GASOLINE FLAT RATE GUIDE

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Jennifer Shepherd
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1 Gasoline Tables FLAT RATE TABLE INSTRUCTIONS MERCURY MERCRUISER EXPLANATION OF TABLE All Mercury Marine products have a flat rate table which is used to complete warranty claims for labor reimbursement. The times listed for each repair include all operations and procedures required to complete that job. The times are listed in hours and tenths of hours. Mercury Marine warranty labor reimbursement is computed at your approved warranty labor rate currently on record. The tables are arranged by engine sub systems and related accessories, e.g. ignition systems, powerhead, remote control, etc. Troubleshooting and test times are listed in the appropriate sections. Only one Troubleshooting / Test code may be selected per failure. Overlapping of flat rate codes is not allowed. Diagnostic time, if applicable, needs to be listed along with the removal and replacement time to properly complete most warranty claims. For example: replacing alternator on a Mercury MerCruiser engine will have two codes listed on the claim: ME51 Alternator and ME75 alternator diagnostics. Repairs requiring an outside expense such as machining, welding, or painting will require the dollar amount to be entered as outside labor. If you have entered a sublet labor amount you must send/fax the receipt to the appropriate Warranty Department at Mercury Marine with a copy of the claim. When a repair requires the replacement of more than one part in a related procedure, use the flat rate that covers the entire repair. For example: long block replacement on Mercury MerCruiser engines code MM64 includes removing and replacing the engine intake and exhaust manifolds. Do not use component codes in addition to MM64. This would result in overlapping of flat rate codes which is not allowed. When a repair requires more than one part in unrelated failures, file a separate warranty claim for each repair. TO USE THE TABLE Find the engine sub system being repaired. Enter the appropriate diagnostic and the removal and replacement code on the claim. For repairs that are not specified in the table or to request additional time beyond the established flat rate, you may use the code NJC (no job code) and manually record the time in hours and tenths of an hour. All claims using an NJC code for labor will require a detailed explanation in the failure description area in order to support the claimed labor. All NJC coded claims will be reviewed. This Manual includes all Mercury MerCruiser Sterndrive and Inboard Gasoline Engine ls and is your guide for completing warranty labor claims. The flat rate times are listed in hours and tenths of hours. rate times were developed from studies using normal hand tools and special tools listed in the Product Service Manuals. This Manual supersedes all previous Manuals MAY Mercury Marine Page 1 / 12

2 This Manual also may serve as a guide for non warranty repairs. Gasoline Tables Remove & Replace (R & R) Complete Engines/Transmissions Remove & Replace (R & R) Complete Engines/Transmissions 2.5L 3.0L V 6 4.3L 5.0L 6.2L 8.1L Complete Sterndrive Engine R & R MA Transmission R & R from Engine MA Complete Inboard Engine R & R Open or Sportfish Complete Inboard Engine R & R Sedan Cruiser¹ Complete Inboard Engine R & R Double Cabin Inboard Transmission (All Including Ski) Only R & R from Boat MA13 In Line 7.0 V Drive MA14 In Line 26.5 V Drive MA15 In Line 16.5 V Drive MA Cooling System ¹Use only when engine is accessed through the salon and is removed through the cabin door. Cooling System 2.5L 3.0L V 6 4.3L 5.0L 616 Fluid Cooler MC Broken / Cracked 507 Heat Exchanger MC Casting Flaw 608 Hose (One) MC Machined Improperly 615 Thermostat Housing MC Water Leak 606 Thermostat/Cover MC Fix Program Water Circulating Pump Engine Water Pump (Sea Water) Engine Mount Water Pump (Sea Water) Engine Mount Major Repair MC Bonding / Adhesive MC MC Water Crossover MC Idler Pulley MC Actuator Cooling Drain MC Drain Cooling System MC Electrical System ¹ MC24 can be claimed on all except MC21. Electrical System 2.5L 3.0L V 6 4.3L 5.0L 301 Alternator ME Assembled Wrong 301 Alternator Major Repair ME Broken Cracked Page 2 / MAY 2005

3 Electrical System Alternator Voltage Regulator Audio Warning Horn/ Timer Audio Warning Oil Switch (Each) Audio Warning Water Switch 2.5L 3.0L V 6 4.3L 5.0L ME Shorted or Open ME Wired Wrong ME Bracket ME Circuit Breaker/Fuse ME Electric Shift Motor R and R Electric Shift Motor Repair ME ME Ignition Switches ME Gauges ME MerCathode Controller MerCathode Electrode R & R ME ME Sender, Oil Pressure ME ² 605 Sender, Water Temperature ME Shift Cut out Switch ME Solenoid (All) ME Solenoid (Starter) ME Starter Motor¹ ME Starter Motor Major Repair Wiring Harness Engine Wiring Harness Instrument ME ME ME Diagnosis ME Temp Sensor ME85 0.2² 699 Thermostat ME86 0.2² Drain Cooling ME Engine Mechanical Engine Mechanical ¹Do Not Rebuild Starters During The Warranty Period. Starter Motors Must Be Replaced With Mercury MerCruiser Starters During The Warranty Period. ²ME87 can be claimed. 2.5L 3.0L V 6 4.3L 5.0L 447 Balance Shaft MM Adjusted Wrong 401 Camshaft MM Assembled Wrong MAY 2005 Page 3 / 12

4 Engine Mechanical Camshaft Gear / Timing Chain Connecting Rod (One) Connecting Rod (One Each Bank) Connecting Rod (Each Additional) Connecting Rod Bearings (One) Connecting Rod Bearing (Each Additional) 2.5L 3.0L V 6 4.3L 5.0L MM Bearing Spalled MM Broken / Cracked MM Detonated / Scored MM Fastener Broke MM Machined Wrong MM Oil Leak 405 Crankshaft MM Seized / Stuck 429 Crankshaft Pulley MM Spun Cylinder Head/ Gasket (One Head) Cylinder Head/ Gasket (All Heads) Cylinder Head / Grind Valves (One Head) Cylinder Head / Grind Valves (Both Heads) Engine Coupler/Drive Plate Engine Mounts (Front) Flywheel / Housing / Mounts MM MM MM MM MM MM MM Torsional Damper MM Hydraulic Valve Lifters (All) Standard Hydraulic Valve Lifters (All) Roller Intake Manifold Gasket MM MM MM Main Bearings (One) MM Adjusted Wrong 413 Main Bearings (Each Additional) MM Assembled Wrong 416 Oil Pan / Gasket MM Bearing Spalled 499 Long Block (See EFI / MPI section for EFI / MPI) MM Broken / Cracked 420 Piston (One) MM Detonated / Scored Piston (One Each Bank) Piston (Each Additional) MM Fastener Broke MM Machined Wrong Page 4 / MAY 2005

5 Engine Mechanical 2.5L 3.0L V 6 4.3L 5.0L 422 Piston Rings (One) MM Oil Leak Piston Ring (One Each Bank Piston Rings (Each Additional All Pistons Removed) Push Rod Cover / Gasket Rocker Arm / Push Rod Rear Main Seal (Two Piece) Rear Main Cover Oil Seal Rocker Arm Cover / Gasket Timing Gear Cover / Seal / Gasket Valve Stem Oil Seal / Valve Spring (One) MM Seized / Stuck MM Spun MM Water Leak MM ¹ MM MM MM MM MM Drain Cooling System MM Exhaust System ¹Drain of cooling not necessary. Exhaust System Components Between Elbow & Exhaust Pipe (Any/All Per Side) Components Between Elbow & Transom Assembly (Any/All Per Side) 2.5L 3.0L V 6 4.3L 5.0L 6.2L MX Casting Flaw MX Corroded / Pitted 503 Exhaust Elbow MX Machined Wrong 506 Exhaust Pipe/ Block Off Pipe MX Broken / Cracked 513 Exhaust Riser MX Water Leak 505 Manifold (One) MX ¹ 504 Water Shutter (One) MX Diagnosis MX Water Man. MX20 1.5¹ 599 Drain Cooling MX23 0.5¹ ¹Drain system required MAY 2005 Page 5 / 12

6 Fuel System Fuel System 2.5L 3.0L V 6 4.3L 5.0L 703 Carburetor MF Adjusted wrong Carburetor Minor repair Carburetor Major repair / 2 Barrel Carburetor Major repair / 4 Barrel MF Assembled wrong MF Broken / Cracked MF Fuel Leak 713 Fuel Lines (All) MF Shorted / Open Diagnosis MF Fuel Pump (Electric) MF Fuel Pump (Mechanical) Ignition System Ignition System MF L 3.0L V 6 4.3L 5.0L 308 Distributor Cap MI Broken / Cracked 313 Distributor Points / Condenser MI Burnt 307 Distributor R and R MI Fastener Loose 319 Distributor Rotor MI Shorted / Open 353 Ignition Module MI Ignition Coil MI Ignition Sensor MI Spark Plug Wires (Each) MI Diagnosis MI Crank Sensor MI Cam Sensor MI Ignition Coil (Add) MI Remote Control Remote Control 2.5L 3.0L V 6 4.3L 5.0L 221 Control Cable MR Assembled Wrong 318 Complete Control MR Broken / Cracked 318 Control Major Repair MR Electrical Connection Loose 316 Neutral Safety Switch MR Seized / Stuck 318 Electric Shift Switches ( In Remote Control.) MR Shorted / Open Page 6 / MAY 2005

7 Power Trim System Power Trim System Alpha One / Two Three X 105 Cylinder Complete MH Assembled Wrong 105 Cylinder Major Repair MH Broken Cracked Hose Connector to Cylinder (1 or More) Hose, Pump to Connector Valve (1 or Both) MH Contamination (Debris) MH Electrical connection loose 107 Hydraulic Connector MH Oil Leak 122 Plastic Reservoir MH Seized / Stuck Pump Adaptor or Valve Body & Gear Assy. Pump Assembly (Oildyne Only) Pump Pressure Relief Valve Pump Rebuild Kit (Oildyne Only) Trim Control Trailer Switches Trim Control Switches Remote Control Trim Limit Switches/ Sender Leads Trim Limit Switches/ Trim Position Senders Trim Pump Motor Repair Wiring Harness Trim Control MH Shorted / Open MH MH MH MH MH MH MH MH MH Test / Diagnosis¹ MH Electronic Trim Limit / Trim Sender MH ¹Use Only When Claiming A Trim Pump Rebuild; Use ME75 When Claiming Electrical Diagnosis Of Trim System MAY 2005 Page 7 / 12

8 Steering System Steering System Alpha One One / Two Three 815 Power Steering Hoses MS Broken / Cracked Power Steering Pump Complete Power Steering Control Valve Complete MS Fastener Broke MS Oil Leak Test MS Seized / Stuck 804 Plastic Pulley MS Pulley Bent / Failed Sterndrive Unit Sterndrive Unit Shift Shaft Bushing / Seal Drive Shaft Housing Complete Drive Shaft Housing Major Repair Drive Shaft Housing Resealing (All Seals) Gear Housing Cleaning & Inspection¹ Gear Housing Complete Gear Housing Major Repair Gear Housing Resealing (All Seals) Sterndrive Unit Complete Replace² U Joint Cross and Bearings/ Yokes Water Pump / Water Tube Alpha Alpha LH Rotation One / Two Three X MD MD Assembled wrong MD Bearing Spalled MD Broken / cracked MD Casting flaw MD Machined Wrong MD Oil Leak MD Water Leak MD MD MD Bearing Adapter MD31 0.5¹ 234 Drive Oil Reservoir Bottle MD ¹Use Only When Claiming A Drive Shaft Housing Repair. ²Use MD28 Only When Replacing A Complete Sterndrive Unit. Page 8 / MAY 2005

9 ³Use MD22 Only when rebuilding upper unit. Transmission / Drive Shaft Extension Transmission / Drive Shaft Extension Alpha Non Shimm ed 2004 (Shimmed) 226 Drive Shaft R & R MK Assembled Wrong Drive Shaft Extension Bearing Support Assembly R & R Drive Shaft Extension Support Repair Drive Shaft Output Shaft Housing Assembly Repair Drive Shaft U Joint Replace (Each) MK Bearing Spalled MK Broken / Cracked MK Casting Flaw MK Machined Wrong 226 Diagnosis MK Transom Assembly Transom Assembly Alpha All X, XR, XL 203 Bell Housing MT Assembled Wrong 203 Bell Housing Shift Shaft MT Bearing spalled 501 Exhaust Bellows MT Broken / Cracked 506 Exhaust Tube MT Corroded / Pitted 212 Gimbal Bearing MT Machined Wrong 213 Gimbal Housing MT Seized / Stuck Gimbal Housing Assy. Transom Gaskets / Seals Gimbal Ring / Swivel Shaft / Steering Lever MT MT Inner Transom Plate MT Shift Cable MT Swivel Pin Seals / Bearing / Bushing MT U Joint Bellows MT Diagnosis / Test MT Electronic Steering Indicator Electronic Fuel Injection MT Cod e Electronic Fuel Injection 757 Pressure Regulator V 6 4.3L EFI 5.0L MPI 7.4L EFI 7.4L MPI MPI¹ MPI¹ 8.1L MJ Air leak MAY 2005 Page 9 / 12

10 Cod e Electronic Fuel Injection Vapor Separator Tank Fuel Pump (Electric) in VST Float, needle, and Assembly 740 Diaphragm Assembly V 6 4.3L EFI 5.0L MPI 7.4L EFI 7.4L MPI MPI¹ MPI¹ 8.1L MJ N/A 03 Assembled wrong MJ N/A 07 Broken / Cracked MJ N/A 10 Casting Flaw MJ Fuel Filler MJ Flame Arrestor Electrical Connection Loose MJ Oil Leak 727 Throttle Body MJ Shorted / Open 718 Plenum MJ19 N/A N/A 1.0 N/A 1.0 N/A Intake Manifold MJ ² 736 Fuel Rail MJ21 N/A N/A 2.5 N/A Fuel Injectors MJ Electric Control Module (ECM) Coolant Temperature Sensor (CTS) Manifold Absolute Pressure Throttle Position Sensor (TPS) MJ MJ ² MJ MJ Page 10 / MAY 2005

11 Cod e Electronic Fuel Injection Manifold Air Temperature Idle Air Control (IAC) Valve V 6 4.3L EFI 5.0L MPI 7.4L EFI 7.4L MPI MPI¹ MPI¹ 8.1L MJ N / A MJ Knock Sensor MJ ² Electronic Spark Control (ESC) module Water Cooled Fuel System (Pre 1997) R and R and/or Fuel Pump Water Cooled Fuel System (Post 1997) R and R and/or Fuel Pump Water Cooled Fuel System (Pre 1997) R and R and/or Cooler Water Cooled Fuel System (Post 1997) R and R and/or Cooler MJ MJ31 N/A N/A 2.0 N/A N/A N/A N/A N/A MJ ² MJ33 N/A N/A 2.3 N/A N/A N/A N/A N/A MJ ial Engine MM ² 331 Diagnosis / Test EFI / MPI Harness MJ MJ Drain Cooling MJ Low Pressure Pump MJ Fuel Line MJ Gen 3 Cool Fuel Remove and Install Gen 3 Cool Fuel High Pressure Pump Gen 3 Cool Fuel Low Pressure Pump MJ MJ MJ ¹ This column for models with serial numbers higher than 0L ²Drain of cooling system can be claimed MAY 2005 Page 11 / 12

12 Jetdrive Jetdrive V 6 4.3L MPI 5.0L MPI 8.1L Anodes (All) AJ Ball Joint Assy Steering AJ Engine Mount Plate¹ AJ Impeller ² AJ Intake Grate AJ Jet Pump Assy R & R AJ Jet Pump Disassy Gearbox¹ AJ Jet Pump Disassy Stator "wet end" AJ Jet Pump Major Rebuild ³ AJ Pump Stator Seals & Bearings ² AJ Reverse Cylinder & Mechanism R & R AJ Reverse Gate AJ Reverse Shaft AJ Reverse Tiller Inboard AJ Steering Nozzle AJ Steering Shaft AJ Steering Tiller Inboard AJ Trim Plate AJ Wear Ring² AJ ¹ Removal of gearbox end cover and related parts to gain access to gear box. Will require Engine R and R. ²To remove and re fit listed parts with stator removed from unit. ³ Complete change of all wearing parts Products of Mercury Marine W6250 Pioneer Road Fond du Lac, WI Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision s, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha,, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. Page 12 / MAY 2005

4 HP THRU 60 HP 4-STROKE WARRANTY FLAT RATE MANUAL

4 HP THRU 60 HP 4-STROKE WARRANTY FLAT RATE MANUAL This Manual includes all Mercury and Mariner Outboard ls and is your guide for completing warranty labor claims. The flat rate times are listed in hours