MAIN MENU SERVICE MANUAL Number 26 MARINE ENGINES GM 4 Cylinder 181 cid (3.0L) Printed in U.S.A.
MerCruiser # 26 GM 4 Cylinder 181 cid (3.0L) 90-861329--1 MerCruiser # 26 GM 4 Cylinder 181 cid (3.
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.
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.
Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM 3.0L (181 CID) - Alpha Drive Section 3 - Engine A - 3.
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GENERAL INFORMATION SERVICE MANUAL NUMBER 26 IMPORTANT INFORMATION 1 Section 1A - General Information A Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . How to Read a Parts Manual . . . . . . . . . . . Directional References . . . . . . . . . . . . . . . . . Engine Rotation . . . . . . . . . . . . . . .
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 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.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 How to Read a Parts Manual POWER STEERING PUMP ASSEMBLY 8 2 10 6 1 4 3 7 9 5 REF. NO. 1 2 3 4 5 6 7 8 9 10 PART NO. 90507A12 36- 95805 73873A1 16- 41877 57- 65607T 32- 806684 25- 89879 25- 806232 13- 35048 61990 SYM. QTY. 1 1 1 1 1 1 1 1 1 1 DESCRIPTION PUMP ASSEMBLY–Power Steering CAP PULLEY STUD V-BELT HOSE–Pressure (FITTINGS ON BOTH ENDS) O-RING O-RING LOCKWASHER (3/8 in.) CABLE TIE REF. NO. : Number shown next to part on exploded view PART NO.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 Directional References Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this maintenance manual, all directional references are given as they appear when viewing boat from stern looking toward bow.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 Engine Serial Number Locations a b 71559 a - Serial Number Plate b - Starter Motor Propeller Information Refer to the “Propeller” section in appropriate MerCruiser Sterndrive Service Manual, or order publication 90-86144, “What You Should Know About Quicksilver Propellers.” Changing diameter, pitch or coupling of a propeller will affect engine rpm and boat performance. The blade configuration also will affect performance.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 Water Testing New Engines Use care during the first 20 hours of operation on new MerCruiser engines or possible engine failure may occur. If a new engine has to be water-tested at full throttle before the break-in period is complete, follow this procedure. 1. Start engine and run at idle rpm until normal operating temperature is reached. 2. Run boat up on plane. 3. Advance engine rpm (in 200 rpm increments) until engine reaches its maximum rated rpm.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 For best speed and minimum spray, the corner between the bottom and the transom should be sharp. c b 72003 a a - Bottom b - Corner c - Transom The bottom is referred to as having a “hook” if it is concave in the fore-and-aft direction. A hook causes more lift on the bottom near the transom and forces the bow to drop. This increases wetted surface and reduces boat speed.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 Marine Fouling Fouling is an unwanted build-up (usually animal-vegetable-derived) occurring on the boat’s bottom and drive unit. Fouling adds up to drag, which reduces boat performance. In fresh water, fouling results from dirt, vegetable matter, algae or slime, chemicals, minerals and other pollutants. In salt water, barnacles, moss and other marine growth often produce dramatic build-up of material quickly.
SERVICE MANUAL NUMBER 26 GENERAL INFORMATION Weight Distribution Weight distribution is extremely important; it affects a boat’s running angle or attitude. For best top speed, all movable weight - cargo and passengers - should be as far aft as possible to allow the bow to come up to a more efficient angle (3 to 5 degrees). On the negative side of this approach is the problem that, as weight is moved aft, some boats will begin an unacceptable porpoise.
GENERAL INFORMATION SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 1A-10 90-861329--1 MARCH 1999
MAINTENANCE SERVICE MANUAL NUMBER 26 IMPORTANT INFORMATION 1 Section 1B - Maintenance B Table of Contents Maintenance Schedule . . . . . . . . . . . . . . . . . 1B-2 Maintenance Intervals . . . . . . . . . . . . . . . 1B-2 Scheduled Maintenance That Can Be Performed By Owner/Operator . . . 1B-2 Scheduled Maintenance That Should Be Performed By A Dealer . . . . . . . . . . 1B-3 Engine and Tune-Up Specifications . . . . . . 1B-4 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE MANUAL NUMBER 26 Maintenance Schedule Maintenance Intervals Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in previously printed schedules, 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.
MAINTENANCE SERVICE MANUAL NUMBER 26 Scheduled Maintenance That Should Be Performed By A Dealer NOTE: Only perform maintenance which applies to your particular power package. Task Interval Whenever insufficient seawater flow is Seawater Pickup Pump - Disassemble and suspected (if operating temperature inspect. exceeds normal range.) Crankcase Oil and Filter - Change. Ignition System - Clean and inspect condition. Flame Arrestor and Crankcase Ventilation Hose - Clean and inspect.
MAINTENANCE SERVICE MANUAL NUMBER 26 Engine and Tune-Up Specifications MODEL MCM 3.0L Propshaft Horsepower (SAV1 Rating) 1351 (1142) Propshaft Kilowatts (SAV1 Rating) 1011 (852) Number of Cylinders 4 Displacement Bore/Stroke In. (mm) Compression Ratio Compression Pressure 181 cid (3.0L) 4.00 X 3.60 (101.6 X 91.4) 9.25:1 Minimum 100 psi (690 kPa)7 Idle rpm (In Neutral)3 700 rpm5 Max rpm (At W.O.T.
MAINTENANCE SERVICE MANUAL NUMBER 26 Fluid Capacities NOTICE Unit Of Measurement: U.S. Quarts (Liters) All capacities are approximate fluid measures. MODEL Crankcase (With Filter) MCM 181 cid / 3.0L 1 Seawater Cooling System 4 (3.8) 2 9 (8.5) Closed Cooling System 9 (8.5) 1 Always use dipstick to determine exact quantity of oil or fluid required. 2 Seawater Cooling System capacity information is for winterization use only. Engine Rotation and Firing Order L.H.
MAINTENANCE SERVICE MANUAL NUMBER 26 After Break-in Period To help extend the life of your MerCruiser power package, the following recommendations should be considered; • Use a propeller that allows the engine to operate at or near the top of the maximum rpm range (See “Specifications” section) when at full throttle with a normal boat load. • Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at maximum (full throttle) rpm.
MAINTENANCE SERVICE MANUAL NUMBER 26 Some of these adverse effects are due to the tendency of gasolines containing alcohol to absorb moisture from the air, resulting in a phase of water and alcohol separating from the gasoline in the fuel tank. The adverse effects of alcohol are more severe with methyl alcohol (methanol) and are worse with increasing alcohol content.
MAINTENANCE SERVICE MANUAL NUMBER 26 Fuels containing alcohol will absorb moisture from the air. At first, this moisture will remain in solution, but once the water content of the fuel has built up to about one-half of one percent, it will separate out (phase separation), bringing the alcohol with it.
MAINTENANCE SERVICE MANUAL NUMBER 26 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 correct viscosity, with an API service rating of SH,CF/CF-2 may be used.
MAINTENANCE SERVICE MANUAL NUMBER 26 Adding Crankcase Oil 1. Coat sealing ring on new filter with engine oil, and install. Tighten filter securely (following filter manufacturer’s instructions). Do not overtighten. b a 75809 a - Oil Filter b - Sealing Ring 2. Fill crankcase with oil. 3. Start engine and check for leaks. Checking Engine Oil Level/Filling IMPORTANT: ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN “MAINTENANCE SCHEDULE” CHART.
SERVICE MANUAL NUMBER 26 MAINTENANCE Changing Oil and Filter 1. Start engine and run until it reaches normal operating temperatures. IMPORTANT: Change oil when engine is warm from operation, as it flows more freely, carrying away more impurities. 2. Stop engine. 3. Remove drain plug from oil pan or from oil drain hose. NOTE: If drain plug is not accessible because of boat construction, oil may be removed through dipstick tube, using a Quicksilver Crankcase Oil Pump. 4.
MAINTENANCE SERVICE MANUAL NUMBER 26 Power Steering System Checking Fluid Level ENGINE WARM 1. Stop engine and position drive unit so that it is straight back. 2. Remove fill cap/dipstick from power steering pump and note fluid level. a b 75809 a - Fill Cap / Dipstick b - Power Steering Pump 3. Level should be between the FULL HOT mark and ADD mark on dipstick. a 72518 a - Proper Fluid Level with Engine Warm 4.
MAINTENANCE SERVICE MANUAL NUMBER 26 ENGINE COLD 1. With engine stopped, position drive unit so that it is straight back. 2. Remove fill cap/dipstick from power steering pump and note fluid level. 3. Level should be between FULL COLD mark and bottom of dipstick. a 72519 a - Proper Fluid Level with Engine Cold 4.
MAINTENANCE SERVICE MANUAL NUMBER 26 5. Position drive unit so that it is straight back and stop engine. Remove fill cap from pump. Allow any foam in pump reservoir to disperse, then check fluid level and add fluid, as required, to bring level up to FULL HOT mark on dipstick. DO NOT OVERFILL. Reinstall fill cap securely. IMPORTANT: Drive unit must be positioned straight back and power steering fluid must be hot to accurately check fluid level. 6.
MAINTENANCE SERVICE MANUAL NUMBER 26 Flushing System If engine is operated in salty, polluted, or mineral-laden water, flush cooling system (preferably after each use) to reduce corrosion and prevent the accumulation of deposits in the system. Thoroughly flush cooling system prior to storage. BOAT OUT OF WATER WARNING When flushing cooling system with boat out of the water, be certain that area in vicinity of propeller is clear and that no person is standing nearby.
MAINTENANCE SERVICE MANUAL NUMBER 26 2. Partially open water tap(s) (approximately 1/2 maximum capacity) and allow drive unit and cooling system to fill completely. Do not use full tap water pressure. a b 72672 a - Quicksilver Flushing Attachment b - Water To Drive Unit NOTE: Drive unit is full when water is discharged out of drive unit, and/or seawater section of closed cooled system is full when water is discharged through propeller. CAUTION Do not run engine above 1500 rpm when flushing.
MAINTENANCE SERVICE MANUAL NUMBER 26 9. Raise drive unit to full UP position. 10. Remove hose and flushing attachment. CAUTION If boat is in the water, seacock (water inlet valve), if equipped, must remain closed until engine is to be restarted to prevent water from flowing back into cooling system and/or boat. If boat is not fitted with a seacock, water inlet hose must be disconnected and plugged to prevent water from flowing back into cooling system and/or boat.
MAINTENANCE SERVICE MANUAL NUMBER 26 Shift Cable a b b 75811 a - Pivot Points b - Guide Contact Surface Engine Coupler / U-Joint Shaft Splines Lubricate coupler and splines with Quicksilver Engine Coupler Spline Grease (92-816391A4). IMPORTANT: Sterndrive unit does not have to be removed to grease coupler. NOTE: Refer to MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation if necessary.
MAINTENANCE SERVICE MANUAL NUMBER 26 Cold Weather or Extended Storage Precautions CAUTION Sterndrive unit should be stored in full DOWN position. Universal Joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to service. CAUTION If Power Package will not be used for an extended period of time or will be exposed to freezing temperatures, drain water from seawater section of cooling system.
MAINTENANCE SERVICE MANUAL NUMBER 26 CAUTION A discharged battery can be damaged by freezing. IMPORTANT: MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe) antifreeze be used in seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer’s recommendations.
MAINTENANCE SERVICE MANUAL NUMBER 26 d. Squirt the remaining 2 ounces (57 g) of Storage Seal (or oil) rapidly into carburetor, just as the engine begins to stall, due to lack of fuel. Allow engine to stop. e. Turn ignition key to OFF position. f. Refer to “Flushing Cooling System” and appropriately remove water supply to the seawater pickup pump. 9. Clean flame arrestor and crankcase ventilation hoses and reinstall. 10. Drain seawater section of cooling system as outlined in “Draining Instructions.” 11.
MAINTENANCE SERVICE MANUAL NUMBER 26 If your engine is equipped with this device, follow this procedure: 1. Detach the hoses from the top fittings. a 76243 a - Fittings 2. Lower hoses into bilge. If hoses have developed a “set,” T-handle retrieval tool can be used to push hoses below their connection point. a b 76244 a - Hoses b - Connection Points IMPORTANT: Hoses must be lowered below their connection point on the engine in order to drain completely. 3.
MAINTENANCE SERVICE MANUAL NUMBER 26 Draining Seawater (Raw-Water) Cooled Models NOTICE Refer to “Cold Weather or Extended Storage Precautions” in this section, BEFORE proceeding. 1. Engine must be as level as possible to ensure complete draining of cooling system. 2. Remove drain plugs from cylinder block and manifold. a 71424 a - Drain Plug (Port and Starboard) 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained.
MAINTENANCE SERVICE MANUAL NUMBER 26 5. Insert a small wire (repeatedly) to make sure that vent holes and water drain holes and passages (as shown) are unobstructed and open. e b d f c c a 70134 f 71216 a b c d e f - Speedometer Pitot Tube - Gear Housing Cavity Drain Hole - Trim Tab Cavity Vent Hole - Trim Tab Cavity Drain Passage - Gear Housing Water Drain Hole (One Each - Port and Starboard) - Gear Housing Cavity Vent Hole 6.
MAINTENANCE SERVICE MANUAL NUMBER 26 8. For additional assurance against freezing and rust, remove the thermostat cover and thermostat. Fill the engine seawater cooling system with a mixture of antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage. Using a new gasket, reinstall thermostat and cover. Tighten cover bolts to 30 lb-ft (41 Nm).
MAINTENANCE SERVICE MANUAL NUMBER 26 Draining Seawater Section of Closed Cooled (Coolant) Models NOTICE Refer to “Cold Weather or Extended Storage Precautions” in this section, BEFORE proceeding. CAUTION If boat is in the water or is to remain in the water, seacock (if equipped) must remain closed until engine is to be restarted to prevent contaminated water from flowing back into cooling system.
MAINTENANCE SERVICE MANUAL NUMBER 26 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. 4. Make sure gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed. a c b d 71216 a - Vent Holes b - Anode Cavity Drain Holes c - Drain Hole d - Speedometer Pitot Hole 5.
MAINTENANCE SERVICE MANUAL NUMBER 26 Recommissioning NOTICE Refer to “Cold Weather or Extended Storage Precautions” in this section BEFORE proceeding. WARNING To prevent possible injury or damage to equipment, do not install battery until all maintenance has been performed on engine. 1. Check that all cooling system hoses are connected properly and hose clamps are tight. Check that all drain plugs are installed and tightened securely. 2. Inspect drive belts.
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MAINTENANCE SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 1B-30 90-861329--1 MARCH 1999
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 IMPORTANT INFORMATION 1 Section 1C - Troubleshooting C Table of Contents Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Used Spark Plug Analysis . . . . . . . . . . . . . . 1C-3 Spark Plug Analysis . . . . . . . . . . . . . . . . . . . 1C-4 Normal Condition . . . . . . . . . . . . . . . . . . . 1C-4 Chipped Insulator . . . . . . . . . . . . . . . . . . . 1C-4 Wet Fouling (Oil Deposits) . . . . . . . . . . . 1C-4 Cold Fouling . . . . . . .
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Precautions WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire or explosion. WARNING Be careful when cleaning flame arrestor and crankcase ventilation hose; gasoline is extremely flammable and highly explosive under certain conditions. Be sure that ignition key is OFF. DO NOT smoke or allow sources of spark or open flame in area when cleaning flame arrestor and crankcase ventilation hose.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 WARNING When running engine with boat out of water, be certain that area in vicinity of propeller is clear and that no person is standing nearby. As a precautionary measure, it is recommended that the propeller be removed. CAUTION DO NOT run engine above 1500 rpm, as suction created by seawater pickup pump may collapse water supply hose and cause engine to overheat.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Spark Plug Analysis Normal Condition Few deposits are present and probably will be light tan or gray in color. This plug shows that plug heat range is compatible with engine, and engine is electrically and mechanically in good running condition. With proper plug servicing (clean, file and re-gap), this plug can be reinstalled with good results. 72420 Chipped Insulator Chipped insulator usually results from careless plug re-gapping.
SERVICE MANUAL NUMBER 26 TROUBLESHOOTING Cold Fouling Dry, black deposits indicate rich fuel mixture or weak ignition. Clogged flame arrestor, flooding carburetor, sticky choke or weak ignition components all are probable causes. If, however, only one or two plugs in set are fouled, check for sticking valves or bad ignition leads. After correcting cause, service (clean, file and re-gap) plugs and reinstall. 72421 Overheating Insulator is dull white or gray and appears blistered.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Scavenger Deposits Powdery white or yellow deposits are built up on shell, insulator and electrodes. This is normal appearance with certain branded fuels. Accumulation on ground electrodes and shell areas may be unusually heavy, but may be easily chipped off. Plugs can be serviced (clean, file and re-gap) and reinstalled. 72422 Pre-Ignition Damage Pre-ignition damage is caused by excessive high temperatures.
SERVICE MANUAL NUMBER 26 TROUBLESHOOTING Splashed Deposits Spotted deposits, which sometimes occur after long delayed tune-up, accumulate after a long period of misfiring. When normal combustion temperatures are restored, upon installation of new plugs, deposits loosen from top of piston and head and are thrown against hot insulator. Clean and service plugs and reinstall. 72423 Mechanical Damage Mechanical damage to spark plug firing end is caused by foreign object in combustion chamber.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Poor Boat Performance and/or Poor Maneuverability Symptom Cause A. Improper drive unit trim angle B. Improper weight distribution C. Boat is underpowered Bow too low D. Permanent or power hook in boat bottom E. False bottom full of water F. Improperly adjusted trim tabs (after planes) G. Dirty boat bottom (marine growth) A. Improper drive unit trim angle B. Propeller pitch too great C. Dirty boat bottom (marine growth) D. Poor running engine Bow too high E.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Improper Full Throttle Engine RPM RPM Too High Cause Special Information Propeller Damaged; pitch too low; diameter too small; propeller hub slipping. Boat Water pickup or through hull fittings mounted too close to propeller (ventilation); keel located too close to propeller and/or too deep in the water (ventilation). Drive installed too high on transom; wrong gear ratio. Operation Unit trimmed out too far.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Engine Cranks Over But Will Not Start Or Is Hard To Start Important Information 1. First, determine which engine system is causing the problem. To make an engine run, basic components fuel, spark (ignition), and compression are required. If all three components are present, the engine should run. If any one of the three are missing, weak, or arriving at the wrong time the engine will not run. 2.
SERVICE MANUAL NUMBER 26 TROUBLESHOOTING EST Ignition System Check Test Description Numbers below refer to circled numbers on the diagnostic chart. 1. Two wires are checked, to ensure that an open is not present in a spark plug wire. a. If spark occurs with EST connector disconnected, pick-up coil output is too low for EST operation. 2. A spark indicates the problem must be the distributor cap or rotor. 3. Normally, there should be battery voltage at the “C” and “+” terminals.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Ignition System Check(1 of 2) 1 • IF A TACHOMETER IS CONNECTED TO THE TACH TERMINAL, DISCONNECT IT BEFORE PROCEEDING WITH THE TEST. • CHECK SPARK AT PLUG WIRE USING AN INDUCTIVE PICKUP TIMING LIGHT WHILE CRANKING. A FLASHING LIGHT INDICATES SPARK. (IF NO SPARK ON FIRST WIRE, CHECK SECOND WIRE.) A FEW SPARKS AND THEN NOTHING IS CONSIDERED NO SPARK. NO SPARK SPARK • DISCONNECT 4 TERMINAL CONNECTOR ON DISTRIBUTOR AND CHECK FOR SPARK.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Ignition System Check (2 of 2) TEST LIGHT a b CHART CONTINUED FROM PREVIOUS PAGE TO DC POWER SUPPLY (1.5 to 8 V) LIGHT BLINKS LIGHT ON STEADY Fig. 1 5 6 • • • • • • DISCONNECT DISTRIBUTOR 4 TERMINAL CONNECTOR. REMOVE DISTRIBUTOR CAP. DISCONNECT PICK-UP COIL CONNECTOR FROM MODULE. CONNECT VOLTMETER FROM TACH. TERMINAL TO GROUND. IGNITION “ON.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Engine Will Not Crank Over/Starter Inoperative Cause Special Information Remote control lever not in neutral position Battery charge low; damaged wiring; loose electrical connections Circuit breaker tripped Blown fuse Ignition switch Slave solenoid Faulty neutral start safety switch Open circuit Starter solenoid Starter motor Mechanical engine malfunction Charging System Inoperative Cause Special Information Loose or broken drive belt Engine rpm too low on i
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Noisy Alternator Cause Special Information Loose mounting bolts Drive belt Worn, frayed or loose belt Loose drive pulley Worn or dirty bearings Faulty diode trio or stator Fuel System Rich Cause Warm engine carburetor percolation Special Information Fuel boils out of float bowl when shut off and warm. Floods intake manifold.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Fuel System Lean Special Information Cause Empty fuel tank Fuel shut-off valve closed (if equipped) Vapor lock Engine will not start after warm engine shut down Automatic choke Stuck open, wrong adjustment Fuel tank vent plugged Engine will start initially. After a short time of running, engine will stall and will not restart for a period of time. Can verify it is a vent problem by running engine with filler cap loose. Fill cap will act as a vent.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Carburetor Malfunction (continued) A. Accelerator pump B. Leaking gaskets C. Automatic choke D. Power piston or power valve Hesitation or acceleration flatness E. Throttle valves F. Throttle body heat passages plugged G. Main metering jets H. Float adjustment I. Secondary air valve wind-up A. Main metering jets B. Leaking gaskets Engine surges C. Float adjustment D. Saturated float E. Power piston or valve F. Throttle valves A.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Engine Runs Poorly At Idle Cause Special Information Clogged flame arrestor Improper idle fuel mixture adjustment Problem in ignition system causing the engine to run rough Idle mixture screw adjusted incorrectly Engine floods at idle Bad needle and seat Incorrect float level drop If carburetor (2 barrel only) has a solid needle, replace with a spring loaded needle Moisture on ignition components Cap or spark plug wires arcing Water in fuel Low grade or stale
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Engine Acceleration Is Poor Cause Special Information Also refer to “Poor Boat Performance” Idle mixture screws Incorrect ignition timing Incorrect distributor or amplifier advance curve Refer to SECTION 4B Accelerator pump Check for stream of raw fuel from accelerator pump discharge nozzle, when opening throttle with engine shut off Cracked or dirty distributor cap or rotor Vacuum leak Intake manifold or carburetor base Spark plugs Fouled, burned; wrong h
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Engine Runs Poorly At High RPM (continued) Cause Special Information Coil Distributor Excessive play in shaft Engine overheating Refer to “Engine Overheats” Low compression Worn valves, rings, cylinders, etc.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Radio Noise Cause Special Information A popping noise that will increase with engine rpm. Noise will stop as soon as engine is turned off.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Instrumentation Malfunction Cause Special Information Faulty wiring, loose or corroded terminals Faulty key switch Test, as outlined in SECTION 4D Faulty gauge Test, as outlined in SECTION 4D Faulty sender Test, As outlined in SECTION 4D Engine Noise Important Information No definite rule or test will positively determine source of engine noise. Use the following information only as a general guide to engine noise diagnosis. 1.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Valve Cover Area Location Possible Causes A. Rocker arm striking valve cover Valve cover area, timed to one-half engine B. Rocker arm out of adjustment speed, noise could be confined to one C. Worn rocker arm cylinder or may be found in any multitude D. Bent push rod of cylinders E. Collapsed filter Cylinder Area Location Possible Causes A. Sticking valve B. Carbon build-up C.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Crankshaft Area Location Possible Causes A. Crankshaft timing sprocket Crankshaft area, front of engine, timed to engine speed B. Timing chain C. Main bearing D. Rod bearing A. Crankshaft striking pan or pan baffle Crankshaft area, center of engine, timed to engine speed B. Main bearing C. Rod bearing A. Loose flywheel cover B. Loose coupler Crankshaft area, rear of engine, timed to engine speed C. Loose flywheel D. Main bearing E. Rod bearing A.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Miscellaneous Location / Noise Possible Causes A. Advanced timing B. Low octane fuel Engine spark knock C. Engine running hot D. Carbon deposits in engine A. Wrong ignition timing B. Carburetor set too lean C. Faulty accelerator pump Popping through carburetor D. Vacuum leak E. Valve adjustment F. Valve timing G. Burned or stuck valve A. Vacuum leak B. Leaking exhaust (manifolds or pipes) Hissing C. Loose cylinder heads D. Blown head gasket A.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Oil Pressure Miscellaneous Problem Special Information Measuring oil pressure Use a good automotive oil pressure test gauge. Do not rely on the oil pressure gauge in the boat.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Low Oil Pressure Cause Special Information Low oil level in crankcase Defective oil pressure gauge and/or sender Verify with an automotive test gauge. Refer to SECTION 4D for instrument testing.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Excessive Oil Consumption NOTE: Normal consumption is one quart of oil consumed in 5-15 hours of operation at wideopen-throttle (especially in a new or rebuilt engine).
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Water in Engine Important Information IMPORTANT: First determine location of water in engine. This information can be of great help when trying to determine where the water came from and how it got into the engine. The three most common problems are “water on top of pistons, water in crankcase oil or water in crankcase oil and on top of pistons.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Water On Top Of Pistons Cause Special Information Operator shut engine off at high rpm Engine “diesels” or tries to run backwards Engine out of tune, poor fuel, high idle rpm, timing set too high Rain water running into flame arrestor Hatch cover Spark plug misfiring Improper combustion causes moisture in the air to accumulate in the cylinder Backwash through the exhaust system Improper engine or exhaust hose installation Cracked exhaust manifold Improper m
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Engine Overheats Mechanical Cause Special Information Engine rpm below specifications at wide-open-throttle (engine laboring) Damaged or wrong propeller; growth on boat bottom; false bottom full of water Wrong ignition timing Timing too far advanced or retarded Sticking distributor advance weights Spark plug wires crossed (wrong firing order) Lean fuel mixture Refer to “Carburetor Malfunction” in this section Wrong heat range spark plugs Exhaust restriction
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Cooling System Cause IMPORTANT: The first step is to verify if the engine is actually overheating or the temperature gauge or sender is faulty Special Information IMPORTANT: Best way to test gauge or sender is to replace them.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Power Steering Poor, Erratic or No Assist Cause Drive belt Special Information Worn, broken or out of adjustment Low fluid level Air in system Air leak in lines or pump, or air from installation. Refer to SECTION 8A for bleeding procedure. Leaking hoses Refer to SECTION 8A for bleeding procedure.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Noisy Pump Cause Drive belt Special Information Check belt tension Low fluid level Air in fluid Air leak in lines, pump, or air form installation Faulty pump Use stethoscope to listen for noise in pump Restricted fluid passages Kinks or debris in hoses or debris in passages Stop nut adjusted improperly Refer to appropriate Sterndrive Service Manual Steering cables installed that do not meet BIA standards Refer to appropriate Sterndrive Service Manual Fl
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 Insufficient Water Flow From Alpha One Sterndrive Unit Seawater Pickup Pump Cause Special Information Seawater shutoff valve partially or fully closed (if equipped) Water pickup clogged with foreign material Kinked or broken bell housing to gimbal housing water tube hose Corroded through gimbal housing water tube Water pickup inserts warped. (Engine will overheat while boat is underway.
TROUBLESHOOTING SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 1C-36 90-861329--1 MARCH 1999
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 REMOVAL AND INSTALLATION Section 2A - MCM 3.0L (181 cid) - Alpha Drive Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal . . . . . . . . . . . . . . . . . . . . 2 2A-2 2A-2 2A-2 2A-3 2A-3 Installation . . . . . . . . . .
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 Torque Specifications DESCRIPTION lb-ft Nm Power Steering Hydraulic Hose Fittings 23 31 Front Engine Mounts 35 47 Rear Engine Mounts 38 52 Drive Unit Shift Cables (Cable End and Cable End Guide) lb-in. Tighten Until Contacts, Then Loosen 1/2 Turn.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 Removal IMPORTANT: Sterndrive unit must be removed prior to engine removal. Refer to Sterndrive Service Manual. Engine Removal 1. Disconnect battery cables from battery. a b c 22052 a - Negative (-) Battery Cable b - Positive (+) Battery Cable c - Rubber Boot (Slid Back From Terminal) 2. Remove instrument harness connector plug from engine harness receptacle after loosening clamp. WARNING Be careful when working on fuel system.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 4. Disconnect throttle cable from carburetor and retain locknuts and hardware. c b a d e 75810 a b c d e - Cable End Guide - Throttle Cable Anchor Screw - Cable Barrel - Elastic Stop Nut And Flat Washer - Throttle Lever 5. Disconnect shift cables and shift assist assembly (if equipped).
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 6. Disconnect and cap power steering hoses. Plug control valve hose connection holes. a b 75812 a - Power Steering Hoses b - Control Valve 7. Loosen clamp and unplug wiring harness. a b c 50626 a - Engine Wiring Harness Receptacle (Bracket) b - Instrumentation Wiring Harness c - Hose Clamp 8. Disconnect bullet connectors of trim sender wires (coming from transom assembly) from engine harness.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 9. Disconnect engine harness wires from shift cut-out switch harness. a 75499 a - Shift Cutout Switch Wires 10. Disconnect MerCathode wires from MerCathode controller if equipped. 11. Disconnect seawater inlet hose from gimbal housing. c b a 72614 a - Water Tube b - Hose Clamp (Tighten Securely) c - Water Hose 12. Loosen hose clamps and disconnect exhaust elbow hose. 13. Remove both shift cables from shift plate. Retain locknuts and hardware.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 14. Disconnect any grounding wires and accessories that are connected to engine. a 50636 a - Ground Stud 15. Disconnect (and suitably plug) fluid hoses from power steering control valve on transom. CAUTION Center lifting eye (located on top of thermostat housing) is used for engine alignment only. DO NOT use to lift entire engine. CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur. 16.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 Installation Engine Installation 1. Be certain fiber washers (cemented in place) on inner transom plate are present. Inspect fiber washers. Replace if worn or damaged. 2. Install double wound lockwashers onto inner transom plate inside fiber washer. a b c d a b c d 72023 - Double Wound Lockwasher - Fiber Washer - Inner Transom Plate Mount - Locknut 3. Be certain rear engine mount locknuts are in position as shown. 4.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 7. Lift engine into position (in boat), using an overhead hoist. b a b 75815 a - Center Lifting (Aligning) Eye b - Lifting Eye 8. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tubes with exhaust pipe hoses (bellows). Do not fasten attaching hardware until you have aligned engine.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 IMPORTANT: Engine attaching hardware must be installed in sequence shown. 9. Install both rear engine mounting bolts and hardware as shown. 10. Torque mounting bolts to 38 lb-ft (52 Nm).
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 Engine Alignment IMPORTANT: The modified 91-57797A3 tool or the new tool 91-805475A1 will align all current Alpha One as well as all older engines that used the older 91-57797A3. CAUTION To avoid damage to gimbal bearing, engine coupler, or alignment tool: w DO NOT attempt to force alignment tool! w DO NOT raise or lower engine with alignment tool inserted (or partially inserted) in gimbal bearing or engine coupler. 1.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 4. Relieve hoist tension entirely and fasten both front mounts to boat stringer using appropriate hardware (lag bolts or through-bolts, etc). 5. Recheck alignment with alignment tool. Tool must enter coupler splines freely. If not, readjust front mounts. 6. When alignment is correct, tighten locknut or nut with lockwasher on each mount securely.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 Engine Connections IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and secured to avoid coming in contact with hot spots on engine and avoid contact with moving parts. 1. Connect seawater inlet hose to water tube at gimbal housing with hose clamp. Tighten clamp securely. c b a 72614 a - Water Inlet Tube b - Hose Clamp c - Seawater Inlet Hose 2. Connect instrument harness to engine harness with clamp.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 3. Connect trim position sender leads from gimbal housing to leads from engine harness. b a d 72992 c a b c d - BROWN/WHITE - From Engine Harness - BLACK - From Engine Harness - BLACK - From Transom Assembly - BLACK - From Transom Assembly WARNING Be careful when working on fuel system. Gasoline is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 5. Connect throttle cable using hardware retained and adjust as follows: a. Place remote control handle(s) in NEUTRAL, idle position. IMPORTANT: Be sure that cable is routed in such a way as to avoid sharp bends and/ or contact with moving parts. DO NOT fasten any items to throttle cable. Outer cable must be free to move when cable is actuated. a b 75817 a - Anchor Bolt b.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 d. Place remote control throttle lever in the wide-open-throttle (W.O.T.) position. Ensure that throttle shutters (valves) are completely open and throttle shaft lever contacts carburetor body casting. e. Return remote control throttle lever to idle position and ensure that throttle lever contacts idle speed adjustment screw.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 7. Connect MerCathode wires to MerCathode controller assembly as shown, if equipped. Apply a thin coat of Quicksilver Liquid Neoprene to all connections.
MCM 3.0L (181 CID) - ALPHA DRIVE SERVICE MANUAL NUMBER 26 11. Connect battery cables to battery by FIRST connecting POSITIVE (+) battery cable (usually RED) to POSITIVE (+) battery terminal. 12. Tighten clamps securely. 13. Connect NEGATIVE (–) battery cable (usually BLACK) to NEGATIVE (–) battery terminal. 14. Tighten clamp securely. NOTE: Spray terminals with a battery connection sealant to help retard corrosion.
SERVICE MANUAL NUMBER 26 MCM 3.
MCM 3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 ENGINE Section 3A - 181 cid (3.0L) 4 Cylinder GM Engine Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . 3A-3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Lubricants/Sealants/Adhesives . . . . . . . . . . 3A-5 Engine Specifications . . . . . . . . . . . . . . . . . . 3A-5 Cylinder Bore . . . . . . . . . . . . . . . . . . . .
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Table of Contents (continued) Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Sprocket . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . .
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Torque Specifications Fastener Location lb-in. Camshaft Sprocket Bolts lb-ft 80 Nm 9 Connecting Rod Cap Nuts 45 61 Cylinder Head Bolts 901 122 Distributor Clamp 20 27 Engine Coupler to Flywheel 35 47 Flywheel Housing to Block 21 28 Flywheel to Crankshaft Bolts 65 88 Front Cover Bolts 27-35 3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Tools Description Parts Number Piston Ring Expander 91-24697 Torch Lamp 91-63209 Special Tools KENT MOORE SPECIAL TOOLS Kent-Moore Special Tools 29784 Little Mack Roseville, MI 48066 Phone: (313) 574-2332 Description Parts Number Valve Spring Compressor (Head on) J5892 Valve Spring Compressor (Head off) J8062 Valve Stem Seal Tester Valve Guide Reamer (Standard) J23738-A J8814 Valve Guide Reamer (.015 in.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Lubricants/Sealants/Adhesives Description Parts Number Quicksilver Perfect Seal 92-34227--1 Quicksilver 2-4-C Marine Lubricant with Teflon 92-825407A3 Quicksilver RTV Sealer 92-809826 Engine Specifications NOTICE Unit Of Measurement: U.S. Inches (Millimeters) Model 3.0L Displacement 181 cid (3.0L) Cylinder Bore Diameter Out of Round Taper Production 3.9995-4.0025 (101.588-101.790) Production .0005 (0.012) Max Service .002 (0.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Piston Ring: Oil Groove Clearance Gap Production .001-.006 (0.026-0.152) Service Limit .007 (0.17) Max Production .010-.030 (0.254-0.762) Max Service Limit .040 (1.01) Max Piston Pin Diameter Clearance .9270-.9271 (23.546-23.550) Production .0003-.0006 (0.008-0.016) Service Limit .001 (0.02) Max Fit in Rod .0008-.0019 (0.020-0.050) Interference Crankshaft Diameter Main Journal Taper Out of Round Production .0002 (0.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cylinder Head .003-.008 in any 6 in. (152) or .007 (0.15) Overall Max Gasket Surface Flatness Valve System Lifter Hydraulic Rocker Arm Ratio 1.75 to 1 Collapsed Tappet Gap 3/4 Turn Down from Zero Lash Face Angle Intake 45° Exhaust 45° Seat Angle (Intake & Exhaust) 46° Seat Runout (Intake & Exhaust) .002 (0.05) Max Seat Width Production Stem Clearance Service Intake 1/16 (.0625 in.) (1.16 mm) Exhaust 1/16-5/64 [.0625-.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Engine Identification The MerCruiser Model can be determined by looking at the LAST TWO LETTERS of the engine code stamped into the cylinder block. This code number is stamped on all MerCruiser power packages and replacement partial engines, but not replacement cylinder block assemblies. If the engine serial number and/or model decals are missing, the engine code letters may help in determining the engine models. a 74520 G.M.
SERVICE MANUAL NUMBER 26 181 CID (3.0L) 4 CYLINDER GM ENGINE Firing Order 50683 Firing Order 1-3-4-2 Priming Engine With Oil IMPORTANT: This applies to all power packages that have not been run within 6 months, replacement of partial engines or after rebuilding an engine. Tool Required 71089 Remote Starter Kit (91-52024A1) 1. Fill crankcase to proper level with the recommended engine oil. 2. Remove spark plugs. 3. Leave ignition key in “OFF” position. 4.
181 CID (3.
181 CID (3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Piston Failures Pre-Ignition Pre-ignition is abnormal fuel ignition, caused by combustion chamber hot spots. Control of the start of ignition is lost, as combustion pressure rises too early, causing power loss and rough running. The upward motion on the piston is opposed by the pressure rise. This can result in extensive damage to the internal parts from the high increase in combustion chamber temperature. 72424 Pre-Ignition Damage CAUSES 1.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Detonation Detonation, commonly called “fuel knock,” “spark knock” or “carbon knock,” is abnormal combustion of the fuel which causes the fuel to explode violently. The explosion causes overheating or damage to the spark plugs, pistons, valves and, in severe cases, results in pre-ignition. CAUSES IMPORTANT: Use of improper fuels will cause engine damage and poor performance. 1.
181 CID (3.
SERVICE MANUAL NUMBER 26 181 CID (3.0L) 4 CYLINDER GM ENGINE Rocker Arm Cover Removal It may be necessary to remove exhaust manifold before removing rocker arm cover. Refer to SECTION 7B for removal. 1. Disconnect crankcase ventilation hose. 2. Remove any items that interfere with the removal of rocker arm covers. IMPORTANT: DO NOT pry rocker arm cover loose.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Push Rod Cover Removal 1. Remove the pushrod cover bolts. 2. Remove the pushrod cover. 3. Remove the gasket. 76247 Installation 1. Clean sealing surfaces on pushrod cover with degreaser. 2. Install new pushrod cover gasket in position. 3. Install pushrod cover. Torque bolts to 40 lb-in. (4.5 Nm).
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Rocker Arm/Push Rod a b c e d 74287 Valve Mechanism a - Nut b - Ball Unit c - Rocker Arm d - Push Rod e - Rocker Arm Stud Removal NOTE: When servicing only one cylinder’s rocker arms, bring that cylinder’s piston up to TDC before removing rocker arms. When servicing all rocker arms, bring No. 1 piston up to TDC before removing rocker arms. 1. Remove rocker arm covers as outlined. 2. Remove rocker arm assemblies and push rods.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Installation IMPORTANT: When installing rocker arms and rocker arm balls, coat bearing surfaces of rocker arms and rocker arm balls with engine oil. 1. Install push rods in their original locations. Be sure push rods seat in lifter socket. 2. Install rocker arms, rocker arm balls and rocker arm nuts in their original locations. 76232 3. Turn nut down 1/4 additional turn and pause 10 seconds until engine runs smoothly.
SERVICE MANUAL NUMBER 26 181 CID (3.0L) 4 CYLINDER GM ENGINE 2. With engine in No. 1 firing position as determined above, the following valves may be adjusted: • No. 1 Cylinder - Exhaust and Intake • No. 2 Cylinder - Intake • No. 3 Cylinder - Exhaust • No. 4 Cylinder - Intake 3. Loosen adjusting nut until lash is felt at push rod, then tighten adjusting nut until all lash is removed. This can be determined by moving push rod up and down while turning adjusting nut until all play is removed.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 IMPORTANT: The following preload adjustment must be done slowly to allow lifter to adjust itself, thus preventing possibility of the valve head contacting the top of piston, which may result in internal damage and/or bent push rods. 5. Repeat Steps 2-4 to adjust other valves. 6. Install rocker arm cover, torque to 40 lb-in. (4.5 Nm). 7. Adjust carburetor idle mixture and idle speed. Check for leaks.
SERVICE MANUAL NUMBER 26 181 CID (3.0L) 4 CYLINDER GM ENGINE Removal 1. Remove as previously outlined: a. Rocker arm covers. b. Push rod cover. IMPORTANT: Keep valve push rod and hydraulic lifter from each valve together as a matched set and mark or store them so they can be reinstalled in the same location later. c. Rocker arm assemblies and push rods. 2.
181 CID (3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Replacing Oil Seal (Head Installed) 1. Remove rocker arm cover. 2. Remove spark plug, rocker arm and push rod on cylinder to be serviced. 3. Place piston for that cylinder at TDC to prevent valves from dropping into the cylinder. 4. Compress valve spring with tool (J-5892) and remove valve keys, valve spring cap, spring shield and valve spring. b a 72881 a - Valve Spring Compressor (J-5892) b - Rocker Arm Nut 5. Remove valve stem oil seal.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cylinder Head 10 9 6 5 2 3 1 4 7 8 Cylinder Head Torque Sequence 1. Drain engine cooling system. 2. Remove as outlined: a. Exhaust manifolds. b. Intake manifold. c. Rocker arm cover. d. Pushrod cover. e. Rocker arm assemblies and push rods (keep in order for reassembly in their original locations). 76232 f. Any components attached to front or rear of cylinder head. g. Spark plugs. h. Head bolts.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cleaning and Inspection 1. Clean gasket material and sealer from engine block and cylinder heads. 2. Inspect sealing surfaces for deep nicks and scratches. 3. Inspect for corrosion around cooling passages. 4. Clean head bolt threads and engine block bolt hole threads, making sure no dirt, old oil or coolant remains.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cylinder Head and Valve Conditioning Disassembly 1. Using valve spring compressor, compress valve spring (J-8062) and remove valve locks. Slowly release tool. 2. Remove all valve components. 3. Remove valves from cylinder head and place in a rack, in order, for reassembly in their original locations. a 72333 a - Valve Spring Compressor (J-8062) Cleaning 1. Clean push rods and rocker arm assemblies. 2.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 5. Thoroughly clean valve guides with valve guide cleaner (J-8101). a 74286 a - Valve Guide Cleaner (J-8101) Inspection 1. Inspect cylinder head for cracks in exhaust ports, water jackets and combustion chambers (especially around spark plug holes and valve seats). Replace heads if any cracks are found. 2. Inspect cylinder head gasket surface for burrs, nicks, erosion or other damage.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 c. If clearance exceeds specifications, it will be necessary to ream valve guides for oversized valves, as outlined under “Valve Guide Bore Repair.” b c a 72336 a - Valve Stem b - Dial Indicator c - Valve Guide Rocker Arm Studs Rocker arm studs with damaged threads or with loose fit in cylinder heads should be replaced with new, oversize studs. Studs may be installed after reaming holes as follows: 1. Drain water from cylinder block. 2.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 3. Ream hole for oversize stud with Tool J-5715 for .003 in. oversize or Tool J-6036 for .013 in. oversize. a 74289 a - Reamer Tool J-5715 IMPORTANT: Do not attempt to install an oversize stud without reaming stud hole. 4. Coat press-fit area of stud with Perfect Seal. Install new stud, using Tool J-6880 as a guide. Gauge should contact head.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Valve Springs - Checking Tension Using valve spring tester, as shown, check valve spring tension with dampers removed. Refer to “Specifications.” IMPORTANT: Springs should be replaced if not within 10 lbs. (44 N) of specified tension.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Several different types of equipment are available for refacing valves. The recommendation of the manufacturer of the equipment being used should be carefully followed to attain proper results. 50695 a b c d Exhaust - .372 In. (9.45 mm) - 1/32 [.031] In. (0.79 mm) Min. - .341 In. (8.16 mm) - 1/32 [.031] In. (0.79 mm) Min. Intake Reassembly 1. Lubricate valve guides and valve stems with engine oil. 2.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 7. Install valve locks (grease may be used to hold them in place) and slowly release tool, making sure locks seat properly in upper grooves of valve stem.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 8. Check installed height of valve springs using a narrow, thin scale. Measure from spring seat to top of valve spring, as shown. If measurement exceeds specified height, install a valve spring shim and recheck. DO NOT shim valve springs to give an installed height less than the minimum specified.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Oil Pan a a - Oil Pan Gasket Removal 1. Disconnect battery. NOTE: Removal of engine from boat may be required. 2. Drain crankcase oil. 3. Remove starter motor. 4. Remove oil pan screws, oil pan and gasket(s). Installation 1. Clean sealing surfaces of engine block and oil pan. 2. Apply a small amount of Quicksilver RTV Sealer to joints of rear seal retainer and joints of front cover.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Oil Pump The oil pump consists of two gears and a pressure regulator valve enclosed in a two-piece housing. Oil pump is driven by distributor shaft which is driven by a helical gear on camshaft. Removal 1. Remove oil pan as previously outlined. 2. Remove gasket carefully as the one-piece gasket for the oil pan may be reused if still pliable and not cracked, torn, etc. 3. Remove oil pump. a 76234 a - Oil Pump Disassembly 1.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cleaning and Inspection 1. Wash all parts in cleaning solvent and dry with compressed air. 2. Inspect pump body and cover for cracks or excessive wear. 3. Inspect pump gears for damage and excessive wear. 4. Check for loose drive gear shaft in pump body. 5. Inspect inside of pump cover for wear that would permit oil to leak past ends of gears. IMPORTANT: Pump gears and body are not serviced separately.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Torsional Damper Removal 1. Support front of engine (if in boat) with overhead hoist. 2. Remove front mounting bracket and drive belt. Remove retaining bolt, if equipped. 3. Install tool J-6978-E to balancer and turn puller. Remove drive pulley, then remove torsional damper retaining bolt.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 c. Install torsional damper on crankshaft by turning nut until it contacts. a 74529 a - Torsional Damper Remover and Installer (J-23523-E) d. Remove tool from crankshaft. e. To prevent oil leakage, apply Quicksilver RTV sealant to torsional damper keyway. f. Install torsional damper bolt. Torque to 70 lb-ft (95 Nm). 4. Install drive pulley(s). Torque bolts to 35 lb-ft (48 Nm). 5. Install and adjust drive belts.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Crankcase Oil Seal Replacing Oil Seal Without Removing Front Cover REMOVAL 1. Remove torsional damper. 2. Pry seal out of cover from the front with a large screwdriver. Be careful not to distort front cover or damage crankshaft. INSTALLATION IMPORTANT: Correct rotation oil seal must be used to prevent oil leak. 1. Apply Quicksilver Perfect Seal to seal retainer mating surface and apply grease to seal lips. 2.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Crankcase Front Cover Removal 1. Remove engine from boat if necessary to gain access to cover. 2. Remove torsional damper and oil pan. 3. Remove water circulating pump. 4. Remove crankcase front cover. 5. If damaged, drive oil seal out of front cover (from the rear) using a punch. Cleaning and Inspection Clean front cover in solvent and dry with compressed air.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Flywheel and Engine Coupler Removal 1. Remove engine from boat. Refer to SECTION 2 “Removal and Installation.” 2. Refer to “Flywheel Housing” description in this section and remove flywheel housing and related parts. a b c 72318 a - Flywheel Housing b - Cover c - Press Mount Out with Press 3. Remove MCM coupler. 4. Remove flywheel. 72349 Alpha One Coupler Inspection 1. Inspect splines in coupler for wear. 2.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Installation 1. Clean mating surfaces of flywheel and crankshaft. Remove any burrs. Mating surfaces must be clean bare metal. 2. Align dowel hole in flywheel with dowel in crankshaft. 3. Install flywheel. 4. Torque bolts to 75lb-ft (100Nm). 5. Check flywheel runout as follows: a. Attach a dial indicator to engine block. b. Take readings around outer edge of flywheel. Push in on flywheel to remove crankshaft end play. Maximum runout - .008 in.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Rear Main Oil Seal The rear crankshaft oil seal can be replaced without removing the oil pan or rear main bearing cap from engine. Removal 1. Remove seal by using a screwdriver to pry it out of retainer as shown. c a b 72355 a - Rear Seal b - Seal Retainer c - Slots (Three) Cleaning and Inspection 1. Clean crankshaft/seal running surface and seal retainer. 2. Clean gasket material from mating surfaces. 3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 3. Coat seal lips with clean motor oil. 4. Install gasket and oil seal retainer with rear main seal. 5. Coat threads of oil seal retainer fasteners with Loctite Pipe Sealant with Teflon. 6. Install oil seal retainer fasteners and torque to 133 lb-in. (15 Nm). 7. Install oil pan fasteners. Torque 1/4-20 threaded fasteners to 80 lb-in. (9 Nm) and 5/16-18 threaded fasteners to 165 lb-in. (19 Nm).
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Checking Clearances To obtain accurate measurements while using Plastigage, or its equivalent, engine must be out of the boat and upside down so crankshaft will rest on the upper bearings and total clearance can be measured between lower bearing and journal. To ensure the proper seating of the crankshaft, all bearing cap bolts should be at their specified torque.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 5. On the edge of the gauging plastic envelope there is a graduated scale which is correlated in thousandths of an inch. Without removing the gauging plastic, measure its compressed width (at the widest point) with the graduations on the gauging plastic envelope as shown. a b 72358 a - Compressed Gauging Plastic b - Graduated Scale NOTE: Normally main bearing journals wear evenly and are not out of round.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Connecting Rod Bearings Connecting rod bearings are of the precision insert type and do not use shims for adjustment. DO NOT FILE RODS OR ROD CAPS. If clearances are found to be excessive, a new bearing will be required. Service bearings are available in standard size and .001 in. and .002 in. undersize for use with new and used standard size crankshafts, and in .010 in. and .020 in. undersize for use with reconditioned crankshafts.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 e. Install the bearing cap and torque nuts to 45 lb-ft (61 Nm). IMPORTANT: Do not turn the crankshaft with the gauging plastic installed. f. Remove the bearing cap and using the scale on the gauging plastic envelope, measure the gauging plastic width at the widest point as shown. 72362 6. If the clearance exceeds specifications, select a new, correct size bearing and measure the clearance.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Connecting Rod/Piston Assembly Removal 1. With oil pan, oil pump and cylinder head removed, use a ridge reamer to remove any ridge and/or deposits from upper end of cylinder bore. IMPORTANT: Before ridge and/or deposits are removed, turn crankshaft until piston is at bottom of stroke and place a cloth on top of piston to collect cuttings.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cleaning and Inspection CONNECTING RODS 1. Wash connecting rods in cleaning solvent and dry with compressed air. 2. Check for twisted and bent rods and inspect for nicks and cracks. Replace damaged connecting rods. PISTONS NOTE: Cylinder bore and taper must be within specifications before pistons can be considered for reuse. 1. Clean varnish from piston skirts with a cleaning solvent. DO NOT WIRE BRUSH ANY PART OF PISTON.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 PISTON PINS 1. Piston pin clearance is designed to maintain adequate clearance under all engine operating conditions. Because of this, piston and piston pin are a matched set and not serviced separately. 2. Inspect piston pin bores and piston pins for wear. Piston pin bores and piston pins must be free of varnish and scuffing when measured. Measure piston pin with a micrometer and piston pin bore with a dial bore gauge or inside micrometer.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 1. Assemble piston to connecting rod using piston pin remover as shown. Follow instructions supplied with tool. a 72371 a - Piston Pin Remover (J-24086-B) 2. Once assembled, check piston for freedom of movement (back and forth and up and down) on connecting rod. Piston should move freely in all directions. If it does not, piston pin bore is tight and piston/pin assembly must be replaced. 3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 6. Clean and inspect pistons, if not previously done. 7. Install piston rings as follows: a. Install oil ring spacer in groove and insert anti- rotation tang in oil hole. b. Hold spacer ends butted and install lower steel oil ring rail with gap properly located. c. Install upper steel oil ring rail with gap properly located. d. Flex the oil ring assembly to make sure ring is free.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 d. Use a hammer handle with light blows to install piston into bore. e. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. IMPORTANT: Be sure to install new pistons in same cylinders for which they were fitted, and used pistons in same cylinder from which they were removed. Each connecting rod and bearing cap should be marked, beginning at front of engine.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Crankshaft Removal 1. Remove engine from boat. 2. Drain crankcase oil. 3. Remove as outlined: a. Starter. b. Flywheel housing. c. Drive coupler and flywheel. d. Belts. e. Water pump. f. Crankshaft pulley and torsional damper. g. Spark plugs. h. Oil pan and dipstick tube. i. Oil pump. j. Timing chain cover. 4. Turn crankshaft to align timing mark with camshaft mark. 5. Remove camshaft sprocket. 6. Remove rear main seal and retainer. 7.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Cleaning and Inspection 1. Wash crankshaft in solvent and dry with compressed air. 2. Measure main bearing journals and crankpin dimensions with a micrometer for out-of-round, taper or undersize (see “Specifications”). 3. Check crankshaft for runout (by supporting at front and rear main bearings journals in V-blocks) and check at front and rear intermediate journals with a dial indicator (see “Specifications”). 4.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 11. Install as outlined: a. Timing chain and sprocket on camshaft - align marks with crankshaft. b. Timing chain cover. c. Oil pump. d. Dipstick tube and oil pan. e. Spark plugs. f. Torsional damper and crankshaft pulley. g. Water pump. h. Belts. i. Flywheel and drive coupler. j. Flywheel housing. k. Starter. 12. Install new oil filter. Fill crankcase with oil. Crankshaft Sprocket Removal 1.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Camshaft Measuring Lobe Lift NOTE: Procedure is similar to checking valve timing. If improper valve operation is indicated, measure lift of each push rod in consecutive order and record readings. 1. Remove valve mechanism as previously outlined. 2. Position indicator with ball socket adaptor tool on push rod. Be sure that push rod is in lifter socket. a 72907 a - Ball Socket Adaptor Tool (J-8520-1) 3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 5. Pull camshaft and gear assembly out through front of block. IMPORTANT: Support camshaft carefully when removing to protect camshaft bearings. a b 74438 a - Timing Marks b - Screw Access Holes Inspection 1. Measure camshaft bearing journals with a micrometer for out-of-round condition. If journals exceed .001 in. (0.02 mm) out-of-round, camshaft should be replaced. 2.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Camshaft Gear Replacement 1. If inspection indicates that camshaft, gear or thrust plate should be replaced, remove gear from camshaft. 2. Place camshaft through gear remover, place end of remover on table of a press shaft out of gear. CAUTION Position thrust plate so that woodruff key in shaft does not damage plate when shaft is pressed out of gear. Also support hub of gear, or gear will be seriously damaged.
SERVICE MANUAL NUMBER 26 181 CID (3.0L) 4 CYLINDER GM ENGINE 3. Check camshaft and crankshaft gear run-out with a dial indicator. Camshaft gear run-out should not exceed .004 in. (0.1 mm) and crankshaft gear run-out should not exceed .003 in. (0.07 mm). 74440 Checking Timing Gear Run-Out 4. If gear run-out is excessive, remove gear and clean burrs from shaft or replace gear. 5. Check backlash between timing gear teeth with a dial indicator. Backlash should not be less than .004 in. (0.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Camshaft Bearings Removal Camshaft bearings can be replaced while engine is disassembled for overhaul or without complete disassembly. To replace bearings without complete disassembly, remove camshaft and crankshaft, leaving cylinder heads attached and pistons in place. Before removing crankshaft, fasten connecting rods against sides of engine so that they will not interfere while replacing camshaft bearings. 1.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Inspection Clean camshaft bearing bores in cylinder block with solvent and blow out with compressed air. Be sure grooves and drilled oil passages are clean. Installation CAUTION Oil holes in bearings must line up with oil holes in cylinder block.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 b. Index front bearing (as explained in “Important” above), and drive it into position with tool. Check position of oil hole(s) in bearing to ensure bearing is positioned correctly. 74479 Removal And Installation Camshaft Bearings a - Installation Tool b - Camshaft Bearing c. Install rear bearing in same manner. Be sure to index bearing correctly. 3. Install a new camshaft rear plug. IMPORTANT: Plug must be installed flush to 1/32 in. (0.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 7. Measure cylinder bores to ensure they meet specifications. CAUTION Measure cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator or inside micrometer. Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine out-of-round condition.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 8. Check cylinder head gasket surfaces for warp with a machinist’s straight-edge and a feeler gauge, as shown. Take measurements diagonally across surfaces (both ways) and straight down center. If surfaces are warped more than .003 in. (0.07 mm) in a 6 in. area or .007 in. (0.2 mm) overall, block must be resurfaced by an automotive machine shop. a b 72910 a - Machinist’s Straight-Edge b - Feeler Gauge CYLINDER CONDITIONING 1.
SERVICE MANUAL NUMBER 26 181 CID (3.0L) 4 CYLINDER GM ENGINE CYLINDER HONING 1. Follow hone manufacturer’s recommendations for use of hone and cleaning and lubrication during honing. 2. Occasionally, during the honing operation, thoroughly clean cylinder bore and check piston for correct fit in cylinder. 3.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 PISTON SELECTION 1. Check used piston to cylinder bore clearance as follows: a. Measure cylinder bore diameter with a snap gauge 2-1/2 in. (64 mm) from top of cylinder bore as follows. 72386 b. Measure piston diameter at skirt across center line of piston pin as shown. 72911 c. Subtract piston diameter from cylinder bore diameter to determine piston-to-bore clearance. d.
181 CID (3.0L) 4 CYLINDER GM ENGINE SERVICE MANUAL NUMBER 26 Oil Filter By-Pass Valve Inspection and/or Replacement With oil filter removed, check spring and fiber valve for operation. Inspect for a cracked or broken valve. If replacement is necessary, pry valve out with screwdriver. Install and seat a new valve by tapping in place with a 9/16 in. thin wall deep socket. Refer to “Engine Parts List” when ordering parts for oil filter by-pass valve. 1.
181 CID (3.
SERVICE MANUAL NUMBER 26 181 CID (3.
181 CID (3.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 ELECTRICAL SYSTEM Section 4A - Starting System Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Replacement Parts Warning . . . . . . . . . . . . 4A-2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Battery Cable Recommendations . . . . . 4A-3 Starting System Components . . . . . . . . . . . 4A-4 Replacement Parts Warning . . . . . . . . . . . . 4A-5 Maintenance . . . . . . . . . . . . . . . . . .
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Identification The starter identification number is located as shown. a 72059 Delco PG 260 Starter Motor a - Starter Identification Number 75820 Delco PG260F1 Starter Motor NOTE: The RP long block, S/N 0L097000 and above, has 3 starter motor mounting holes in the cylinder block. The RK long block, S/N 0L096999 and below, has 2 starter motor mounting holes in the cylinder block.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Battery Battery Cold Cranking Amperage 3.0L 375 cca, 475 mca, 90Ah Battery Cable Recommendations IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder, as it may cause corrosion and failure. Cable Gauge Cable Length Up to 3-1/2 ft (1.1 m) 4 (25 mm2) 3-1/2 - 6 ft (1.1-1.8 m) 2 (35 mm2) 6 - 7-1/2 ft (1.8-2.3 m) 1 (50 mm2) 7-1/2 - 9-1/2 ft (2.3-2.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Starting System Components h a C c I A B d b e f g 72929 a b c d e f g h - Ignition Switch - Neutral Safety Switch - Starter Slave Solenoid - Circuit Breaker (not on all models) - Engine Ground Stud - Starter Solenoid - Wire Junction - 20 Amp Fuse INDEX Page 4A-4 90-861329--1 MARCH 1999
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion. Use of replacement electrical, ignition or fuel system components that do not comply with these rules and regulations could result in a fire or explosion hazard and should be avoided.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 1. Ensure that the battery meets the following certain conditions before testing: CAUTION Test battery in well ventilated area as gases given off by battery are hazardous. • Battery must be 60 to 100°F (16 to 38°C). • Electrolyte level must be correct in all cells. • Battery must be at least half charged. • No obvious defects. 2. Place battery under heavy load (as during engine cranking or with a variable resistor tester) and test cell voltage while under load: a.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Testing A strong battery must be maintained. If battery shows less than 9-1/2 volts when under starting load, (at 80° F or 27° C) it should be recharged. Check with DC voltmeter. 5 10 15 0 5 10 15 b 74307 a a - Voltmeter b - Battery Place battery under heavy load (as during engine cranking or with a variable resistor tester) and test cell voltage while under load. Certain conditions must be met before testing. • Battery must be 60 to 100°F (16 to 38°C).
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Positive Current Flow This is a general description of the positive current flow, from the battery and through the system until the starter motor cranks. • Battery to the solenoid switch (on starter) (RED battery cable). • Solenoid switch to circuit breaker (RED). • Circuit breaker to wire junction (RED-PUR). • Wire junction to wiring harness plug (RED-PUR) terminal 6. • Wiring harness plug to 20 amp fuse (RED-PUR).
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Charging Guide 12 Volt Battery Recommended Rate* and Time for Fully Discharged Condition Twenty Hour Rating 5 Amperes 10 Amperes 20 Amperes 30 Amperes 5 Hours 2-1/2 Hours 2 Hours 7-1/2 Hours 3-1/2 Hours 20 Hours 10 Hours 30 Hours 50 Ampere-Hours or 10 Hours less Above 50 to 75 15 Hours Ampere-Hours Above 75 to 100 Ampere-Hours Above 100 to 150 Ampere-Hours Above 150 Ampere-Hours 40 Amperes 50 Amperes 2-1/2 Hours 2 Hours 1-1/2 Hours 5 Hours 3 Hou
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Slave Solenoid Identification Types There are two types of slave solenoids (“standard” or “switch”) used on MerCruiser engines. These engines use a standard type solenoid; do not substitute a switch type solenoid. The other engines use a slave solenoid to energize the starter motor solenoid. Some model engines use the small terminal on the “switch type” solenoid for ignition by-pass during the starting of the engine.
SERVICE MANUAL NUMBER 26 STARTING SYSTEM Testing/Replacement 1. Using continuity meter, connect test leads as shown and connect 12-volt battery with jumper leads as shown. 72630 2. If no meter movement is present, replace solenoid. Solenoid Switch The solenoid switch, along with plunger, return spring, and shift lever, are completely sealed and permanently mount-ed in the drive housing. If solenoid is defective, entire drive housing must be replaced.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 PG260 Starter Motor PG260 Specifications Delco I.D. Number MerCruiser Part Number 9000820 50-806963 No Load Test Engine Rotation Volts Min. Amps Max. Amp Min. rpm Max. rpm LH 10.6 60 95 2750 3250 Pinion Clearance Bearing Depth (Gear) Bearing Depth (Housing) Brush Spring Tension Oz. (Grams) 83-104 oz. (23522948) .101-.160 (.025-4.06mm) .011-.014 (0.28-.038mm) Maximum .009-.017 (0.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 PG260 Exploded View 20 1 6 2 7 8 3 9 16 4 17 10 11 18 21 5 12 13 14 15 74270 19 1 - Screw (2) 2 - End Cap 3 - Brush With Holder 4 - Armature 5 - Field Frame (With Permanent Magnets) 6 - Washer 7 - Shield 8 - Planetary Gears 9 - Shaft 10 - Gear 11 - Drive 12 - Collar 13 - Retaining Ring 14 - Trust Collar 15 - Drive Housing 16 - Nut 17 - Solenoid 18 - Solenoid Drive Arm 19 - Screw (3) 20 - Screw (2) 21 - Rubber Grommet INDEX 90-861329--1 MARCH 1999 Page
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Starter Motor Repair Removal WARNING Disconnect battery cables at battery before removing starter. 1. Disconnect battery cables from battery. 2. Disconnect wires from solenoid terminals. IMPORTANT: Some starter motors may use a special mounting shim for gaining flywheel clearance. Do not lose this shim; it will be needed when remounting starter on engine block. 3. Remove starter mounting bolts. 4. Pull starter assembly away from flywheel and remove from engine.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 2. Remove through bolts and separate end frame from field frame and end cap. c a 74040 b a - End Cap b - Through Bolt c - Drive Housing 3. Remove brush holder from end cap. c 74037 a b a - Brush Holder b - End Cap c - Screws (2) 4. Remove armature and field frame from drive housing. 5. Pull armature out of field frame. NOTE: Permanent magnets inside field frame will be holding armature in place.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 6. Remove shield and washer. 74038 a b a - Shield b - Washer 7. Remove the three screws retaining the solenoid. Remove solenoid from drive housing. c 74036 b a a - Drive Housing b - Solenoid c - Screws (3) 8. Remove drive and associated parts from drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 9. Remove solenoid arm and rubber grommet from the drive housing. a 74105 b 74048 c 74018 a - Rubber Grommet b - Solenoid c - Drive Housing 10. Remove thrust collar, retaining ring and collar from planetary shaft.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 11. Remove drive and gear from planetary shaft. b a c 74087 a - Gear b - Planetary Gear Shaft Assembly c - Drive Cleaning and Inspection IMPORTANT: Do not use grease dissolving solvents to clean electrical components, planetary gears, or drive. Solvent will damage insulation and wash the lubricant out of the drive and gears. Use clean rags and compressed air to clean components. 1. Test over-running clutch action of drive.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Armature Tests TEST FOR SHORTS Check armature for shorts by placing on growler and holding hack saw blade over armature core while rotating armature. If saw blade vibrates, armature is shorted. After cleaning between commutator bars, recheck. If saw blade still vibrates, replace armature. a b c 01440 a - Hacksaw Blade b - Armature Cover c - Growler TEST FOR GROUND 1. With continuity meter, place one lead on armature core or shaft and other lead on commutator.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Armature Bearing (Commutator End) REMOVAL Use a universal puller plate, as shown, to remove bearing. a b 72068 a - Universal Puller Plate b - Bearing INSTALLATION IMPORTANT: Brush holder must be installed on armature before installing armature bearing. Using the correct size driver, press on inner bearing race until it contacts shoulder of armature shaft. Gear Bearing REMOVAL Using the correct size driver, press bearing out of gear. INSTALLATION 1.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 2. Lubricate bearing and gear teeth with a small amount of Quicksilver 2-4-C Marine Lubricant with Teflon. Shaft Assembly Bearing IMPORTANT: Roller bearing is not replaceable. If bearing is defective, replace entire shaft assembly. Apply Quicksilver 2-4-C Marine Lubricant with Teflon to bearing before starter reassembly. a 72070 a - Roller Bearing Drive End Housing Bearing REMOVAL Using the correct size driver, press bearing out of housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 INSTALLATION 1. Using the correct size driver, press bearing into housing, from direction shown, to depth specified. a b 72626 a - Depth - .009-.017 in. (0.25-0.45 mm) b - Installation Direction 2. Lubricate bearing with a small amount of Quicksilver 2-4-C Marine Lubricant with Teflon. Brushes and Brush Holder INSPECTION Replace brushes and holder when brush leads are touching guide. Make sure brushes move freely in guides.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 INSTALLATION 1. Push each brush up into its guide to allow spring to hold it in place, as shown. a c b 72072 a - Brush b - Guide c - Brush Spring 2. Place brush holder on armature and push brushes down against commutator, as shown. b a c 72069 a - Brush Holder b - Brush c - Commutator 3. Install armature bearing as previously described.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Reassembly 1. Install end frame on brush holder. Align holes of end frame with holes of brush holder. Tighten screws securely. b c a d 76250 a b c d - Screw (2) - End Cap - Brush Holder - Armature 2. Install gear and drive over planetary shaft.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 3. Assemble drive on shaft assembly as follows: a. Lubricate drive end of shaft assembly with SAE 10W oil. b. Place gear over shaft. c. Slide drive assembly onto shaft with pinion facing outward. d. Slide retainer onto shaft with cupped surface facing end of shaft (away from pinion). e. Position snap ring on upper end of shaft and hold in place with block of wood. Strike wood block with hammer, thus forcing snap ring over end of shaft.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 4. Install the planetary gears on planetary shaft. 5. Install solenoid arm and rubber grommet in the drive housing. a 74105 b 74048 c 74018 a - Rubber Grommet b - Solenoid c - Drive Housing 6. Install drive and associated parts in drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 7. Place solenoid in drive housing and tighten screws. c 74036 b a a - Drive Housing b - Solenoid c - Screw (3) 8. Install shield and washer in drive housing. 74038 a b a - Shield b - Washer 9. Install field frame over armature. Align slot in end cap and field frame for proper positioning of rubber grommet.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 10. Install field frame and end cap in drive housing align slots in field frame with recess in drive housing. a b 76252 a - Drive Housing b - End Cap and Field Frame 11. Install through bolts and brush lead. Tighten fasteners securely. Starter Solenoid Testing/Replacement 1. Using continuity meter, connect test leads as shown, and connect 12 volt battery with jumper leads as shown. 72630 a - Brush Lead 2. If no meter movement is present, replace solenoid. 3.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 5. Momentarily touch a jumper lead from solenoid motor to starter motor frame. This shifts pinion into cranking position where it will remain until battery is disconnected. 72629 6. Push pinion back toward commutator end to eliminate slack. 7. Measure distance between pinion and pinion retainer. 8. If clearance is not within limits of .010-.160 in. (0.25-4.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Installation IMPORTANT: Install special mounting shim (if equipped) between starter motor and engine block. 1. Place starter motor in position and install mounting bolts. Torque bolts to 30 lb-ft (41 Nm). 2. Connect YELLOW/RED wire to terminal S of solenoid. Connect ORANGE wire, RED wire, and battery cable to large terminal of solenoid. Tighten fasteners securely. Coat terminals with Quicksilver Liquid Neoprene. Install battery cable boot, if so equipped. 3.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 PG260F1 Starter Motor PG260F1 Specifications Delco I.D. Number MerCruiser Part Number 9000839 - 9000840 50-807904 No Load Test Engine Rotation Volts Min. Amps Max. Amp Min. rpm Max. rpm LH 11.5 40 90 3200 4800 Brush Spring Length Brush Spring Tension Oz. (Grams) Length New - 0.36 - 0.42 in. (9.2 - 10.7 mm) Length Used - 0.18 - 0.23 in. (4.62 - 5.98 mm) Pinion Clearance 0.009 - 0.160 in. (0.23-4.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Exploded View 20 1 6 2 7 8 3 9 10 16 11 12 4 21 22 17 13 18 5 14 15 19 74270 INDEX Page 4A-32 90-861329--1 MARCH 1999
STARTING SYSTEM SERVICE MANUAL NUMBER 26 1 - Screw (2) 2 - End Frame and Bearing 3 - Brush With Holder 4 - Armature 5 - Field Frame (With Permanent Magnets) 6 - Washer 7 - Shield 8 - Planetary Gears 9 - Shaft 10 - Gear 11 - Drive 12 - Collar 13 - Retaining Ring 14 - Trust Collar 15 - Drive Housing 16 - Nut 17 - Solenoid 18 - Solenoid Drive Arm 19 - Screw (3) 20 - Long Screw (2) 21 - Rubber Grommet 22 - Metal Disc Starter Motor Repair Removal WARNING Disconnect battery cables at battery before removing s
STARTING SYSTEM SERVICE MANUAL NUMBER 26 2. Separate end frame from field frame. 3. Remove brush holder from end frame. 4. Remove armature and field frame from drive housing. 5. Pull armature out of field frame. NOTE: Permanent magnets inside field frame will be holding armature in place. b a c d e 74270 a - End Frame and Bearing b - Screws (2) c - Brush Holder d - Armature e - Field Frame 6. Remove shield and washer from drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 7. Remove the three screws retaining the solenoid. Remove solenoid from drive housing. c b 74036 a a - Drive Housing b - Solenoid c - Screws (3) 8. Remove drive and associated parts from drive housing. a 74035 75821 b a - Drive Housing b - Drive 9. Remove solenoid arm, metal disc and rubber grommet from the drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 10. Remove thrust collar, retaining ring and collar from planetary shaft with drive. b a c d 75821 a - Thrust Collar b - Retaining Ring (Inside Collar) c - Collar d - Planetary Shaft and Drive 11. Remove drive and gear from planetary shaft.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Cleaning and Inspection IMPORTANT: Do not use grease dissolving solvents to clean electrical components, planetary gears, or drive. Solvent will damage insulation and wash the lubricant out of the drive and gears. Use clean rags and compressed air to clean components. 1. Test over-running clutch action of drive. Pinion should turn freely in over-running direction and must not slip in cranking direction. Check pinion teeth.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 TEST FOR GROUND 1. With continuity meter, place one lead on armature core or shaft and other lead on commutator. 2. If meter hand moves, armature is grounded and must be replaced. b c d a 01441 a - Commutator b - Armature Core c - Shaft d - Growler Reassembly 1. Install brush holder and bearing on armature. 2. Align brush lead grommet with field frame cut-out. Align holes of end frame with holes of brush holder and drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 3. Install gear and drive over planetary shaft. a b c 74087 Typical a - Planetary Gear Shaft Assembly b - Gear c - Drive 4. Assemble drive on shaft assembly as follows: a. Lubricate drive end of shaft assembly with SAE 10W oil. b. Place gear over shaft. c. Slide drive assembly onto shaft with pinion facing outward. d. Slide retainer onto shaft with cupped surface facing end of shaft (away from pinion). e.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 f. Assemble thrust collar on shaft with shoulder next to snap ring. g. Position retainer and thrust collar next to snap ring. Then, using two pliers, grip retainer and thrust collar and squeeze until snap ring is forced into retainer. b a c 72074 a - Retainer b - Thrust Collar c - Snap Ring 5. Install the planetary gears on planetary shaft. 6. Install solenoid arm, metal disc and rubber grommet in the drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 7. Install drive and associated parts in drive housing. a 75821 74035 b a - Drive Housing b - Drive 8. Attach solenoid arm to solenoid. Place solenoid in drive housing and tighten screws. c b a 74036 a - Drive Housing b - Solenoid c - Screw (3) 9. Install washer and shield in drive housing.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 10. Install field frame over armature. Align slot in field frame with rubber grommet. b c 75821 a a - Armature b - Field Frame Slot c - Rubber Grommet 11. Install field frame and end frame in drive housing. 12. Install long screws and brush lead. Tighten fasteners securely.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 3. Momentarily touch a jumper lead from battery terminal to switch terminal. This shifts pinion into cranking position where it will remain until battery is disconnected. 72629 4. Push pinion back toward commutator end to eliminate slack. 5. Measure distance between pinion and pinion retainer. 6. If clearance is not within limits of .010-.160 in. (0.25-4.
STARTING SYSTEM SERVICE MANUAL NUMBER 26 Installation IMPORTANT: Install special mounting shim (if equipped) between starter motor and engine block. 1. Place starter motor in position and install mounting bolts. Torque bolts to 30 lb-ft (41 Nm). 2. Connect YELLOW/RED wire to terminal S of solenoid. Connect ORANGE wire, RED wire, and battery cable to large terminal of solenoid. Tighten fasteners securely. Coat terminals with Quicksilver Liquid Neoprene. Install battery cable boot, if so equipped. 3.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 ELECTRICAL SYSTEM Section 4B - Ignition System Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealants/Adhesives . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . .
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Identification 70103 DELCO EST (Electric Spark Timing) Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Tools Description Part Number Dwell Meter 91-59339 Magneto Analyzer 91-76032 Remote Starter Switch 91-52024A1 Timing Light 91-99379 Volt / Ohm Meter 91-99750A1 Timing Jumper 91-818812A1 Point Spring Tension Gauge Obtain Locally Special Tools Kent-Moore Special Tools Kent-Moore Special Tools 29784 Little Mack Roseville, MI 48066 Phone: (313) 574-2332 Module Tester J24642 Lubricants/Sealants/Adhesives Description Distributor Cam Lubricant Liquid Neo
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Specifications Timing Timing (At Idle rpm)1 1° BTDC2 / 1° ATDC3 / 2° ATDC4 1Timing must be set using a special procedure as outlined in this section. Timing cannot be properly set using the conventional method. 2Serial number break: 0L096999 and below 3Serial number break: 0L097000 - 0L0340999 4Serial number break: 0L341000 and above. Spark Plugs Spark Plug Gap .035 In. (0.9 mm) 3.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Description EST or Electronic Spark Timing is a High Energy Ignition System (HEI). The distributor itself has no centrifugal advance mechanism or devices. The spark plug wires are a carbon-impregnated cord conductor with a silicone rubber jacket. It is important they be handled with care, and routed so as not to cross each other or to be in contact with other parts of the engine to prevent rubbing.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Molded into the module is a two-prong connector for the coil terminals and four prong connector. Only three of the four terminals of the second connector are used by MerCruiser (one for the shift interrupt and two white leads are used to “freeze” advance for properly setting initial timing). Inside the distributor, the pick-up coil attaches to the module at a molded prong connector.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Cleaning And Inspection Spark Plugs 1. Inspect each plug individually for badly worn electrodes, glazed, broken or blistered porcelain and replace plug where necessary. 2. Inspect each spark plug for manufacturer and heat range. All plugs must be the same manufacturer and number or heat range. Refer to “Specifications” for spark plug numbers. 3. Check spark plug gaps with a round feeler gauge. Adjust if necessary.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Distributor Cap and Rotor 1. Loosen distributor cap retaining screws. 2. Remove distributor cap. 3. Clean cap with warm soap and water and blow off with compressed air. 4. Check cap contact for excessive burning or corrosion. Check center contact for deterioration. IMPORTANT: Distributor caps (for marine use) should have brass contacts, aluminum contacts should not be used. 5. Check cap for cracks or carbon tracks using magneto analyzer. 6. Remove rotor. 7.
SERVICE MANUAL NUMBER 26 IGNITION SYSTEM Engine Disturbed 1. Locate No. 1 piston in firing position by either of two methods described below. a. Remove No. 1 spark plug and, with finger on plug hole, crank engine until compression is felt in No. 1 cylinder. Continue cranking until pointer lines up with timing mark on crankshaft pulley, or b. Remove rocker cover and crank engine until No. 1 intake valve closes, continuing to crank slowly until pointer lines up with timing mark on crankshaft pulley. 2.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 3. Start engine and run at idle speed until it reaches normal operating temperature. a b a 70103 a - WHITE Leads b - Jumper Lead 4. Install a jumper wire between the two WHITE leads on the distributor. Use Quicksilver 91-818812A1, or fabricate a jumper wire using a 6 in. (150 mm) section of 16 gauge wire with two male bullet terminal ends connected. 5. Bypass the shift interrupt switch, as follows: a. Disconnect wires at shift interrupt switch. b.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 6. Aim timing light at timing tab, located on the timing gear cover and crankshaft torsional damper. Check the timing. Refer to “Specifications.” 73664 72328 Typical 7. Adjust timing by loosening distributor clamp and rotating distributor body as required until timing mark on damper or pulley lines up with the mark on tab specified in “Specifications.” Tighten clamp and recheck location of timing mark. 8.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 IMPORTANT: Be sure to remove jumper wire before returning engine to service, otherwise timing will not advance. 11. Remove jumper wire at distributor white leads. a b a 70103 a - WHITE Leads b - Jumper Lead 12. With timing light still connected, start the engine and run at IDLE. Verify that timing did advance to : • If initial timing is 1° BTDC: 12° BTDC, plus or minus 2°.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Testing Ignition Coil 1. If not already done, disconnect wiring from ignition coil. Connectors are molded and keyed to assure proper positioning. The terminal (e) feeds 12 volts to the distributor. NOTE: Upon reinstallation, first install black connector (distributor harness) to coil. Then install gray connector (engine harness). 2.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 4. Repeat Step 3 with ohmmeter connected to GREEN lead. Reading should be infinite. If not, replace pickup coil. 5. Set ohmmeter to “Rx100” scale. Connect ohmmeter to GREEN and WHITE pickup coil leads. Reading should be constant, unchanging value in the range of 500-1500 ohms. If not, replace pickup coil. Be certain to flex leads by hand during this test to locate possible intermittent “open” circuits (loss of continuity). If any exist, replace pickup coil.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 Advance Curve Module Part Number: 811637 Module Advance: See Notice Initial Timing: 1° BTDC1 / 1° ATDC2 / 2° ATDC3 Total Advance: 23° 1Serial number break: 0L340999 and below unless specified differently below 2Serial number break: 0K001529 - 0L097000 Timing changes to 1° ATDC only if engine experiences a cylinder head gasket failure that has blown out toward the intake exhaust manifold on the port side of the engine. 3Serial number break: 0L341000 and above.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 35° TOTAL SPARK ADVANCE 30° MAX. 25° MIN. 20° 15° 10° 5° 500 1000 1500 2000 2500 3000 3500 ENGINE R.P.M.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 35° TOTAL SPARK ADVANCE 30° MAX. 25° MIN. 20° 15° 10° 5° 500 1000 1500 2000 2500 3000 3500 ENGINE R.P.M.
IGNITION SYSTEM SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 4B-18 90-861329--1 MARCH 1999
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 ELECTRICAL SYSTEM Section 4C - Charging System Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Replacement Parts Warning . . . . . . . . . . . . 4C-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-3 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 System Components . . . . . . . . . . . . . . . . . . 4C-5 Periodic Maintenance . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Identification c b a 72078 Mando 55 Amp Alternator a - Excitation Wire - PURPLE b - Sensing Wire - RED/PURPLE c - Mando Part Number (Hidden In This View) 76093 Mando 65 Amp Alternator INDEX Page 4C-2 90-861329--1 MARCH 1999
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire or explosion hazard and should be avoided.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Precautions CAUTION The following precautions MUST BE observed when working on the alternator system. Failure to observe these precautions may result in serious damage to the alternator or alternator system. • DO NOT attempt to polarize the alternator. • DO NOT short across or ground any of the terminals on the alternator, except as specifically instructed in the “Troubleshooting Tests.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 System Components The alternator system consists of the alternator, battery, the ignition switch and the wiring which connects these components.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Periodic Maintenance The following maintenance check should be performed every 50 hours or 60 days (whichever comes first) in fresh water areas or every 25 hours or 30 days in salt water areas. CAUTION Remove all battery cables from battery (before conducting the following check) to prevent accidentally shorting out electrical system. 1. Inspect entire alternator system for corroded or loose connectors. 2. Check wiring for frayed or worn insulation. 3.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Drive Belt Tension Adjustment Alternator 1. Install drive belt on pulleys and adjust tension as follows: a. Pivot alternator away from engine, as required, until correct tension is obtained as shown. Belt should depress 1/4in. (6 mm). a b 76094 a - Check Point b - Alternator Pivot Bolt b. After obtaining correct tension, securely retighten alternator brace attaching bolts and alternator mounting bolts. 2.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Circuitry Test Perform the following tests, using a 0-20 volt DC voltmeter, to check that all of the circuits between the alternator and the other components within the alternator system are in good condition. OUTPUT CIRCUIT 1. Connect positive (+) voltmeter lead to alternator output terminal and negative (–) lead to a ground terminal on alternator. 2. Wiggle engine wiring harness while observing voltmeter.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 5. If reading is between 6.0 and 7.0 volts, rotor field circuit probably is open. Remove regulator and inspect for worn brushes or dirty slip rings. Replace brushes if less than 1/4 in. (6 mm) long. If brushes and slip rings are in good condition, disassemble and perform rotor test as outlined under “Component Testing - Rotor” following.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Current Output Test Perform this test to check if alternator is capable of producing rated current output, using a 0-50 amp DC ammeter. WARNING Be sure that engine compartment is well-ventilated and that there are no gasoline vapors present (during the test) to prevent the possibility of an explosion and/or a fire, should a spark occur. 1. Disconnect negative (–) battery cable from battery. 2.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Voltage Output Test Perform this test to determine if voltage regulator is operating correctly, using a 0-20 volt DC voltmeter. IMPORTANT: Battery MUST BE fully charged (1.260 or above specific gravity) to obtain proper voltage reading in this test. If necessary, charge battery with a battery charger or allow engine to run a sufficient length of time to fully charge battery before taking reading. 1.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 5. If a voltmeter reading of 14.5 volts or above is now obtained, voltage regulator is faulty and must be replaced. If voltmeter reading is below 14.5 volts, inspect brushes and slip rings for wear, dirt or damage. If brushes and slip rings are good, alternator is faulty internally. Disassemble alternator and test components, as outlined under “Alternator Repair,” following.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Exploded View 22 25 27 29 20 21 24 26 28 23 2 10 12 17 19 16 2 10 6 3 1 3 2 4 5 8 9 2 13 3 15 1 13 2 14 10 18 7 11 72276 1 - Screws (3) 2 - Nut (9) 3 - Flat Washer (4) 4 - Sensing Wire (RED / PURPLE) 5 - Excitation Wire (PURPLE) 6 - Cover 7 - Tie Strap 8 - Rubber Gasket 9 - Condenser 10 - Insulator 11 - Bolt (4) 12 - End Frame (Rear) 13 - Cap (2) 14 - Brush / Regulator Assembly 15 - Rectifier Assembly 16 - Flat Washer 17 - Screw 18
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Disassembly IMPORTANT: The following instructions are for complete disassembly and overhaul of the alternator. In many cases, however, complete disassembly of alternator is not required and, in those cases, it is necessary only to perform the operations required to repair or replace the faulty part. 1. Mount alternator in a vise so that rear end frame is facing you. 2. Disconnect regulator leads from terminals on rear end frame.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 IMPORTANT: DO NOT insert screwdriver blades more than 1/16in. (1.5 mm) into openings (in next step), as stator windings may be damaged. 7. Separate rear end frame and stator assembly from front end frame and rotor assembly using two thin blade screwdrivers (positioned 180 degrees apart from one another) at the locations shown. Use the two slots shown to initially separate units. b c e a a d 72824 a b c d e - DO NOT Insert Screwdriver Blades More Than 1/16in.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 11. Unsolder the three stator leads from the rectifier heat sink. Place a needle nose pliers on diode terminal between solder joint and diode body to help prevent heat damage to diodes. Unsolder joints as quickly as possible and allow diode terminal to cool before removing pliers.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 13. Remove the three Phillips head screws and lockwashers which secure the front bearing retaining plate. a b 72829 a - Phillips Head Screws and Lockwashers b - Front Bearing Retaining Plate 14. Remove front bearing from front end frame using an arbor press and a suitable size mandrel. Discard bearing. a b c 72830 a - Press b - Mandrel c - Bearing 15. If rotor slip rings or rear bearing requires replacement, entire rotor must be replaced.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Cleaning and Inspection 1. Clean all parts with a clean, soft cloth. DO NOT use solvent, or electrical components may be damaged. 2. Inspect the following parts for wear and damage: a. Brush/regulator assembly - inspect for cracked casing, damaged brush leads, poor brush lead solder connections, weak or broken brush springs or worn brushes. Replace brush set if brushes are less than 1/4in. (6 mm) long. b.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Component Testing ROTOR 1. Test rotor field circuit for opens, shorts or high resistance (Test 1), using an ohmmeter (set on R x1 scale), as follows: a b 72831 Testing Rotor Field Circuit a - Test 1 b - Test 2 a. Connect one ohmmeter lead to each slip ring. b. Ohmmeter reading should be 4.2 to 5.5 ohms with rotor at room temperature 70-80°F (21-26°C). c. If reading is high or infinite (no meter movement), high resistance or an open exists in the field circuit.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 2. Test rotor field circuit for grounds (Test 2), using an ohmmeter (set on R x1 scale) as follows: a. Connect one lead of ohmmeter to either slip ring and the other lead to rotor shaft or pole pieces. b. Meter should indicate no continuity (meter should not move). c. If continuity does exist, complete rotor assembly must be replaced.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 RECTIFIER AND DIODE ASSEMBLY NOTE: Failure of any component in tests following will require replacement of entire rectifier assembly. NEGATIVE (–) RECTIFIER IMPORTANT: Rectifier MUST BE disconnected from stator for this test. CAUTION DO NOT use a test instrument with more than a 12 volt source (in the following test), as rectifier may be damaged. 1.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 3. Meter should indicate a high or infinite resistance (no meter movement) when connected one way and a low reading when connected the other. If both readings are high or infinite, rectifier is open. If both readings are low, rectifier is shorted. 4. Repeat Steps 1 through 3 for two other rectifiers in heat sink. b c 72834 a a - Stud b - Rectifier Terminal c - Repeat Test Between These Terminals And Stud 5.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 CONDENSER 1. Using magneto analyzer and accompanying instructions, perform the following condenser tests: a. Condenser Capacity Test (must be .5 mfd). b. Condenser Short or Leakage Test. c. Condenser Series Resistance Test. 2. Replace condenser if test results are not within specifications. Reassembly 1. Install new front bearing into front end frame bearing bore using an arbor press. If necessary, use a bearing driver that contacts outer race only.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 IMPORTANT: DO NOT clamp vise on rotor pole pieces when tightening pulley nut (in next step), or pole pieces may be distorted. 4. Slide fan spacer onto rotor shaft. Install fan, pulley, lockwasher and nut on shaft. Clamp pulley in a vise, using protective jaws or an old oversize V-belt to protect pulley, and torque nut to specifications. Tighten vise only enough to allow tightening of nut, as excessive tightening may distort pulley. 5.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 8. Position rear end frame and stator assembly over front end frame and rotor assembly and align scribe marks on each (scribed during disassembly). Hand-press end frames together, then install four screws. Tighten screws securely. a e d c 72561 b a b c d e - Rear End Frame - Stator - Front End Frame - Scribe Marks - Insert Screws (4) (Two Hidden) 9. Depress brushes flush with top of brush holder and insert a #54 drill bit or smaller (.050in.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 10. Install brush/regulator assembly in rear end frame cavity and secure with two mounting screws, as shown. Tighten screws securely. Remove drill bit to release brushes against slip rings. a b 72837 a - Brush/Regulator Assembly b - Mounting Screws 11. Install tie strap to rectifier stud and stud on brush/rectifier assembly. Tighten nuts securely.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 12. Install cover with one Phillips head screw and two nuts. Install two leads with nuts. a b 72963 c a - Phillips Head Screw b - Nuts (4) c - Leads 13. Install insulator caps.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Installation 1. Position alternator in mounting bracket and install mounting bolt, washers (if used), spacer and nut. Place washers (if used), on each side of spacer. DO NOT tighten securely at this time. 2. Fasten alternator brace to alternator with bolt, washers and spacer (if used). DO NOT tighten bolt at this time. 3. Position alternator drive belt on pulleys and adjust tension as explained under “Drive Belt Tension Adjustment.” 4.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Batteries Battery Cables Select proper size positive (+) and negative (–) battery cables, using chart. Battery should be located as close to engine as possible. IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and a subsequent failure. Cable Gauge Cable Length Up to 3 - 1/2 ft (1.1m) 4 (25 mm2) 3-1/2 - 6 ft (1.1-1.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Mando 55 Amp Alternator Identification c b a 72078 Mando 55 Amp Alternator a - Excitation Wire - PURPLE b - Sensing Wire - RED/PURPLE c - Mando Part Number (Hidden In This View) Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Tools Description Bearing Removal and Installation Kit Part Number 91-31229A7 Magneto Analyzer 91-76032 Universal Puller Plate 91-37241 Multi-Meter/DVA Tester 91-99750A1 Ammeter (0-50 Amps) Obtain Locally Lubricants/Sealants/Adhesives Description Quicksilver Liquid Neoprene Part Number 92-27511--3 Torque Specifications Fastener Location lb-in. End Frame Screws 55 6.5 Brush Setscrews 18 1.5 Regulator Mounting Screws 43 4.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Battery Isolator Diagram b a h c 2 2 2 d 1 c d f f g e 72934 a b c d e f g h - Circuit Breaker - Harness Connector - Alternator - Starter - Cranking Battery - Ground Stud - Auxiliary Battery - Isolator 1 - Disconnect Orange Wire From Alternator “Batt” Terminal. Splice Sufficient Gauge Wire To The Orange Wire And Connect As Shown.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Mando 65 Amp Alternator Identification c b 72078 a Mando 65 Amp Alternator a - Excitation Wire - PURPLE b - Sensing Wire - RED/PURPLE c - Mando Part Number (Hidden In This View) Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Tools Description Bearing Removal and Installation Kit Universal Puller Plate Part Number 91-31229A7 91-37241 Multi-Meter/DVA Tester 91-99750A1 Ammeter (0-100 Amp) Obtain Locally Lubricants/Sealants/Adhesives Description Quicksilver Liquid Neoprene Part Number 92-27511--3 Torque Specifications Fastener Location lb-in. lb-ft Nm End Frame Screws 55 5.5 Brush Setscrews 18 1.5 Regulator Mounting Screws 42 4.2 Regulator Leads 25 2.
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 Exploded View 22 25 27 29 20 21 24 26 28 23 2 10 12 17 19 16 2 10 6 3 1 3 2 4 5 8 9 2 13 3 15 1 13 2 14 10 18 7 11 72276 1 - Screws (3) 2 - Nut (9) 3 - Flat Washer (4) 4 - Sensing Wire (RED / PURPLE) 5 - Excitation Wire (PURPLE) 6 - Cover 7 - Tie Strap 8 - Rubber Gasket 9 - Condenser 10 - Insulator 11 - Bolt (4) 12 - End Frame (Rear) 13 - Cap (2) 14 - Brush / Regulator Assembly 15 - Rectifier Assembly 16 - Flat Washer 17 - Screw 18
CHARGING SYSTEM SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK INDEX Page 4C-36 90-861329--1 MARCH 1999
INSTRUMENTATION SERVICE MANUAL NUMBER 26 ELECTRICAL SYSTEM Section 4D - Instrumentation Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Special Information . . . . . . . . . . . . . . . . . . . . Lighting Options . . . . . . . . . . . . . . . . . . . . Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil, Fuel and Temperature . . . . . . . . . . . Battery Gauge . . . . . . . . . . . . . . . . . . . . . Cruiselog Meter . . . . . . . . . . . . . . . .
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Identification One of three distinct lines (Series) of Quicksilver gauges may be installed (if equipped with Quicksilver gauges). Aside from different gauge face appearances and styling, the back of the gauges and wiring connections are different as shown.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Special Information Lighting Options COMMODORE AND INTERNATIONAL SERIES These gauges may be wired so that the illumination lighting is provided from the ignition switch or a separate instrumentation lighting switch. By removing contact strip “I” from between + terminal and the screw as shown following, and supplying a separate +12 V power supply to the screw connection, illumination lights can be operated independent of ignition switch.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 QSI SERIES These gauges are equipped with optional illumination lighting. Light bulb socket can be removed and contacts can be aligned to be used with ignition switch lighting circuit +12 V or separate instrumentation lighting circuit LT. IMPORTANT: Light socket must be removed from gauge and turned counterclockwise (facing back of gauge) when adjusting to desired setting. Turning socket while still installed in gauge could result in damage to gauge or socket.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Gauges Oil, Fuel and Temperature IMPORTANT: If testing proves gauge to be defective, it must be replaced as there is no repair available. TESTING 1. Turn ignition switch to OFF. 2. Remove wire from terminal S (SEND). a 72965 Typical a - Sender Terminal 3. Turn ignition switch to RUN. Gauge being tested must be at position A. 72747 Typical Position A 4. Turn ignition switch to OFF.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 5. Connect jumper wire from terminal G (GND) to terminal S (SEND). 72748 Typical 6. Turn ignition switch to RUN. 7. Indicator needle of gauge being tested must read at position B. If not, replace gauge.
SERVICE MANUAL NUMBER 26 INSTRUMENTATION Battery Gauge TESTING 1. Remove cables from battery and fully charge battery. 2. Connect negative (–) jumper lead from battery to gauge terminal G (GND). 3. Connect positive (+) jumper lead from battery to gauge terminal I or +12 V. 72750 Typical 4. Check gauge reading; if not as shown replace gauge.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Cruiselog Meter TESTING 1. Connect jumper wire from negative (–) battery terminal to negative (–) gauge terminal. 2. Connect jumper wire from positive (+) battery terminal to positive (+) gauge terminal. 72752 3. Observe gauge run indicator. If indicator is turning, gauge is operable; if not, replace gauge. a 72753 a - Indicator Vacuum Gauge TESTING 1. Disconnect vacuum hose from engine.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Speedometer TESTING IMPORTANT: When testing speedometer gauge for accuracy, the air supply used for the test must be regulated to the specified air pressure. Do not apply excessive air pressure to speedometer gauge. 1. Apply air pressure directly to speedometer gauge (specified in chart) and note gauge reading. Light tapping of pressure gauge is required during accuracy check. 2. If gauge readings are not within specifications, gauge is defective.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Senders Oil Pressure TESTING IMPORTANT: Use following test procedure for checking accuracy of oil pressure sender only. If oil pressure gauge indicates zero oil pressure, refer to SECTION 4C “Troubleshooting.” 1. Remove wire from sender terminal. 2. Connect ohmmeter between sender terminal and sender case. Check ohms reading without engine running (zero pressure), then check reading with engine running.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Water Temperature Sender There is no accurate test that can be done without special equipment. Install new sender. TESTING 1. Connect an ohmmeter between temperature sender terminal (+) and hex (case) for ground (–) as shown. a b 72768 a - Ohmmeter Leads b - Water Temperature Sender WARNING The following test involves the use of intense heat. Failure to follow appropriate procedures or warnings can cause burns which can result in severe personal injury.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 2. Follow these instructions: a. With ohmmeter connected as outlined and using suitable container, thermometer and heat source, suspend sender with tip in water. b. Heat water and observe thermometer. c. As temperature rises ohmmeter readings must be within the ranges specified for each temperature (see chart below). d. Turn heat source off. Allow water and components to cool. NOTE: While water cools you may recheck ohmmeter readings.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 INSTALLATION 1. Apply Loctite Pipe Sealant with Teflon to threads of temperature sender. 2. Install sender in thermostat housing and tighten securely. 3. Connect TAN wire and coat with liquid neoprene. a b a - TAN Wire b - Water Temperature Sender 4. Refill closed cooling system with approved coolant as outlined in SECTION 6B. DUAL STATION SENDER IDENTIFICATION Sender will have 362-BC stamped on hex.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Fuel Tank Sender Flange Type TESTING 1. Disconnect wire from terminal on sending unit and ground wire from sending unit mounting screw. 2. Remove sending unit from fuel tank. 3. Connect ohmmeter between sending unit terminal and sending unit housing. 4. With float arm in FULL position (arm horizontal), ohmmeter should read 30 ohms (+ 5 ohms). a 72755 b a - Ohmmeter Leads b - Vertical Float Arm 5.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Capsule Type TESTING 1. Disconnect wire from terminal on fuel tank capsule. 2. Remove two screws and remove capsule assembly. 3. Place a magnet under fuel capsule. 4. Connect ohmmeter between fuel capsule terminal and metal portion of capsule housing. a b c 72757 a - Ohmmeter Leads b - Capsule Assembly c - Magnet 5. Turn magnet counterclockwise until fuel capsule indicator reads EMPTY. Ohmmeter should read 240 ohms (+ 5 ohms).
INSTRUMENTATION SERVICE MANUAL NUMBER 26 6. Turn magnet clockwise until fuel capsule indicator reads FULL. Ohmmeter should read 30 ohms (+ 5 ohms). Fuel capsule is defective if not within specifications. a 72759 a - Capsule Reading Full Switches Ignition Key Switch TESTING WARNING Disconnect battery cables from battery before testing ignition key switch with wires still connected to switch. 1.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Audio Warning System Buzzer WARNING The following test involves the use of electricity. Failure to follow appropriate procedures can cause burns or shock which can result in severe personal injury or death. TESTING 1. Turn the ignition switch to the ON position without cranking the engine. The horn will sound if the system is working correctly. 2. If horn does not sound: a. Connect jumper wires as shown. b. If horn does not sound, replace it. 3.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 Oil Pressure Switch Refer to SECTION 4E for switch locations. Switch is normally closed. TESTING 1. Remove wire from sender terminal. 2. Connect continuity meter between sender terminal and sender hex. (Sender shown removed for clarity.) 72764 3. With engine not running, meter should indicate full continuity. 4. Start engine. With engine running and engine oil pressure above 6 psi (41 kPa), meter should indicate NO continuity.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 WARNING The following test involves the use of intense heat. Failure to follow appropriate procedures or warnings can cause burns which can result in severe personal injury. While performing the following test, observe these general precautions: • Wear personal protective clothing such as rubber gloves, a non-flammable apron, and eye protection - preferably full face shield or safety glasses. • The appropriate heat source should only be electric.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 c. As temperature rises, switch will close and ohmmeter will indicate continuity. Refer to chart below for specifications. 48952 Switch Opens 150-170°F (60-77°C) Closes 190-200°F (88-93°C) 87-86080 Switch Opens 175-195°F (79-91°C) Closes 215-225°F (102-107°C) a b 72767 Switch Identification a - 48952 Switch with Red Mylar Sleeve b - 87-86080 Switch with Black Mylar Sleeve 4. Turn heat source off. Allow sand to cool.
INSTRUMENTATION SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index 90-861329--1 MARCH 1999 Page 4D-21
INSTRUMENTATION SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 4D-22 90-861329--1 MARCH 1999
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 ELECTRICAL SYSTEM Section 4E - WIRING DIAGRAMS Table of Contents Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . 4E-2 MCM 3.0L Gasoline Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 4E-2 Quicksilver Instrumentation Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-6 Battery Meter Gauge . . . . . . . . . . . . . . . . . 4E-10 Cruiselog . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Wiring Diagrams MCM 3.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 NOTE: Gray lead for use with service tachometer.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 WITH CIRCUIT BREAKER A 1 2 C 3 3 1 2 1 3 2 D 1 5 6 2 3 4 B 74101 Index Page 4E-4 90-861329--1 MARCH 1999
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 NOTE: Gray lead for use with service tachometer.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 PPL 5 WHT WHT BLK GRAY 8 BLK 2 16 LT. BLU 10 RED GXL 12 YEL–RED GXL 8 ORN GXL 11 GRAY 4 16 GRY 8 BLK 8 ORN GXL 8 BLK GXL 14 RED–PPL GXL 16 R 16 PPL GXL 16 LT.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index 90-861329--1 MARCH 1999 Page 4E-7
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Quicksilver Instrumentation Wiring Diagram SINGLE STATION INSTALLATION - TYPICAL a J b c f d h g i BLK BLU BRN GRY GRN ORN PNK PUR RED TAN WHT YEL LIT DRK = = = = = = = = = = = = = = e i BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK i 7 Index Page 4E-8 90-861329--1 MARCH 1999
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Refer to gauge manufacturer’s instructions for specific connections. NOTE: 1 Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection. NOTE: 2 Power for a Fused Accessory Panel May Be Taken from This Connection. Load Must Not Exceed 40 Amps. Panel Ground Wire Must Be Connected to Instrument Terminal That Has an 8-Gauge Black (Ground) Harness Wire Connected to it.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 DUAL STATION USING A NEUTRAL SAFETY SWITCH IN ONLY ONE REMOTE CONTROL SECONDARY STATION d c b e f g h i b a PRIMARY STATION l d e f g j g l b j k b 50730 a b c d e f g h i j k l - See Note 5 - See Note 4 - Start/Stop Panel - Water Temperature - Oil Pressure - Tachometer - Battery Meter - See Note 2 - See Note 3 - See Note 1 - Extension Harness To Engine - Fuse NOTE: 1 BROWN/WHITE wire is taped back at instrument end.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 DUAL STATION USING A NEUTRAL SAFETY SWITCH IN BOTH REMOTE CONTROLS SECONDARY STATION d c b e f g h i a PRIMARY STATION c d e f g j b l b j k b a b c d e f g h i j k - See Note 5 - See Note 4 - Start/Stop Panel - Water Temperature - Oil Pressure - Tachometer - Battery Meter - See Note 2 - See Note 3 - See Note 1 - Extension Harness To Engine NOTE: 1 BROWN/WHITE wire is taped back at instrument end.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Battery Meter Gauge a c b 72814 a - Lamp Mounting Hole b - PURPLE (or WHITE) Jumper Wire From This Terminal To “i” (Or +) Terminal On Water Temperature Or Oil Pressure Gauge c - BLACK Jumper Wire From This Terminal To Ground (–) Terminal On Water Temperature Or Oil Pressure Gauge Cruiselog a b 72815 a - Connect to Ignition Switch Activated 12 Volt Positive (+) Source (PURPLE Wire) b - Connect to Negative (–) Ground (BLACK Wire) Index Page 4E-12 90-861329--1
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Fuel Gauge and Sender a b PUR PNK BLK BLK PNK BLK c f e PNK BLK BLK d 72816 Either Guage Uses Either Sender a - Fuel Guage (Black Case) b - See Note 1 c - Tank Sender d - See Note 2 e - Fuel Tank f - Sender Capsule NOTE: 1 Connect to “I” (Ignition) Terminal Or Accessory Terminal Of Ignition Switch NOTE: 2 Connect to NEGATIVE (–) Battery Terminal Or Suitable Ground (–).
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Audio Warning System WARNING Buzzer is not external ignition-proof; therefore, DO NOT mount buzzer in engine or fuel tank compartments.
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 Oil Pressure Gauge a b c 72819 a - BLACK Ground (–) b - PURPLE Switched 12 Volt (+) Terminal c - LIGHT BLUE Sender Lead Clock a c a b 72818 a - Connect To A Terminal On An Adjacent Gauge Or To Another Suitable Ground (–) b - Connect to Instrument Harness RED/PURPLE Lead And Slide A Rubber Sleeve Over Connection c - Connect To An “I” Terminal Of An Adjacent Gauge Or To Any Switched 12 (+) Volt Terminal Index 90-861329--1 MARCH 1999 Page 4E-15
WIRING DIAGRAMS SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 4E-16 90-861329--1 MARCH 1999
FUEL PUMP SERVICE MANUAL NUMBER 26 FUEL SYSTEM Section 5A - Fuel Pump Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealants . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SERVICE MANUAL NUMBER 26 NOTICE For information and procedures on “Troubleshooting,” refer to SECTION 1C. Identification Carter Fuel Pump Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion.
FUEL PUMP SERVICE MANUAL NUMBER 26 Torque Specifications Description Fuel Inlet and Outlet Fittings lb-ft Nm Tighten finger tight then 1-3/4 to 2-1/4 additional turns with wrench. (See Note) Fuel Line to Fuel Outlet Fitting Fuel Pump to Block Securely 20 27 NOTE: Apply #592 Loctite Pipe Sealant with Teflon. Do not use Teflon Tape.
FUEL PUMP SERVICE MANUAL NUMBER 26 Precautions WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire or explosion. WARNING Be careful when changing fuel system components; gasoline is extremely flammable and highly explosive under certain conditions. Be sure that ignition key is OFF. DO NOT smoke or allow sources of spark or flame in the area while changing fuel filters. Wipe up any spilled fuel immediately.
FUEL PUMP SERVICE MANUAL NUMBER 26 Fuel Delivery System Recommendations WARNING Boating industry standards (BIA, ABYC, etc.) federal standards and Coast Guard regulations MUST BE adhered to when installing fuel delivery system. When designing and installing fuel delivery system, the following information MUST BE observed: 1. Fuel tank should be mounted below carburetor level, if possible.
FUEL PUMP SERVICE MANUAL NUMBER 26 Fuel System Components FUEL SYSTEM i g b c d h e 50830 f a Typical a - Fuel Tank b - Anti Siphon Valve c - Water Separating Fuel Filter, if equipped d - Fuel Pump e - Carburetor f - Fuel Filter g - Vent Hose h - Fuel Line i - Sight Tube Water Separating Fuel Filter The fuel filter, if equipped, consists of the fuel filter base and filter element.
FUEL PUMP SERVICE MANUAL NUMBER 26 Replacement NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. 1. Disconnect battery cables from battery. 2. Remove fuel filter from base. A filter wrench may be needed to loosen element. 3. Lubricate sealing ring(s) of new filter with SAE engine oil. 4. Install new filter, tightening securely by hand. 5. Reconnect battery cables. Make sure water is supplied to cooling system and start engine. Check for fuel leaks.
FUEL PUMP SERVICE MANUAL NUMBER 26 Water Separating Fuel Filter NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. Replacement INSPECTION Fuel pumps are equipped with a sight tube. Any evidence of fuel in the sight tube indicates a ruptured diaphragm and fuel pump must be replaced immediately. a b 50738 a - Sight Tube b - Fuel Fitting NOTE: This fuel pump must be replaced as an assembly; it is not repairable with a diaphragm kit. 1. Disconnect battery cables from battery.
FUEL PUMP SERVICE MANUAL NUMBER 26 Testing Fuel Pump NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. 1. Disconnect battery cables from battery. 2. Remove fuel line from carburetor or outlet side of fuel pump. 3. Install Fuel Pressure Connector (91-18078) to carburetor or fuel pump and reinstall fuel line. Tighten connector and fuel line securely. 4. Connect fuel pressure test gauge to connector.
FUEL PUMP SERVICE MANUAL NUMBER 26 Fuel Pump Replacement Removal 1. Remove fuel inlet and outlet lines at fuel pump. 2. Remove sight tube. a b 50738 a - Sight Tube b - Fuel Fitting 3. Remove 2 fuel pump mounting bolts and lock-washers, pump and gasket. CAUTION Plug fuel lines after disconnecting from fuel pump to eliminate any chance of fuel siphoning into bilge. 4. Coat both sides of new gasket with Perfect Seal. 5. Install new gasket on fuel pump. 6. Install pump. 7.
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FUEL PUMP SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 5A-12 90-861329--1 MARCH 1999
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 FUEL SYSTEM Section 5B - MERCARB 2 BARREL CARBURETOR Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Identification 33049565 2301 a b 72680 Carburetor Part Number Location a - Part Number b - Date Code Data Code Explanation: Example 2301 First Figure is Year: 2 = 1992, 3 = 1993, etc. Second Figure is Month: 2 = February, 3 = March, etc. X = October, Y = November, Z = December Third and Fourth Figures are Day of Month: 01 = First day, 02 = Second day, etc.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire or explosion hazard and should be avoided.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Specifications NOTICE Unit Of Measurement: U.S. Quarts (Liters) All capacities are approximate fluid measures. Carburetor Adjustment Specifications Engine Model Carburetor Type Carburetor Number 3.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 High Altitude Re-Jetting Engine flooding problems, at idle rpm, are generally related to the altitude (above sea level) at which they are operated. If engine is running too rich at higher elevation, order a smaller jet from the chart. A jet stamped “165” is a 1.65 mm jet. Model Carburetor Part Number 3.0L 3310-807504 5000 ft (1525 m) and Below 1.55 mm 5000-9000 ft (1525-2745 m) 1.55 mm 9000 ft (2745 m) and Above 1.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Needle/Seat Change If the preceding steps failed to correct the problem, change the needle/seat to the other type. MerCarbs are equipped with either the solid or the spring loaded needle.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Description This MerCarb carburetor is a two bore carburetor and has a separate fuel feed for each venturi. This model also is equipped with an electric choke. A removable venturi cluster (secured to float bowl assembly) has the calibrated main well tubes and pump jets built into it. The venturi cluster is serviced as a unit. The serviceable main metering jets are bleeds to properly meter the correct fuel/air mixture to the engine.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Maintenance Flame Arrestor with Carburetor Cover NOTICE Refer to “Precautions” in this section, BEFORE proceeding. 1. Remove in the following order: a. Nut. b. Sealing washer. c. Crankcase ventilation hoses from flame arrestor and rocker arm covers. d. Flame arrestor. 2. Clean and inspect: a. Clean flame arrestor in solvent and blow dry with compressed air. b. Clean crankcase ventilation hoses. c.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Fuel Inlet Filter NOTICE Refer to “Precautions” in this section, BEFORE proceeding. 1. Remove in the following order: a. Fuel line from fuel inlet filter nut. b. Fuel inlet filter nut and small gasket. c. Large gasket. d. Filter. e. Spring. f. Small gasket - from inside filter nut. b c d e f a 72406 a b c d e f - Fuel Line - Fuel Inlet Filter Nut - Gasket (Large) - Gasket (Small) - Filter - Spring 2.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Choke Inspection The choke does not require any periodic maintenance; however, if a choke malfunction is suspected, the following should be done: 1. With engine turned OFF, remove flame arrestor. 2. Open and close choke several times, and check for binding, loose or disconnected linkages, or other signs of damage. 3. If choke or linkage binds, sticks, or works sluggishly, clean with carburetor choke cleaner. Follow directions on can.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 2. With throttle valves completely closed, measure from flame arrestor mounting surface to top of pump rod. a 72682 a - See Specifications 3. Carefully bend pump rod (where shown) to obtain specified dimension.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Choke Setting Normal choke setting is such that scribed mark on cover is in line with long case mark on choke housing. a c b 72403 a - Scribed Mark b - More Choke c - Less Choke If choke adjustment is necessary: 1. Loosen three choke cover retaining screws and adjust as shown. 2. Tighten three choke cover retaining screws securely.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 2. Turn idle mixture needle in until lightly seated, then back needle out 1-1/4 turns. a 72281 a - Idle Mixture Needle Final Idle Speed and Mixture EMISSIONS CARBURETOR Sealed Carburetor Mixture Screw The carburetor on this engine has a seal on the carburetor mixture screw. This seal prevents adjustment of the fuel mixture setting. CAUTION Do not remove mixture screw seal and/or attempt to adjust fuel mixture setting.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 2. If new or rebuilt carburetor has been installed, turn idle mixture needle in (clockwise) until it lightly contacts seat, then back out needle 1-1/4 turns. This will provide a sufficient setting to allow starting engine. 3. Start engine and run at 1500 rpm until engine reaches normal operating temperature. WARNING DO NOT leave the helm unattended while performing idle speed and mixture adjustments, following.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Repair NOTICE Refer to “Precautions” in this section, BEFORE proceeding. Removal IMPORTANT: Carburetor malfunctions are, in many cases, caused by the presence of dirt, water or other foreign matter in carburetor. To aid in diagnosis, carefully remove carburetor from engine without draining fuel from bowl. Contents of fuel bowl may then be inspected for contamination as carburetor is disassembled. 1.
MERCARB 2 BARREL CARBURETOR 1 2 3 4 5 6 SERVICE MANUAL NUMBER 26 7 8 9 10 11 12 44 45 46 47 48 49 50 51 52 53 54 55 13 14 56 57 15 16 58 59 17 60 61 18 62 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Page 5B-16 35 36 37 38 39 40 41 42 43 72686 90-861329--1 MARCH 1999 INDEX
SERVICE MANUAL NUMBER 26 MERCARB 2 BARREL CARBURETOR Exploded View Parts List 1 - Rod - Accelerator Pump 2 - Accelerator Pump Shaft and Lever Assembly 3 - Washer (Outer) 4 - Washer (Inner) 5 - Screw 6 - Washer 7 - Screw 8 - Spring 9 - Filter 10 - Gasket 11 - Gasket 12 - Nut-Fuel Inlet 13 - Choke-Rod 14 - Gasket 15 - Clip - Retainer 16 - Washer 17 - Pump Shaft and Lever Assembly 18 - Accelerator Pump Assembly 19 - Spring 20 - Screw 21 - Inlet Needle and Seat (Spring Loaded - Optional) 22 - Baffle Plate 23
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Disassembly The following is a step-by-step procedure for completely overhauling carburetor removed from engine. In many cases, however, complete overhaul is not necessary and, in these cases, only the steps required to repair the carburetor malfunction should be performed. Read the instructions carefully to prevent doing any unnecessary steps.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 AIR HORN ASSEMBLY 1. Remove fuel inlet filter nut, washers, spring, and filter, as outlined previously. 2. Remove accelerator pump rod retaining clip. Pivot rod (as required) until retaining ear on rod and slot in pump shaft and lever assembly align, allowing rod to be pulled out. c a b 72283 a - Accelerator Pump Rod b - Retainer Clip c - Pump Shaft and Lever Assembly 3. Remove idle cam screw.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 4. Remove air horn attaching screws as shown. a a a a 72280 a - Air Horn Attaching Screws 5. Carefully lift air horn from float bowl assembly. a b 72400 a - Air Horn Assembly b - Float Bowl Assembly 6. Invert air horn and carefully lay on bench. 7. Remove float hinge pin and lift float assembly from air horn.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 8. Check float weight as shown. a b 72122 a - Grams Scale b - Float 9. Remove air horn gasket and baffle. b 72399 a a - Baffle b - Air Horn Gasket 10. Remove needle assembly.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 11. Remove needle seat. c a b 72289 a - Needle Seat b - Gasket c - Screwdriver a b 72290 Needle and Seat Assemblies a - Spring Loaded Type Needle (Kit 3302-9029) b - Solid Type Needle (Kit 3302-9407) 12. Loosen accelerator pump screw. Slide pump shaft and lever assembly (and washer) out of air horn, then remove accelerator pump assembly.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 13. Remove retainer clip and washer from pump shaft and lever assembly, then remove accelerator pump assembly. b c a 72409 a - Pump Assembly b - Retainer Clip c - Lever Assembly FLOAT BOWL ASSEMBLY 1. Remove accelerator pump return spring from pump well. a 72402 a - Accelerator Pump Spring 2. Remove power valve assembly and gasket.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 3. Remove main metering jets. a b b 72291 a - Main Metering Jets b - Gaskets (Not Shown) IMPORTANT: Use care when removing venturi cluster to prevent damaging brass tubes which protrude from bottom of cluster. DO NOT REMOVE TUBES. These tubes are permanently pressed into the venturi cluster and are not replaceable. 4. Remove three venturi cluster screws, and carefully lift cluster and venturi gasket straight up.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 Cleaning and Inspection IMPORTANT: DO NOT use a wire or drill to clean jet passages or tubes in carburetor, as this may enlarge orifices and seriously affect carburetor calibration. CAUTION To avoid damage to carburetor DO NOT leave carburetor in immersion type carburetor cleaner for more than two hours.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 c. Fuel and Air Passages: Passages must be perfectly clean for proper carburetor operation. d. Accelerator Pump Plunger and Return Spring: Inspect pump plunger cup, pump plunger spring (on pump assembly) and return spring. e. Power Piston Spring: Check power piston spring for weakness or distortion. f. Idle Mixture Needle: Inspect idle mixture needle. If damaged, needle must be replaced. g. Levers and Linkages: Check levers, links and rods for wear.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 2. Install new gasket on venturi cluster as shown. b a 72296 a - Venturi Cluster (I.D. No. 421) b - Gasket 3. Install venturi cluster in carburetor as shown. b a 72397 a - Venturi Cluster b - Gasket 4. Install flat washer and new fiber washer on center screw. Lockwashers and flat washers are used on outer screws. Tighten screws evenly and securely.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 5. Install main metering jets with gaskets as shown. Tighten securely. a b b 72291 a - Main Metering Jets b - Gaskets (Not Shown) 6. Install power valve with new gasket. Tighten securely. b a 72404 a - Power Valve b - Gasket (Not Shown) 7. Place accelerator pump spring in pump well.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 AIR HORN ASSEMBLY IMPORTANT: Accelerator pump assembly MUST BE installed correctly. If pump assembly is installed incorrectly, top of pump assembly will contact air horn casting. 1. If accelerator pump assembly was removed from pump lever, secure pump assembly to pump lever with washer and retainer clip, as shown. c b a 72409 a - Pump Assembly b - Retainer Clip c - Pump Lever 2.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 3. Install needle seat and gasket. Tighten securely. c a b 72289 a - Needle Seat b - Gasket c - Screwdriver IMPORTANT: Float needle and needle seat are factory matched and tested and should be replaced as a set only. 4. Place needle assembly in needle seat. a b 72287 a - Needle Assembly b - Needle Seat 5. Install baffle and gasket.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 6. Install float assembly and hinge pin. Pivot float assembly up and down on hinge pin to ensure it moves freely. b a 72297 a - Float Assembly b - Float Hinge Pin FLOAT LEVEL 1. Turn air horn upside down. Pivot float assembly up and down on hinge pin to ensure it moves freely. IMPORTANT: Before checking float level, raise float and allow it to fall; however, DO NOT force downward by hand. 2.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 3. Bend float arm up or down at point shown to obtain specified dimension. a 72688 a - Bend Float Arm at This Point 4. Visually check float alignment after adjustment. FLOAT DROP 1. Hold air horn right side up to allow float to hang free. 2. Measure float drop using Universal Carburetor Gauge (91-36392). Measure from gasket to toe of float. a 72689 a - Measurement - 1-3/32 in. (27 mm) 3.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 4. Recheck BOTH float level and float drop. 5. Carefully place air horn on float bowl, making sure accelerator pump is correctly positioned in fuel well. Lower air horn straight down to install. a b 72400 a - Air Horn Assembly b - Float Bowl Assembly 6. Install seven short and one long air horn attaching screws. Tighten screws evenly and securely. a a a 72280 a a - Air Horn Attaching Screws 7.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 8. Place idle cam on choke rod. a b 72392 a - Idle Cam b - Choke Rod 9. Secure idle cam (with choke rod installed on cam) on float bowl assembly, using screw. Check that cam is free to move without binding. c b a 72282 a - Screw b - Idle Cam c - Choke Rod 10. Place accelerator pump rod (end with ear) in hole in pump shaft and lever assembly.
MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 26 11. Insert remaining end of accelerator pump rod into hole in throttle lever and secure with retainer clip. a b c 72283 a - Accelerator Pump Rod b - Throttle Lever c - Retainer Clip CHOKE HOUSING ASSEMBLY 1. Install choke housing on air horn; tighten screws securely. Install choke lever; tighten screw securely. c b a 72401 a - Choke Housing b - Choke Housing Attaching Screws c - Choke Lever 2. Install choke cover.
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SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 COOLING SYSTEM Section 6A - Seawater Cooled Models Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealants/Adhesives . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing Cooling System . . . . . . . . . . . . . . .
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 NOTICE For information and procedures on “Troubleshooting,” refer to SECTION 1C. NOTICE For “Cold Weather Or Extended Storage” information and procedures, refer to SECTION 1B.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 Identification a b 72674 Brass Thermostat1 1Serial number break:0L340999 and below. 2Serial number break:0L341000 and above. 71801 Stainless Steel Thermostat2 Flushing Cooling System If engine is operated in salty, polluted or mineral laden waters, cooling system should be flushed periodically (preferably after each use) to reduce corrosion and prevent the accumulation of deposits in the system.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 Sterndrive Seawater Pickup Pump a b 72672 a - Flush Device b - Water Hose 1. Install flush device and connect water hose between it and water tap. 2. Saltwater areas and boat in the water: a. Raise sterndrive unit to full trailer position. b. Install flush device over water intake holes. c. Lower sterndrive unit to full down position. 3. Partially open water tap (approximately 1/2 maximum capacity) and allow cooling system to fill completely.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 Thermostat Removal 1. Drain water from cylinder block and exhaust manifold. 2. Disconnect hoses from thermostat cover. 3. Remove thermostat cover attaching bolts and lockwashers. 4. Remove thermostat from thermostat housing or cover. a b 73572 140° Thermostat Housing Shown a - Thermostat Cover b - Attaching Bolts Testing 1. Clean thermostat in soap and water to remove any deposits or debris. 2. Inspect for corrosion or other visible damage. 3.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 c. Place thermometer in container and position so that bottom of thermometer is even with bottom of thermostat. DO NOT allow thermometer to touch container. a b c 72675 a - Thermometer b - Nylon String c - Thermostat IMPORTANT: When performing Steps d through f, water must be thoroughly agitated to obtain accurate results. d. Plug in tester and observe temperature at which thermostat opens (thermostat drops off thread).
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 Installation 1. Clean gasket surfaces on thermostat cover and thermostat housing. 2. Place thermostat in thermostat housing with thermostatic element end toward housing. Be sure to position thermostat so that mounting flange fits into recess in thermostat housing. 3. Coat both sides of new thermostat housing gasket with Quicksilver Perfect Seal and position on thermostat cover and torque bolts to 30 lb-ft (41 Nm).
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exists. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 If your engine is equipped with this device, follow this procedure: 1. Detach the hoses from the top fittings. a 76243 a - Fittings 2. Lower hoses into bilge. If hoses have developed a “set,” T-handle retrieval tool can be used to push hoses below their connection point. a b 76244 a - Hoses b - Connection Points IMPORTANT: Hoses must be lowered below their connection point on the engine in order to drain completely. 3.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 STANDARD DRAINING PROCEDURES 1. Engine must be level or front of engine slightly higher to properly drain cooling system. 2. Remove drain plugs from cylinder block and manifold. a 71424 a - Drain Plug (Port and Starboard) 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. NOTE: It may be necessary to lift, bend, or lower hoses to allow water to drain completely when hoses are disconnected. 4.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 5. Insert a small wire (repeatedly) to make sure that vent holes and water drain holes and passages (as shown) are unobstructed and open. e b d f c a f c 70134 71216 a b c d e f - Speedometer Pitot Tube - Gear Housing Cavity Drain Hole - Trim Tab Cavity Vent Hole - Trim Tab Cavity Drain Passage - Gear Housing Water Drain Hole (One Each - Port and Starboard) - Gear Housing Cavity Vent Hole 6.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 8. For additional assurance against freezing and rust, remove the thermostat cover and thermostat. Fill the engine seawater cooling system with a mixture of antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage. Using a new gasket, reinstall thermostat and cover. Tighten cover bolts to 30 lb-ft (41 Nm).
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 3. Install fully-charged battery. Clean battery cable clamps and terminals and reconnect cables (see CAUTION listed above). Tighten each cable clamp securely when connecting. 4. Coat terminal connections with a battery terminal anti-corrosion agent. 5. Perform all maintenance tasks listed in the MAINTENANCE SCHEDULES, except those performed during the power package lay up procedure. 6.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 Auxiliary Hot Water Heater Installation When connecting a cabin heater or hot water heater to a MerCruiser engine, certain requirements must be met. • Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5/8 in. (15.8 mm) I.D. (inside diameter). • Make heater connections ONLY at locations described in the following instructions. • Check complete system for leaks after heater is connected into cooling system.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 3. Cut hose for return fitting as shown below. Cut approximately 3/4 in. (19 mm) out of hose to maintain proper hose configuration. a 73572 Typical a - Cut Hose at This Location 4. Install return fitting in hose and tighten hose clamps securely. a 73572 Typical a - Return Fitting 5. Connect hot water return hose to return fitting and tighten hose clamps securely. 6. Ensure that hoses do not rub or chafe against any engine components.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 Cooling System Flow Diagram MerCruiser engines with standard cooling systems use seawater (water in which the boat is being operated), to remove the heat given off by the engine. The seawater is pumped to the cooling system by means of an impeller type pickup pump (located in the vertical drive) which picks up seawater, and delivers it to the centrifugal pump (located over an opening on the front of the cylinder block).
SERVICE MANUAL NUMBER 26 a b c d e f g h i j k l m n o p q SEAWATER COOLED MODELS - Exhaust Elbow Assembly - Overboard (Water/Exhaust) Discharge - Intake And Exhaust Manifold (3.0LX) - Thermostat Housing And Cover Assembly - Engine Circulating Pump - Engine Block And Head Assembly (181 cid [3.
SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 26 THIS PAGE IS INTENTIONALLY BLANK Index Page 6A-18 90-861329--1 MARCH 1999
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 COOLING SYSTEM Section 6B - Closed Cooled Models Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . 6B-2 Lubricants/Sealants/Adhesives . . . . . . . . . . 6B-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Coolant Recovery Bottle . . . . . . . . . . . . . 6B-3 Pressure Cap Maintenance . . . . . . . . . . . . . 6B-4 Heat Exchanger Repair . .
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Torque Specifications Description lb-in. Drain Plugs lb-ft Nm Securely Heat Exchanger End Caps 190 22 Reservoir to Thermostat Housing 30 41 Thermostat Cover 20 27 Hose Clamps Heat Exchanger Mounting Brackets Securely Lubricants/Sealants/Adhesives Description Part Number Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3 Quicksilver Perfect Seal 92-34227--1 Specifications Cooling System Capacity 9 (8.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Coolant Recovery Bottle Before starting engine each day, ensure that coolant is visible in coolant recovery bottle. If coolant is not visible, check fresh water section of cooling system (including coolant recovery system) for leaks and repair, as necessary. Refill fresh water section with recommended coolant solution, as outlined under “Changing Coolant,” following.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Pressure Cap Maintenance Pressure cap is designed to maintain pressure in fresh water section of closed cooling system once the engine has attained normal operating temperature. This raises the boiling point of the coolant, thereby increasing the efficiency of the cooling system.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Heat Exchanger Repair IMPORTANT: Braze with BCUP 2 rod or silver solder. Care must be taken not to melt other joints during repair. 1. Internal leaks can be repaired by brazing shut the ends of the leaking tube. This is only a temporary fix because usually another tube will start leaking after a short period of time and this also causes a reduction in cooling capacity. Do not close more than three tubes. 2.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 5. Attach an automotive-type cooling system pressure tester to filler neck and pressurize closed cooling section to amount specified in following chart, based on pressure cap rating for your engine. Pressure Cap Rating 14 psi (97 kPa) Amount of Pressure Applied to Closed Cooling System 17 psi (117 kPa) 6. Observe gauge reading for approximately two minutes; pressure should not drop during this time.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 3. Put enough coolant into hose to fill the center 4 or 5 inches (10-13 cm) of the “U.” 4. Observe the “U” while the engine is running. a. During Idle and Warm-Up: Some coolant and/or air will leave the reservoir. b. During Cruising Speed (2500-3500 rpm): Coolant and/or air leaving the reservoir should stop after approximately five minutes running at a given rpm.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 3. Inspect gasket (if used) and rubber seal on cap for tears, cuts, cracks or other signs of deterioration. Replace gasket, if damaged, or entire cap if rubber seal is damaged. a c b 72714 a - Rubber Seal (Cap MUST BE Replaced if Damaged) b - Gasket (Look for Cracks under Gasket) c - Locking Tabs (1 Hidden) 4. Check that locking tabs on cap are not bent or damaged. 5.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Thermostat Removal 1. Drain coolant from cylinder block and exhaust manifold. 2. Disconnect hoses from thermostat cover attaching bolts and lock-washers, then remove cover and gasket. 3. Remove thermostat from thermostat housing. a b c 73575 a - Bolts b - Reservoir c - Thermostat Housing Testing 1. Clean thermostat in soap and water to remove any deposits or debris. 2. Inspect thermostat for corrosion or other visible damage. 3.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 4. Check opening and closing temperature of thermostat (using a tester similar to the one shown), as follows: a. Fill tester to within 1 in. (25 mm) of top with tap water. Do not use distilled water. b. Open thermostat valve and insert thread. Position thermostat on nylon string so that it will be just below water level when suspended, then allow valve to close. Suspend thermostat in water. b a c 72675 a - Thermometer b - Nylon String c - Thermostat c.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 CAUTION Avoid seawater pickup pump impeller damage. DO NOT operate engine without cooling water being supplied to seawater pickup pump. 5. With boat in the water and/or cooling water properly supplied to seawater pickup pump, start engine and inspect for leaks. Changing Coolant NOTICE For information and procedures on “Draining The Seawater Cooling System,” and “Cold Weather Or Extended Storage,” refer to SECTION 1B.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. The following draining instructions apply to all engines equipped with closed cooling. The location of petcocks that require opening and hoses that require removal are represented on the following pages for the individual engines. IMPORTANT: Observe precautions previously outlined before proceeding. 1. Remove pressure cap from coolant tank. 2.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 If your engine is equipped with this device, follow this procedure: 1. Detach the hoses from the top fittings. a 76243 a - Fittings 2. Lower hoses into bilge. If hoses have developed a “set,” T-handle retrieval tool can be used to push hoses below their connection point. a b 76244 a - Hoses b - Connection Points IMPORTANT: Hoses must be lowered below their connection point on the engine in order to drain completely. 3.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Draining Diagram b b b a b a 73665 a - Remove and Lower Hoses To Drain b - Remove Drain Plugs Repeatedly Clean Out Holes Using A Stiff Piece Of Wire, Until Entire System Is Drained.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Cleaning System Closed Cooling Section Closed cooling section of the cooling system should be cleaned at least once every two years or whenever decreased cooling efficiency is experienced. A good grade automotive cooling system cleaning solution may be used to remove rust, scale or other foreign material. Always follow manufacturer’s instructions for the cleaner.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 2. Remove bolts which secure end plate to each end of heat exchanger, then remove end plates, seal washers and gaskets. Discard seal washers and gaskets. Clean gasket material from end plate and heat exchanger. d c b a 71515 e a b c d e b 73581 - Bolt - End Cap - Sealing Washer - Gasket - Drain Plug 3. Clean water passages in heat exchanger by inserting a suitable size wire brush into each passage.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Flushing Seawater Section of Closed Cooling System If engine is operated in salty, polluted or mineral-laden waters, seawater section of closed cooling system should be flushed periodically (preferably after each use) with fresh water to reduce corrosion and prevent the accumulation of deposits in the system. Seawater section also should be thoroughly flushed prior to storage.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 CAUTION If cooling system is to be flushed with boat in the water, seacock (if so equipped) must be closed, or water inlet hose must be disconnected and plugged to prevent water from flowing into boat. c. Close seacock (if so equipped) or disconnect and plug seawater inlet hose. 2. Partially open water tap (approximately 1/2 maximum capacity) and allow drive unit and cooling system to fill completely. Do not use full tap water pressure.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 Draining Seawater Section of Closed Cooling System NOTICE For “Cold Weather Or Extended Storage” information and procedures, refer to SECTION 1B. NOTE: It may be necessary to lift, bend, or lower hoses to allow water to drain completely when hoses are disconnected.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 6. After seawater section of cooling system has been drained completely, coat threads of drain plugs with Quicksilver Perfect Seal and reinstall. Tighten drain plugs securely. Reconnect hoses and tighten all hose clamps securely. If NOT equipped with seacock: seawater inlet hose must remain disconnected and plugged until engine is to be restarted. 7.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 5. Perform all maintenance tasks listed in the MAINTENANCE SCHEDULES, except those performed during the power package lay up procedure. 6. Perform all checks in the BEFORE STARTING column of the Operation and Maintenance Manual OPERATION CHART. CAUTION Refer to FLUSHING COOLING SYSTEM before starting engine. 7. Supply water to the seawater pickup pump as outlined in “Flushing Cooling System.” 8.
CLOSED COOLED MODELS SERVICE MANUAL NUMBER 26 4. After engine has reached normal operating temperature (thermostat is fully open), and coolant level remains constant, fill heat exchanger to bottom of filler neck. 5. Observe engine temperature gauge to make sure that engine operating temperature is normal. If gauge indicates excessive temperature, stop engine immediately and examine for cause. 6. Install pressure cap on heat exchanger. 7.
MANIFOLD SERVICE MANUAL NUMBER 26 EXHAUST SYSTEM Section 7A - Manifold Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants/Sealants/Adhesives . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . Through Drive Unit Exhaust . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . 7A-2 7A-2 7A-2 7A-2 7A-3 7A-3 Installation . . . . . . . . . . . . . . . . . . .
MANIFOLD SERVICE MANUAL NUMBER 26 Torque Specifications Fastener Location lb-ft Hose Clamps Nm Securely Exhaust Elbow 20-25 27-34 Exhaust Pipe to Gimbal Housing 20-25 27-34 Lubricants/Sealants/Adhesives Description Part Number Quicksilver Loctite 27131 92-809820 Quicksilver Perfect Seal 92-34227--1 Exhaust System Through Drive Unit Exhaust CAUTION It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install the exhaust system.
MANIFOLD SERVICE MANUAL NUMBER 26 Removal 1. Disconnect battery cables from battery. 2. Drain water from cylinder block, exhaust manifold and exhaust elbow. 3. Disconnect throttle cable at carburetor. 4. Disconnect exhaust hose and cooling hoses. 5. Disconnect fuel line at carburetor. WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Be sure electrical source to engine is disconnected.
MANIFOLD SERVICE MANUAL NUMBER 26 Installation If exhaust manifold body requires replacement, transfer all parts (from old manifold) to new manifold body. 1. Position new gasket on head and install manifold in position, making sure gasket is in place. 2. Tighten fasteners evenly and torque to 23 lb-ft (33 Nm), starting in center and working out toward ends. IMPORTANT: After engine has been brought up to operating temperature, allow engine to cool. Retorque manifold fasteners. 3.
MANIFOLD SERVICE MANUAL NUMBER 26 Upper Exhaust Pipe and Shutter Replacement IMPORTANT: Engine does not have to be removed, however, exhaust elbow may have to be removed. 1. Loosen exhaust bellows clamps. 2. Remove hose clamps. 3. Remove intermediate exhaust pipe. 4. Remove exhaust tube. a c a b 75819 a - Clamps b - Lower Exhaust Tube c - Intermediate Exhaust Pipe 5. Replace shutter (in lower pipe), as shown. a. Slide hose on lower pipe. Tighten clamps securely. b.
MANIFOLD SERVICE MANUAL NUMBER 26 Lower Exhaust Pipe Replacement 1. Remove sterndrive unit. 2. Remove engine, then upper exhaust pipe. 3. Remove screws and lockwashers that secure lower exhaust pipe to gimbal housing. a b 50634 a - Exhaust Pipe b - Screws (4) - 2 Under Exhaust Pipe 4. Remove exhaust pipe and O-ring. 5. Clean mating surfaces on pipe and gimbal housing. 6. Place O-ring in groove of gimbal housing. a b 72736 a - Mating Surfaces b - O-ring 7.
MANIFOLD SERVICE MANUAL NUMBER 26 Emissions Testing Installing Test Probes IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine. The test probes should be installed as follows: 1. Remove plug from exhaust elbow. 74645 2. Install exhaust elbow adapter fitting into elbow. Apply Loctite Pipe Sealant with Teflon to threads that go into elbow. Tighten it securely. 3. Insert exhaust probe into fitting and tighten securely.
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POWER STEERING PUMP SERVICE MANUAL NUMBER 26 POWER STEERING Section 8A - Power Steering Pump Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealants/Adhesives . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Power Steering Pump Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 Torque Specifications Fastener Location Pump Mounting Bracket to Engine lb-ft lb-in. 30 Nm 41 Circulating Pump Pulley 240 27 Tools Description Part Number Pulley Installer 91-93656A1 Special Tools Kent-Moore Special Tools Description Part Number Kent-Moore Tools, Inc.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 Checking Power Steering Pump Fluid Level IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid, or automatic transmission fluid (ATF), Dexron II, in power steering system. With Cold Engine 1. Stop engine and position drive unit so that it is straight back. 2. Remove fill cap/dipstick from power steering pump and note fluid level. a b 75809 a - Fill Cap b - Power Steering Pump 3. Level should be between “FULL COLD” mark and bottom of dipstick.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 With Warm Engine 1. Stop engine and position drive unit so that it is straight back. 2. Remove fill cap/dipstick from power steering pump and note fluid level. 3. Level should be between the “FULL HOT” mark and “ADD” mark on the dipstick. a 72518 a - Proper Fluid Level With Engine Warm 4. If level is low (below “ADD” mark), but still visible in pump reservoir, add fluid through fill cap opening to bring level up to “FULL HOT” mark on dipstick.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 Pump Drive Belt Tension Adjustment NOTICE Refer to “Precautions” in this section, BEFORE proceeding. IMPORTANT: DO NOT pry in pump body. 1. Install drive belt on pulleys and adjust tension as follows: a. Pivot pump attain tension. b. Tighten retaining bolts. 2. Check belt tension using either of two methods, following and readjust pump, if necessary, to obtain proper belt tension. a.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 Pump Pulley Replacement REMOVAL IMPORTANT: Kent-Moore Tool J-25034 must be used to remove the pressed-on pulleys used on power steering pumps. This tool has an end on it that will not mushroom the end of the pump shaft. DO NOT use Kent-Moore Tool J-21239 to remove these pulleys. This tool has a tapered end and will damage the shaft. 1. Install Kent-Moore Tool J-25034 on end of pulley and shaft as shown. 2.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 Power Steering Pump And Cooler Replacement NOTICE Refer to “Precautions” in this section BEFORE proceeding. 1. Install pulley. 74562 2. Install bolts and torque to 20 lb-ft (27 Nm).
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 3. Install 40 inch (1016 mm) drive belt. a 74564 a - 40 inch (1016 mm) Drive Belt 4. Install 37 inch (940 mm) drive belt over circulating pump pulley.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 5. Install front mount assembly with power steering pump assembly. Tighten bolts securely. b a 74558 a - 2-3/4 inch (70 mm) Bolts, Washers and Lockwashers b - Bolts, Washers and Lockwashers 6. Attach power steering pump bracket to engine. Torque bolt to 30 lb-ft (41 Nm). a 74559 a - 1-1/4 inch (32 mm) Long Bolt Without Closed Cooling. 1-1/2 inch (38 mm) Long Bolt With Closed Cooling. 7. Attach power steering pump brace to pump.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 8. Install 37 inch (940 mm) drive belt over pump pulley. 74561 a a - 37 inch (940 mm) Drive Belt 9. Adjust drive belt tension. 10. Route hydraulic hoses as shown. 11. Install fluid cooler and tighten hose clamp-screw securely. a 75812 a - Clamp 12. Install long water hose and tighten hose clamps securely. 13. Install water hoses to power steering fluid cooler and tighten clamps securely.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 INSTALLATION 1. Using hose clamp, install new hose on back of pump. Tighten clamp securely. a b 72848 a - Hose Clamp b - Hose 2. Using hose clamp, install hose on fluid cooler. Tighten clamp securely. a b c 73579 a - Fluid Cooler b - Hose Clamp c - Hose 3. Fill and air bleed system. Refer to Section 1B “Maintenance” (see “Table of Contents”).
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 Low Pressure Hose (Control Valve-to-Cooler) REMOVAL NOTE: Catch fluid that drains from hose, cooler and pump in a suitable container. 1. Loosen hose clamp and remove hose from fluid cooler. a b c 73579 a - Fluid Cooler b - Hose Clamp c - Hose 2. Remove large fitting from control valve at transom. Remove hose.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 INSTALLATION CAUTION Route hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hoses. IMPORTANT: Be careful to not cross-thread or overtighten hose fittings. 1. Thread large fitting into control valve. Position hose properly (as prior to removal). 2. Torque fittings to 23 lb-ft (31 Nm). 73786 3. Route hose along flywheel housing and secure with J-clamp(s) provided. 4.
POWER STEERING PUMP SERVICE MANUAL NUMBER 26 System Flow Diagram 3 a b 2 c c d 5 e f 4 1 f d e g 4 h i 1 2 3 4 5 a b c d e f g h i 5 72995 - Reservoir Bottle and Bracket - Priority Valve and Mounting Bracket - Power Steering Control Valve - Power Steering Pump - Power Steering Fluid Cooler - Pressure Hose (Fitting on Both Ends - Supplied in Kit) - Return Hose (Fitting on One End - Supplied in Kit) - Return Hose from Pump (Cut from Bulk Hose Supplied) - Pressure Hose from Pump - Return Hose f
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