SEPTEMBER 2001 Page 4-1

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1 GASOLINE ENGINE TOOLS SEPTEMBER 2001 Page 4-1

2 Gasoline Engine Tool Application Chart Part Number Page Description GM Ford Air Line Cutter 4 Cyl (224) A1 4-4 Alignment Tool Assembly A2 4-4 DMT 2000A Tachometer / Multi-Meter Kit A1 4-5 DVA / Multi-Meter Kit A1 4-5 Drill Fixture / Panel Mount Remote Control Dyno Model ES Torx Driver Engine Coupler Wrench Flywheel Holder Fuel Fitting Connector A2 4-6 Fuel Pressure Gauge Kit Fuel Pressure Tee Idle Mixture Socket A1 4-7 Ignition Timing (EST) A1 4-7 Installation Jig Lifting Eye Tool MCM Tool Overlay Kit MCM Tool Overlay Update Kit 4-8 Micro Fiche Viewer (120v) 4-9 Micro Fiche Viewer (240v) Oil Pump Alignment Tool Oil Pump Pickup Installer Oil Pump Pickup Installer Piston Ring Expander A Power Steering Adaptor Kit Portable Timing Light A Power Steering Test Gauge Kit A Probe Assembly / SAV A Probe Assembly / SAV Page SEPTEMBER 2001

3 Gasoline Engine Tool Application Chart Part Number GASOLINE ENGINE Page Description GM Ford 4 Cyl (224) A Pulley Pusher Installer A Remote Starter Switch Rocker Stopper Note Description 4-12 Scan Tool Kit / Version Tachometer / Dwell Meter Torch Lamp Torque Wrench, lb-in SEPTEMBER 2001 Page 4-3

4 Air Line Cutter Description: Will prevent collapsing, when used to cut the air lines for the water drain system on 8.1S models. Alignment Tool Assembly A1 Description: Aligns the engine and drive unit during installation DMT 2000A Tachometer / Multi-Meter Kit A3 Description: Measures rpm on both 2 and 4 cycle marine engines, records the maximums and minimums simultaneously and will read accurately in high RFI environments. Replacement components: Inductive Pick-Up 8 ft. (2.4 m) Temperature Probe Ferrite Core Interface Module Hard Carrying Case User s Guide Test Leads Optional Accessories: T 8 ft. (2.4 m) Inductive Pick-Up Extension Clamp-On Current Probe Direct Voltage Adaptor Page SEPTEMBER 2001

5 DVA / Multi Meter Kit A1 Description: Tests the electrical and ignition systems, consists of a VOA meter with built-in direct voltage adaptor Drill Fixture / Panel Mount Remote Control Description: Use for drilling the boat for installation of the Commander 2000, 3000 and 3000 Classic Panel Mounted Remote Controls A1 Dyno Model Description: Use to connect to the propeller shaft on stern drive models. Allows the engine to be operated simulating a loaded condition while the boat is on a trailer. Dyno maximum hp is 575 hp. ES Torx Driver Description: Use to remove the screws that hold the solenoid on the Delco PG260 starter motors. Engine Coupler Wrench Description: Removes and installs the engine coupler, torques the bolts on the couplers that mount directly to the crankshaft, 1/2 in. drive SEPTEMBER 2001 Page 4-5

6 Flywheel Holder Description: Holds and/or turns the flywheel while making engine repairs, also used to torque the flywheel or the engine coupler Fuel Fitting Connector Description: The connector is installed between the full line and the carburetor on 2-barrel MerCarb and 4-barrel Weber carburetors. Can also be used on the inlet side of VST on EFI/MPI models also Fuel Pressure Gauge Kit A2 Description: Use to test the fuel pump pressure, includes: Fuel Pressure Gauge Adaptor Kit Fuel Pressure Tee A1 160 PSI Gauge Fuel Pressure Tee Description: The Tee can be installed between the fuel line and the to measure fuel pump pressure on 2-barrel MerCarb and 4-barrel Weber carburetors. Use with A1, A2, A3 or A7 Fuel Pressure Gauge. The Fuel Pressure Tee is included with the A2 Fuel Pressure Gauge Kit Page SEPTEMBER 2001

7 Idle Mixture Socket Description: Turns the idle mixture screws on the Rochester 4-barrel carburetors Ignition Timing (EST) A1 Description: Use to lock the 3.0L / LX EST ignition system in timing mode to set the initial ignition timing. Installation Jig A1 Description: Use to place the engine mounts when installing Mercury Mercruiser V-8 or V-6 engines Lifting Eye Tool Description: Use on the 8.1S engines for the center alignment eye SEPTEMBER 2001 Page 4-7

MCM Tool Board Overlay Kit 91-877528-1 Description: MCM Tool Overlay Kit (sheet numbers 10-20 ) contains 11 overlay sheets and hooks indicating locations for all the Mercury MerCruiser gasoline

77976 MCM Tool Board Overlay Update Kit 91-883983 Description: Update kit for the original 91-877528 MCM Tool Board Overlay Kit.

8 MCM Tool Board Overlay Kit Description: MCM Tool Overlay Kit (sheet numbers ) contains 11 overlay sheets and hooks indicating locations for all the Mercury MerCruiser gasoline engines and sterndrive units active service tools. Includes MCM Tool Board Overlay Update Kit MCM Tool Board Overlay Update Kit Description: Update kit for the original MCM Tool Board Overlay Kit. This sheet has 12 additional tools for the Bravo XR, XZ and Bravo Three drive units Included in MCM Tool Board Overlay Kit Micro Fiche Viewer (120v) Description: Use to view the parts lists that are on microfiche. Two screen sizes available: Desktop Size 8-1/4 in. x 10-3/4 in. (210 x 273 mm) Dust Cover Glare Shield Full Size 10 in. x 14 in. (254 x 357 mm) Dust Cover Glare Shield Replacement 120v bulb Micro Fiche Tray 12 in. (305 mm) Page SEPTEMBER 2001

9 Micro Fiche Viewer (240v) Description: Use to view the parts lists that are on microfiche. Two screen sizes available: Desktop Size 8-1/4 in. x 10-3/4 in. (210 x 273 mm) Dust Cover Glare Shield Full Size 10 in. x 14 in. (254 x 357 mm) Dust Cover Glare Shield Replacement 240v bulb Micro Fiche Tray 12 in. (305 mm) Oil Pump Alignment Tool Description: Use to align the oil pump during installation on the 4-cylinder Mercury Marine (224) cid engines only Oil Pump Pickup Installer Description: Installs the 5/8 in. (16 mm) diameter oil pickup tube and screen into the engine s oil pump. Oil Pump Pickup Installer Description: Installs the 3/4 in. (19 mm) diameter oil pickup tube and screen into the engine s oil pump SEPTEMBER 2001 Page 4-9

10 Piston Ring Expander Description: Removes and installs the piston rings Portable Timing Light Description: Checks the ignition timing, powered by two D cell batteries Power Steering Adaptor Kit A1 Description: Use with the A3 Test Gauge Kit to test the later model power steering control valves Power Steering Test Gauge Kit A4 Description: Test the power steering system pressure Page SEPTEMBER 2001

11 Probe Assembly / SAV A1 Description: Use to measure SAV regulated emissions on early models with a test port mounted to the side of the exhaust elbow. Probe Assembly / SAV A2 Description: Use to measure SAV regulated emissions on models with a test port mounted to the top of the exhaust elbow. Pulley Pusher Installer A1 Description: Installs the pulley on the power steering pump Remote Starter Switch A1 Description: Provides a remote starter button to crank the engine when performing service procedures Rocker Stopper Description: Plugs the oil holes in the rocker arms to eliminate oil spray while adjusting the valve lash SEPTEMBER 2001 Page 4-11

12 Scan Tool Kit / Version 4.0 Description: Hand-held Scan Tool updated for (refer to Service Bulletin ). Use with models: MCM/MIE EFI (TBI) and MPI Gasoline MCM/MIE 496/8.1S MPI PCM and Newer MCM/MIE Carburetor Models with Thunderbolt Ignition System MCM/MIE D-Tronic Diesel NOTE: Tool must be ordered from Rinda Technologies, Inc., refer to Section 8 / Tool Manufacture List. Note Description Tachometer / Dwell Meter Description: Checks the engine rpm (0-10,000), also checks the dwell on breaker point ignition systems Torch Lamp Description: 120v Torch Lamp, heats bearing bores to make bearing removal and installation easier Replacement bulb 120v NOTE: Torch Lamp 240v is no longer available Replacement 240v bulb is available Torque Wrench. lb-in Description: Sets torques from 9 to 150 lb-in., 3/8 in. drive Page SEPTEMBER 2001

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14 THIS PAGE IS INTENTIONALLY BLANK Page SEPTEMBER 2001

ELECTRICAL SYSTEMS IGNITION SYSTEM

ELECTRICAL SYSTEMS IGNITION SYSTEM ELECTRICAL SYSTEMS 4 72722 B IGNITION SYSTEM Table of Contents Page Electronic Spark Timing (3.0L/3.0LX EST)... 4B-1 Tools/Lubricants/Sealants............... 4B-1 Torque Specifications..................