removal Installation Alignment 3 Electrical System 4 Fuel Systems 5 Engine 6 Drive Systems 7 Accessories 8 Specifications 9 Tools SECTION HEADING Part A General Information Part B Tuneup Part C Lubrication Part A MerCruiser 60 80 90 Part B MerCruiser I Part C MerCruiser II Early Part D MerCruiser II Transom Part E MerCruiser IIT Part F MerCruiser 215H Part G MerCruiser 215E Part J MerCruiser I TR Drive Unit Part A Starting System Part Ignition System Part C Alternator System Part D Instrumentations Part Wiring Diagrams Part Fuel Pumps Part B Carburetors Part A Engine Mechanical In Line GM Part B Engine Mechanical In Line 60 80 90 Part C Engine Mechanical V 8 GM Part D Engine Mechanical V 8 Ford Part A MerCruiser 60 80 90 and MerCruiser1 Part B MerCruiser II Part C MerCruiser 215 Part D MerCruiser TIT Part E Direct Drive Transmission Part F MerCruiser II TR Drive Unit Part G MerCruiser II TR Transmission Part A Power Tilt amp Trim Part B Steering System Part C Remote Controls Part D Cooling Part E General Accessories
4. ed service replace ment parts will void the warranty on those parts which are damaged as a result of the use of other than recommended parts MODELS COVERED IN THIS MANUAL MERCRUISER STERN DRIVE ENGINES MCM Serial Number MCM 60 memo Meu emit AH AA kN E ___ Ak LA AKAN je TEn TE MCM 190 V 8 All MGM 200 6Cyl M ME arenes MEME ene ua Ford 3779774 and below MCM 250 327 CID 4767999 and below 3838787 and below O N N a MCM 310 lt O IO lt lt w co D 21 a ojl ofa i 2 n a MCM 390 MERCRUISER INBOARD ENGINES MIE Mode SerialNumber _ TRANSOM ASSEMBLY AND STERN DRIVE UNITS Mode SerialNumber MCO IE OE ae EE ER BE ME ES MODELS COVERED IN THIS MANUAL MERCRUISER STERN DRIVE ENGINES MCM Serial Number MCM 60 memo Meu emit AH AA kN E ___ Ak LA AKAN je TEn TE MCM 190 V 8 All MGM 200 6Cyl M ME arenes MEME ene ua Ford 3779774 and below MCM 250 327 CID 4767999 and below 3838787 and below O N N a MCM 310 lt O IO lt lt w co D 21 a ojl ofa i 2 n a MCM 390 MERCRUISER INBOARD ENGINES MIE Mode SerialNumber _ TRANSOM ASSEMBLY AND STERN DRIVE UNITS Mode SerialNum
5. nd Stern Drives are designed and manufactured to comply with U S Coast Guard Rules and Regulations to minimize risks of fire or explosion Use of replacement electrical ignition or fuel system components which do not comply to these rules and regulations could result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel sys tems it is extremely important that all components are properly installed and tightened If not any electrical orignition component opening would permit sparks to ignite fuel vapors from fuel system leaks if they existed Engine Mechanical Components Many of the engine mechanical components are de signed for marine applications Unlike automotive engines marine engines are subjected to extended periods of heavy load and wide open throttle opera tion therefore require heavy duty components Spe cial marine engine parts have design and manufactur ing specifications which are required to provide long life and dependable performance Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard auto motive parts within a short period of time Failure to use recommended Quicksilver service re placement parts can result in poor engine performance and or durabiltiy rapid corrosion of parts subjected to salt water and possibly complete failure of the engine Use of parts other than recommend
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