Service Manual Outline

Transcription

1 Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models B - MIE Models Section 3 - Engine A - Engine Mechanical Section 4 - Electrical System A - Starting System B - Ignition System C - Charging System D - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery System Section 6 - Cooling System A - All Models B - Seawater Cooled Models C - Closed Cooled Models Section 7 - Exhaust System A - Manifolds and Elbows B - Collectors Section 8 - Drives A - Velvet Drive In-Line And V-Drive Transmission B - Velvet Drive 5000 Series Transmission C - ZF/Hurth 630 And 800 Series Transmission Section 9 - Power Steering A - Power Steering Pump Important Information Removal And Installation Engine Electrical System Fuel System Cooling System Exhaust System Drives Power Steering OCTOBER 2001 Page v

2 Notice Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus Common Sense operation, are major accident prevention measures. DANGER Immediate hazards which will result in severe personal injury or death. WARNING Hazards or unsafe practices which could result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. 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 marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury MerCruiser product, including 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 marine trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual OCTOBER 2001 Page i

3 Precautions It should be kept in mind, while working on the product, that the electrical system and ignition system are 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, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Engine Mechanical Components Replacement Parts Many of the engine mechanical components are designed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide open throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications that 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 automotive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor engine performance and/or durability, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than the recommended service replacement parts, will void the warranty on those parts that are damaged as a result. WARNING Electrical, ignition and fuel system components on Mercury MerCruiser Engines and 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 systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Page ii OCTOBER 2001

4 Models Covered in This Manual Sterndrive (MCM) Serial Number 5.0L MPI Alpha and Bravo 350 MAG MPI Alpha and Bravo 350 MAG MPI Alpha and Bravo Horizon 0M MX 6.2 MPI MX 6.2 MPI Horizon Inboard and Tow Sports (MIE) 350 MAG MPI Inboard 350 MAG MPI Horizon Inboard MX 6.2 MPI Inboard MX 6.2 MPI Horizon Inboard 350 MAG MPI Tow Sports Serial Number 0M OCTOBER 2001 Page iii

5 THIS PAGE IS INTENTIONALLY BLANK Page iv OCTOBER 2001

6 Introduction A-2 How to Use This Manual A-2 Page Numbering A-2 Engine Serial Number Locations A-3 Mercury/Quicksilver Lubricants, Sealants And Adhesives A-4 Torque Specifications B-2 Special Tools B-2 Lubricants / Sealants / Adhesives B-3 Engine And Tune-Up Specifications.... 1B-4 MCM (Sterndrive) Models B-4 MIE (Tow Sports and Inboard) Models 1B-5 Fluid Specifications B-6 Engines B-6 Sterndrives B-6 Transmissions B-7 Maintenance Schedules B-7 Maintenance Intervals B-7 Gas Sterndrive B-8 Routine Maintenance B-8 Scheduled Maintenance B-9 Gas Inboard And Tow Sports B-11 Routine Maintenance B-11 Scheduled Maintenance B-12 Crankcase Oil B-14 Overfilled Crankcase Oil B-15 Checking B-15 Filling B-16 Changing Oil and Filter B-17 Flushing The Power Package - MCM.. 1B-19 Sterndrive Water Pickups B-19 Alternative Water Pickups B-21 Flushing The Power Package - MIE.... 1B-23 Precautions B-23 Inboard Models B-23 Tow Sports Models B-25 Transmission Fluid B-27 Checking B-27 Changing and Filling B-28 Sterndrive Unit Oil B-28 Checking B-28 Filling B-28 Changing B-29 Power Trim Pump Fluid B-31 Checking B-31 Filling B-31 Changing B-31 Power Steering Pump Fluid B-32 Checking B-32 Filling and Bleeding B-33 Water Inlets B-35 Seawater Strainer B-35 IMPORTANT INFORMATION Section 1A - General Information IMPORTANT INFORMATION Section 1B - Maintenance Closed Cooling System B-36 Checking Coolant Level B-36 Cleaning and Inspection B-36 Changing Coolant B-36 Anodes B-37 Propeller Shaft B-40 Power Package Surfaces B-41 Painting Your Power Package B-41 Battery B-42 Instruments B-42 Gimbal Ring / Steering Connection.... 1B-42 Changing Water Separating Fuel Filter. 1B-43 Steering System B-44 Remote Control B-44 Sterndrive Components B-44 Lubrication B-44 Throttle Cable B-44 Shift Cable and Transmission Linkage 1B-45 Sterndrive Components B-46 Continuity Circuit B-50 MerCathode B-52 Engine Mounts B-52 Electrical System B-52 Cleaning Flame Arrestor B-53 Serpentine Drive Belt B-54 Inboard and Tow Sports Models.... 1B-54 Sterndrive Models B-55 Inspection B-55 Replacing Belt and/or Adjusting Tension B-56 Exhaust System B-57 Seawater Pump B-57 Starter Motor B-58 14MT B-58 Cold Weather And Extended Storage.. 1B-59 Preparing Your Power Package For Storage B-59 Draining Instructions B-61 Identification B-62 Boat In The Water B-63 Boat Out Of The Water B-67 All Models B-70 Page vi OCTOBER 2001

7 IMPORTANT INFORMATION Section 1C - Troubleshooting Used Spark Plug Analysis C-2 Normal Condition C-2 Chipped Insulator C-3 Wet Fouling (Oil Deposits) C-3 Cold Fouling C-4 Overheating C-4 High Speed Glazing C-5 Scavenger Deposits C-5 Pre-Ignition Damage C-6 Reversed Coil Polarity C-6 Splashed Deposits C-7 Mechanical Damage C-7 Poor Boat Performance And/Or Poor Maneuverability C-8 Improper Full Throttle Engine RPM C-10 Engine Cranks Over But Will Not Start Or Starts Hard C-11 Important Information C-11 Engine Will Not Crank Over C-12 Charging System Inoperative C-12 Noisy Alternator C-13 Instrumentation Malfunction C-13 Radio Noise C-13 Poor Fuel Economy C-14 Engine Runs Poorly at Idle C-15 Engine Runs Poorly At High RPM C-16 Engine Acceleration Is Poor C-17 Troubleshooting with Vacuum Gauge C-17 Engine Noise C-18 Important Information C-18 Oil Pressure C-24 Excessive Oil Consumption C-27 Water In The Engine C-28 Important Information C-28 Engine Overheats (Mechanical) C-30 Power Steering C-33 Drain System Will Not Drain Or Drains Slowly 1C OCTOBER 2001 Page vii

8 REMOVAL AND INSTALLATION Section 2A - MCM Models Torque Specifications A-2 Lubricants / Sealants / Adhesives A-3 Special Tools A-4 Removal A-5 Engine Installation A-8 Electrical Connections A-13 EFI Electrical System Precautions.. 2A-13 Installing Continuity Wire A-14 Instrumentation Connections A-14 Trim Position Sender Connections.. 2A-15 MerCathode Connections A-16 Audio Warning Alarm Connections.. 2A-17 Power Trim Pump Connections A-17 Fluid Connections A-18 Fuel A-18 Gear Lube Monitor Hose A-19 Power Steering Hoses A-20 Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups.... 2A-21 Alpha or Bravo Models Using Alternative Water Pickups... 2A-21 Coolant Recovery Bottle A-24 Shift Cable Installation A-25 Alpha Models - Drive Unit Not Installed A-25 Bravo Models A-30 Throttle Cable Installation and Adjustment A-35 Battery Connection A-37 Engine Cover Installation A-37 REMOVAL AND INSTALLATION Section 2B - MIE Models Torque Specifications B-2 Lubricants / Sealants / Adhesives B-2 Removal B-3 Engine Mount Pre-Adjustment B-6 Engine Preparation B-7 Engine Oil Dipstick Relocation B-7 Engine Installation and Initial Engine Alignment B-8 Models With 8 Degree Down Angle Transmissions B-8 Models with V-Drive Transmissions.. 2B-10 All Models B-11 Exhaust System Hose / Tube Connections B-12 Electrical Connections B-13 EFI Electrical System Precautions... 2B-13 Instrumentation Connections B-13 Fluid Connections B-14 Final Engine Alignment B-15 Engine Cover Installation B-19 Fuel Supply Connections B-20 Throttle Cable Installation and Adjustment B-20 Shift Cable Installation And Adjustment. 2B-20 Page viii OCTOBER 2001

9 ENGINE Section 3A - Engine Mechanical Identification A-3 General Specifications A l (305 cid) A l (350 cid) A l (377 cid) A-5 Engine Specifications l (305 cid) and 5.7 l (350 cid) A-6 Cylinder Head A-6 Cylinder Bore A-6 Oil Pump A-6 Piston Bore Clearance A-6 Piston Rings A-7 Piston Pin A-7 Crankshaft A-8 Connecting Rod A-9 Valve A-9 Camshaft A-11 Timing Chain A-11 Flywheel A-11 Engine Specifications l (377 cid).. 3A-12 Cylinder Head A-12 Cylinder Bore A-12 Oil Pump A-12 Piston Clearance A-12 Piston Rings A-13 Piston Pin A-13 Crankshaft A-14 Connecting Rod A-15 Valve A-15 Camshaft A-17 Timing Chain A-17 Flywheel A-17 Torque Specifications A-18 Special Tools A-22 Lubricants / Sealants / Adhesives A-23 Precautions A-25 General Information A-26 Repair Procedures A-26 Special Notice A-26 Engine Rotation A-26 Crankcase Oil Dipstick Measurements 3A-27 Engine Mounts A-28 Exploded Views A-28 Valve Cover A-30 Removal A-30 Cleaning and Inspection A-30 Installation A-30 Rocker Arm / Valve Pushrod A-31 Removal A-31 Cleaning A-31 Inspection A-31 Installation A-32 Valve Stem Oil Seal / Valve Spring - Cylinder Head Installed A-33 Exploded View A-33 Removal A-34 Installation A-35 Valve Adjustment A-38 Engine Stopped A-38 Intake Manifold Assembly A-40 Exploded View A-40 Removal A-41 Cleaning A-43 Inspection A-43 Upper And Lower Intake Manifolds.. 3A-43 Installation A-43 Hydraulic Valve Lifters A-46 Exploded View A-46 Special Information A-46 Removal A-47 Cleaning A-48 Inspection A-48 Installation A-49 Camshaft and Camshaft Bearings A-50 Measuring Camshaft Lobe Lift A-50 Removal A-52 Cleaning A-54 Inspection A-54 Installation A-55 Cylinder Head A-59 Removal A-59 Disassembly A-60 Cleaning A-61 Inspection A-62 Repair A-67 Reassembly A-72 Installation A-75 Oil Pan A-77 Removal A-77 Cleaning A-77 Inspection A-78 Installation A OCTOBER 2001 Page ix

10 Section 3A - Engine Mechanical (continued) Oil Pump A-81 Exploded View A-81 Removal A-82 Disassembly A-82 Cleaning A-83 Inspection A-83 Reassembly A-84 Installation A-86 Crankshaft Balancer A-87 Removal A-87 Cleaning A-87 Inspection A-87 Installation A-88 Front Cover Oil Seal A-90 Oil Seal Replacement Without Removing Front Cover A-90 Front Cover A-91 Removal A-91 Cleaning and Inspection A-92 Installation A-92 Connecting Rod, Bearings and Piston Assembly A-94 Exploded View A-94 Removal A-95 Disassembly A-96 Cleaning A-97 Inspection A-97 Reassembly A-112 Installation A-115 Crankshaft, Main Bearings And Engine Block A-119 Exploded View A-119 Removal A-120 Cleaning A-123 Inspection A-126 Installation A-138 Timing Chain And Sprockets A-150 Removal A-150 Cleaning A-151 Inspection A-151 Reassembly A-151 Installation A-152 Flywheel Housing A-153 Removal A-153 Cleaning A-154 Inspection A-154 Installation A-154 Flywheel A-155 Removal A-155 Cleaning and Inspection A-156 Installation A-156 Rear Oil Seal A-158 Removal A-158 Cleaning A-159 Inspection A-159 Installation A-159 Rear Oil Seal Retainer A-161 Removal A-161 Cleaning A-161 Inspection A-161 Installation A-162 Oil Filter By-Pass Valve and Block Adapter A-163 Exploded View A-163 Removal A-164 Cleaning A-165 Inspection A-165 Installation A-166 Page x OCTOBER 2001

11 Identification A-2 Replacement Parts Warning A-3 General Precautions A-3 Typical Starting System Components.... 4A-4 Positive Current Flow A-5 Battery A-5 Battery Cable Recommendations A-5 Delco PG260F1 Starter A-6 Specifications A-6 Starter Specifications A-6 Torque Specifications A-6 Delco PG260L Starter A-7 Specifications A-7 Starter Specifications A-7 Torque Specifications A-7 Specifications B-2 Spark Plugs B-2 Distributor B-2 Coil B-2 Firing Order B-2 Torque Specifications B-2 Lubricants / Sealants / Adhesives B-3 Spark Plugs B-3 Removal B-3 Inspection B-3 Replacing B-4 Spark Plug Wires B-5 Inspection B-5 Replacing B-5 Delco Alternator C-2 Identification C-2 Replacement Parts Warning C-2 Specifications C-3 Torque Specifications C-3 Special Tools C-3 Precautions C-4 EFI Electrical System Precautions.. 4C-4 Charging System Components C-5 Periodic Maintenance C-5 ELECTRICAL SYSTEM Section 4A - Starting System ELECTRICAL SYSTEM Section 4B - Ignition System ELECTRICAL SYSTEM Section 4C - Charging System Delco 14MT Starter A-8 Specifications A-8 Starter Specifications A-8 Torque Specifications A-8 Lubricants / Sealants / Adhesives A-8 Description A-8 Testing A-9 Removal A-11 Solenoid Switch A-12 Inspection A-12 Installation A-13 Ignition Coil B-7 Removal B-7 Installation B-8 Distributor B-9 Removal B-9 Disassembly B-10 Cleaning and Inspection B-12 Reassembly B-12 Installation B-13 Troubleshooting Tests (Alternator on Engine) C-5 Charging System C-6 Resistance C-7 Circuitry C-9 Removal C-11 Alternator C-11 Alternator Bracket C-11 Installation C-12 Alternator Bracket C-12 Alternator C-12 Battery Isolator Diagram C OCTOBER 2001 Page xi

12 Instrumentation D-2 Single Station Installations - Typical. 4D-2 Power Trim System D-4 Specifications A-2 Torque Specifications A-2 Special Tools A-3 Lubricants / Sealants / Adhesives A-3 Replacement Parts Warning A-3 Abbreviations A-4 Precautions A-5 Fuel Supply Connections A-5 Fuel Delivery System A-6 Recommendations A-6 Exploded Views A-7 Fuel Rail and Injectors A-7 Throttle Body A-8 Cool Fuel System A-9 Fuel System Flow Diagrams A-10 Sensor Locations A-11 Fuel Pressure Relief Procedure A-13 Flame Arrestor A-13 Removal A-13 Cleaning and Inspection A-13 Installation A-13 Throttle Body A-14 Removal A-14 Cleaning and Inspection A-16 Installation A-17 ELECTRICAL SYSTEM Section 4D - Wiring Diagrams MerCathode System Wiring Diagram.. 4D-5 Wiring Diagrams D-6 FUEL SYSTEM Section 5A - Fuel Delivery System Electronic Control Module (ECM) A-18 Removal A-18 Cleaning and Inspection A-18 Installation A-18 Water Separating Fuel Filter A-19 Removal A-20 Installation A-20 Cool Fuel System A-20 Removal A-20 Disassembly A-22 Reassembly A-24 Installation A-28 Intake Manifold A-29 Removal A-29 Disassembly A-31 Cleaning and Inspection A-35 Assembly A-35 Installation A-37 Sensors A-41 Manifold Air Pressure / Temperature (MAPT) Sensor A-41 Throttle Position Sensor (TPS) A-42 Idle Air Control (IAC) Valve A-44 Knock Sensor A-45 Fuel Pump Relay A-46 Main Power Relay A-47 Page xii OCTOBER 2001

13 Torque Specifications A-2 Lubricants / Sealants / Adhesives A-2 Seawater Inlet Recommendations A-3 Seacock (Seawater Inlet Valve) A-3 Seawater Strainer A-3 Seawater Pickups A-4 Through the Hull Mounted A-4 Transom Mounted A-6 Quicksilver Sea Strainer A-8 Removal A-8 Cleaning and Inspection A-9 Installation A-10 Auxiliary Hot Water Heater Installation. 6A-11 Supply Hose Connection A-11 Return Hose Connection A-12 COOLING SYSTEM Section 6A - All Models Seawater Pump A-12 Output Test A-12 Removal A-14 Disassembly A-15 Cleaning and Inspection A-16 Reassembly A-16 Installation A-19 Water Circulating Pump A-20 Removal A-20 Cleaning and Inspection A-21 Installation A-22 Water Distribution Housing A-23 Removal A-23 Cleaning And Inspection A-23 Installation A-23 COOLING SYSTEM Section 6B - Seawater Cooled Models Torque Specifications B-2 Lubricants / Sealants / Adhesives B-2 Specifications B-2 Seawater Cooling System Capacity. 6B-2 Thermostat B-2 Flushing Seawater Cooling System.... 6B-3 Thermostat B-3 Removal B-3 Testing B-4 Installation B-5 Torque Specifications C-2 Lubricants / Sealants / Adhesives C-2 Specifications C-2 Closed Cooling System Capacity... 6C-2 Coolant Specification C-2 Thermostat C-2 Pressure Cap Rating C-2 Description C-3 Coolant Recommendations C-3 Maintaining Coolant Level C-4 Pressure Cap Maintenance C-5 Testing Closed Cooling System C-6 Testing Coolant for Alkalinity C-6 Pressure Testing System C-7 Testing for Cylinder Head Gasket Leak C-9 Testing Pressure Cap C-10 Water Tap Location For Shaft Log Seal. 6B-6 Water Flow Diagrams B-7 Seawater Cooled Models With An Engine Mounted Seawater Pump 6B-7 Seawater Cooled Models Without An Engine Mounted Seawater Pump 6B-8 COOLING SYSTEM Section 6C - Closed Cooled Models Thermostat C-12 Removal C-12 Testing C-12 Installation C-14 Heat Exchanger C-15 Testing C-15 Removal C-15 Disassembly C-16 Cleaning And Inspection C-16 Repair C-16 Assembly C-17 Installation C-18 Heat Exchanger Bracket Hardware.... 6C-19 Heat Exchanger Hose Connections.... 6C-20 Water Tap Location For Shaft Log Seal. 6C-21 Closed Cooling System Water Flow Diagram C OCTOBER 2001 Page xiii

14 EXHAUST SYSTEM Section 7A - Manifolds, Elbows And Risers Torque Specifications A-2 Lubricants / Sealants / Adhesives A-2 Exploded View A-3 Removal A-4 Torque Specifications B-2 Lubricants / Sealants / Adhesives B-2 Important Information B-3 Exhaust Y -Pipe B-4 Water Shutter B-4 Through Transom Exhaust B-6 Water Shutter B-6 Below Swim Platform Exhaust Pipe B-8 Removal B-8 Cleaning And Inspection B-8 Installation B-8 Silent Choice Exhaust System B-9 Removal B-9 EXHAUST SYSTEM Section 7B - Collectors Cleaning and Inspection A-5 Manifold Leak Test A-6 Installation A-6 Cleaning and Inspection B-10 Installation B-11 Air Tube Routing B-12 Air Pump Maintenance B-13 Troubleshooting Silent Choice Exhaust Silencer System B-14 Exhaust Muffler Kit B-15 Removal B-15 Maintenance B-15 Cleaning and Inspection B-16 Installation B-17 DRIVES Section 8A - Velvet Drive In-Line And V-Drive Transmission Identification A-2 Specifications A-3 Operating Specifications A-3 Ratios And Part Numbers A-3 Fluid Specifications A-4 Pressure Specifications A-4 Torque Specifications A-4 Lubricants / Sealants / Adhesives A-5 Precautions A-5 Transmission / Propeller Rotation A-6 Fluid Level A-7 Checking A-7 Changing A-7 Filling A-9 Removal A-10 Installation A-11 Shift Lever Installation A-13 Shift Control And Cables A-14 Transmission Shift Lever and Shift Cable Bracket A-15 Installation and Adjustment A-16 Pressure Test A-20 Transmission Repair A-20 Page xiv OCTOBER 2001

15 DRIVES Section 8B - Velvet Drive 5000 Series Transmission Identification B-2 Specifications B-3 Ratios and Part Numbers B-3 Fluid Specifications B-3 Pressure Specifications B-4 Torque Specifications B-4 Lubricants / Sealants / Adhesives B-4 Precautions B-5 Transmission / Propeller Rotation B-6 Fluid Level B-7 Checking B-7 Changing B-7 Filling B-8 Removal B-9 Installation B-10 Shift Lever Installation B-12 Shift Control And Cables B-13 Transmission Shift Lever and Shift Cable Bracket B-14 Installation and Adjustment B-16 Pressure Test B-20 Transmission Repair B-20 DRIVES Section 8C - ZF/Hurth 630 And 800 Series Transmission Identification C-2 Specifications C-3 Operating Specifications C-3 Ratios and Part Numbers C-3 Fluid Specifications C-4 Pressure Specifications C-4 Torque Specifications C-4 Special Tools C-4 Lubricants / Sealants / Adhesives C-5 Precautions C-5 Transmission / Propeller Rotation C-6 Fluid Level C-7 Checking C-7 Changing C-7 Filling C-8 Torque Specifications A-2 Lubricants / Sealants / Adhesives A-2 Special Tools A-2 Precautions A-3 Power Steering Pump And Components Exploded View A-3 Power Steering Pump Pulley Replacement A-4 Removal A-4 Installation A-4 Power Steering Pump A-5 Removal A-5 Flow Control Valve Servicing A-6 Pump Shaft Oil Seal Replacement.... 9A-7 Installation A-9 Removal C-9 Installation C-10 Shift Control And Cables C-13 Transmission Shift Lever and Shift Cable Bracket C-13 Installation and Adjustment C-15 Pressure Test C-19 Transmission Repair C-19 POWER STEERING Section 9A - Power Steering Pump Replacing Belt And/Or Adjusting Tension 9A-10 Filling And Bleeding A-10 Checking Fluid Level A-10 Hydraulic Hoses And Fluid Cooler A-11 High Pressure Hose (Pump-To-Control Valve) A-11 Low Pressure Hose (Pump-To-Fluid Cooler) A-13 Low Pressure Hose (Control Valve-To-Fluid Cooler) A OCTOBER 2001 Page xv

16 THIS PAGE IS INTENTIONALLY BLANK Page xvi OCTOBER 2001

17 SERVICE MANUAL NUMBER 31 Table of Contents IMPORTANT INFORMATION Section 1A - General Information GENERAL INFORMATION 1 A Introduction A-2 How to Use This Manual A-2 Page Numbering A-2 Engine Serial Number Locations A-3 Mercury/Quicksilver Lubricants, Sealants And Adhesives A OCTOBER 2001 Page 1A-1

18 GENERAL INFORMATION SERVICE MANUAL NUMBER 31 Introduction This comprehensive overhaul and repair manual is designed as a service guide for the models previously listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines. Before attempting repairs or tune-up, it is suggested that the procedure first be read through to gain knowledge of the methods and tools used and the cautions and warnings required for safety. How To Use This Manual This manual is divided into sections which represent major components and systems. Some sections are further divided into parts that more fully describe the component. Refer to the Service Manual Outline following Models Covered In This Manual for section titles. Page Identification The service manual number and section title appear at the top of the page. Two number groups appear at the bottom of each page. Following is an example and a description. a b c d e f g a -Section Number b-section Part c -Page Number d-manual Number e -Revision Number f -Month Printed g-year Printed Page 1A OCTOBER 2001

19 SERVICE MANUAL NUMBER 31 Engine Serial Number Locations GENERAL INFORMATION a b a -Serial Number Plate b-starter Motor OCTOBER 2001 Page 1A-3

20 GENERAL INFORMATION SERVICE MANUAL NUMBER 31 Mercury/Quicksilver Lubricants, Sealants And Adhesives Tube Ref. # 4 Description Needle Bearing Assy. Lubricant Container Size Mercury Part Number Quicksilver Part Number 8 oz (226.8 g) tube N/A A1 6 Dielectric Grease 8 oz (226.8 g) can N/A Loctite Thread Locker Loctite 567 PST Pipe Sealant Loctite Master Gasket Kit 2 Cycle Premium Outboard Oil 10 ml tube N/A ml tube N/A N/A US qt (0.94 L) A Q1 19 Perfect Seal 16 oz (0.45 kg) can N/A Liquid Neoprene 8 oz (226.8 g) can N/A Bellows Adhesive 1.5 oz (42.5 g) tube N/A Q Loctite 680 Retaining Compound 10 ml tube N/A Special Lubricant oz (226.8 g) tube A Q U-Joint and Gimbal Bearing Grease Loctite 222 Thread Locker Loctite 242 Thread Locker 4 Cycle 25W40 Engine Oil Premium Gear Lubricant High Performance Gear Lube Engine Coupler Spline Grease Anti-Corrosion Grease A Q1 10 ml tube N/A ml tube N/A A Q1 1 US qt (0.94 L) A Q1 1 US qt (0.94 L) A Q1 14 oz (0.39 kg) cartridge A Q1 8 oz (226.8 g) tube A Q C with Teflon 8 oz (226.8 g) tube A Q Stroke 10W30 Outboard Oil Power Trim & Steering Fluid 1 US qt (0.94 L) A Q1 8 oz (226.8 g) A Q1 Page 1A OCTOBER 2001