NOTE: Not all models listed below, see links for additional MerCruiser Models Mercruiser GM V8 454 cid 7.4L 502 cid 8.2L Service Manual Service Manual Application: Gen. VI Engines Sterndrive (MCM) Models: MCM 454 Mag MPI (Serial Number 0L010029 & Up), MCM 502 Mag MPI (Serial Number 0L017000 & Up).

• Mercruiser Engine Manual

Inboard (MIE) Models: MIE 454 Mag MPI Horizon (Serial Number 0L002200 & Up), MIE 8.2L MPI (Serial Number 0L002450 & Up). L-29 Engines - Sterndrive (MCM) Model: MCM 7.4L MPI (Serial Number 0L010003 & Up). Inboard (MIE) Model: MIE 7.4L MPI (Serial Number 0L002006 & Up). 1 Service Manual Applications: 2001, 2002, 2003, 2004, 2005 and 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Gasoline Multiport Injection Engine. Service Manual #31 Part Number 90-864260.

Mercruiser Engine Manual

Exact model application: Models Application: Sterndrive (MCM) starting with serial number OM300000 and above, 5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Dow Sports (MIE) starting with serial number OM310000, 350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports. 1983-1990 MerCruiser R MR Alpha One & Alpha SS Sterndrive Manual Service Manual Application: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 MerCruiser #6 Service Manual for Sterndrive Units R-MR-Alpha One & Alpha One SS, MC 120R/140B/185R/488R/898R/228R/260R Serieal Number - 62289, MC 120MR/140MR/170MR/185MR/190MR/200MR/230MR/260MR/300 Tempest MR Serieal Number - 6849290 0A471374, MC Alpha One/Alpha One SS Serieal Number 0A471375 and Above. 1988-1998 MerCruiser Bravo Sterndrives Service Manual Sterndrive Service Manual Application: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 & 1998 MerCruiser #11 Bravo, Bravo One Sterndrive Unit Serial # B664190 and Above, Bravo Two Sterndrive Unit Serial # B892613 and Above, Bravo Three Sterndrive Unit Serial # D763691 and Above, Bravo Transom Assembly (Standard) Serial #. B673048 and Above, Bravo Transom Assembly (High Performance) Serial # D796083 and Above, Bravo Transom Assembly (Magnum) Serial # K104738 and Above.

Some Standard Bravo Transom Assemblies could have been converted to High Performance Transom Assemblies by use of a High Performance Gimbal Ring Kit (822374A2). Refer to Transom Assembly sections of this manual for identification information. 1991 2007 MerCruiser ALPHA 1 Gen 2 Sterndrive Service Manual Service Manual Application: Mercury Mercruiser Service Manual #14 (#-14, Number 14) 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 & 2007 Alpha 1 Generations II (Gen 2, Gen II, Gen Two) Outdrive, Sterndrive (Stern Drive) Unit. Mercury Mercruiser Bravo + Sport Master Service Repair Manual Service Manual Application: All Bravo Models (Serial Number 0M100000 and Above) + Sport Master Models (Serial Number 0M052945 and Above). Mercury Mercruiser Bravo One,Two,Three + Transom Service Manual Service Manual Application: Bravo One, Bravo One X, Bravo One X Diesel, (Serial Number 0M198373 and Above). Bravo One XR (Serial Number 0W240000 and Above). Bravo Two, Bravo Two X, Bravo Two X Diesel, Bravo Three, Bravo Three X, Bravo Three X Diesel (Serial Number 0M198373 and Above).

Bravo Three XR (Serial Number 0W240000 and Above). Transom Standard (Serial Number 0W173658 and Above) Transom High Performance(Serial Number 0W150260 and Above) Mercury Mercruiser D1.7L DTI Service Repair Manual Service Manual Application: D1.7L DTI ( Serial Number OM055001 and Above) Mercury Mercruiser In-ine Diesel D2.8L D4.2L D-Tronic Manual Service Manual Applicaiton: Sterndrive (MCM) Models: D2.8L D-Tronic (Serial Number 0K000001 and Above), D4.2L D-Tronic (Serial Number 0K000001 and Above). Inboard (MIE) Models: D2.8L D-Tronic (Serial Number 0K000001 and Above), D4.2L D-Tronic (Serial Number 0K000001 and Above). Introduction These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning the inboard engine or stern drive. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.

These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of these manuals and the actual inboard or stern drive. Illustrations in these manuals are used to show the basic principles of operation and work procedures. These manuals are intended for use by technicians who already possess the basic knowledge and skills to service inboard or stern drive motors and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only.

Never attempt to perform any work with out the assistance of a service manual. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers. Maintenance Schedules NOTE: Only perform maintenance which applies to your particular power package. Maintenance Intervals Maintenance intervals and the corresponding tasks to be performed, as shown in this current schedule or as found in a previously printed schedule, are generally based on an average boating application and environment. However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and the corresponding tasks to be performed.

In some cases, this may allow for more individual tasks in a single visit to the servicing dealer. Therefore, it is very important that the boat owner and the servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, the environment and the maintenance requirements. Routine Maintenance Check the crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush the cooling system after each use. Check the drive unit oil level, the trim pump oil level and the power steering pump fluid level. Check the water inlets for debris or marine growth. Check the seawater strainer and clean.

Check the coolant level. Inspect the drive unit anodes and replace if 50 percent eroded.
Lubricate the propeller shaft and retorque the nut (if operating in only freshwater, this maintenance may be extended to every four months). Operating in Saltwater Only: treat the engine surface with corrosion guard.
Check the battery connections and the fluid level.
Ensure that the gauges and the wiring connections are secure. Clean the gauges.

Scheduled Maintenance Touch-up paint the power package and spray with corrosion guard. Change the crankcase oil and filter.
Change the drive unit oil and retorque the connection of the gimbal ring to the steering shaft. Replace the fuel filters.

Check the steering system and the remote control for loose, missing or damaged parts. Lubricate the cables and the linkages. Inspect the U-joints, the splines and the bellows.

Check the clamps. Check the engine alignment.

Lubricate the U-joint splines. Lubricate the gimbal bearing and the engine coupler. Check the continuity circuit for loose or damaged connections. Test the MerCathode unit output on Bravo Models. Retorque the engine mounts.
Check the spark plugs, the wires and the distributor cap.
Clean the flame arrestor and the crankcase ventilation hoses.

Replace the PCV valve. Check the electrical system for loose, damaged or corroded fasteners. Inspect the condition and the tension of the belts.
Check the cooling system and exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. Disassemble and inspect the seawater pump and replace worn components.

Clean the seawater section of the closed cooling system. Clean, inspect and test the pressure cap. Replace the coolant. Crankcase Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil. This oil is a special blend of 25-weight and 40-weight oils for marine engines. If not available, a good grade, straight weight, detergent automotive oil of the correct viscosity, with an API classification of SH, CF/CF-2, may be used. In those areas where Quicksilver 4-Cycle 25W-40 Marine Engine Oil or a recommended straight weight oil are not available, a multi-viscosity 20W-40 or, as a second but less preferable choice, 20W-50, with API service ratings of SH, CF/CF-2 may be used.

IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Quicksilver 25W-40 or a good quality 20W-40 or 20W-50), synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. The chart below is a guide to crankcase oil selection. The oil filter should always be changed when changing the engine oil. Used Spark Plug Analysis Spark plug condition can suggest a variety of possible engine malfunctions and indicate needed engine repairs. When the old plugs are replaced, replace the entire set.

Perform plug service only on those plugs suitable for additional service, using the following procedures: 1. Remove any oil deposits with solvent and dry plugs thoroughly. Open the electrode gap wide enough to permit cleaning and filing. Remove the combustion deposits from the firing end of the spark plug with a plug cleaner.

Use compressed air to remove abrasives. File the electrode surfaces to restore clean, sharp edges. Remove filings with compressed air. Reset the gap to specifications by bending only the side electrode with the proper tool. Normal Condition Few deposits are present and probably will be light tan or gray in color.

This plug shows that the plug heat range is compatible with the engine, and the engine is electrically and mechanically in good running condition. With proper plug servicing (clean, file and regap), this plug can be reinstalled with good results. Wet Fouling (Oil Deposits) The plug becomes shorted by excessive oil entering the combustion chamber, usually in the engine with many hours of operation.

Worn piston rings, cylinder walls, valve guides or valve stem seals are causes of oil entering the combustion chamber. Only engine repairs will permanently relieve oil wet fouling. IMPORTANT: New engines or recently overhauled engines may wet foul the plugs before normal oil control is achieved with proper break-in procedures. Such fouled plugs may be serviced (clean, file and regap) and reinstalled.

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 prod- ucts, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended 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 pe rformed and of the possible hazards an d/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 recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As re quired, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products.

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 met- ric 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. Mis- matched 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 when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual.

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 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 automo- tive parts within a short period of time.

Failure to use recommended Quicksilver service replacement parts can result in poor en- gine performance and/or durability, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replacement parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replace- ment parts. Electrical, ignition and fuel system components on 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 hazar d and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properl y installed and tightened. If not, any electrical or ig- nition component opening would permit sparks to ignite fuel vapors from fuel sys- tem leaks, if they existed.