MERCRUISER

Mercury MERCRUISER Service Manual

Mercury MERCRUISER

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Wire Color Code Abbreviations

Wire Color Abbreviations

BLK Black

BLU Blue

BRN Brown GRY or GRA Gray

GRN Green ORN or ORG Orange

PNK Pink PPL or PUR Purple

RED Red TAN Tan

WHT White YEL Yellow

LT or LIT Light DK or DRK Dark

Electrical Components

Page 4E-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015

Table of Contents

Important Information, Maintenance, and 17
- Table of Contents7
- Serial Number Decal Placement8
- Introduction8
- Engine Serial Number8
- Directional References9
- Seacore9
- Seacore Components and Castings9
- Stainless Steel Fasteners9
- Proper Break9
- 20-Hour Break-In Period9
- Gasoline Containing Alcohol10
- Using Reformulated (Oxygenated) Gasoline (USA Only)10
- Fuel Ratings10
- After the Break-In Period10
- Fuel Requirements10
- Engine Oil11
Important Information, Maintenance, and 117
- 6.2 MPI ECT and 6.2 MPI Non-ECT19
- Engine19
- Engine and Tune-Up Specifications19
- Fluid Specifications19
- Notes on Engine Specifications19
- Maintenance Intervals20
- Maintenance Schedule-Inboard Models20
- Power-Assisted Steering and Power Trim Fluids20
- Routine Maintenance20
- Scheduled Maintenance20
- Maintenance Schedule-Towsport Models21
- Routine Maintenance21
- Scheduled Maintenance21
- Maintenance Schedule-Sterndrive Models22
- Routine Maintenance22
- Scheduled Maintenance23
- Checking and Filling the Engine Oil24
- Engine Oil24
- Changing the Engine Oil and Filter25
- Transmission Fluid27
- Changing29
- Checking29
- Filling29
- Power Trim Fluid29
- Flame Arrestor30
- Serpentine Drive Belt31
- Inspection and Routing32
- Replacing Belt32
- Fuel System33
- Water-Separating Fuel Filter33
- Changing Coolant35
- Checking Coolant Level35
- Cleaning and Inspection35
- Closed-Cooling System35
- Power-Assisted Steering Fluid35
- Power-Assisted Steering Fluid-Sterndrive Only35
- Changing37
- Compact Hydraulic Steering37
- Bravo Sterndrive Gear Lube38
- Checking38
- Filling38
- System Check38
- Changing39
- Battery40
- Electrical System40
- Exhaust System40
- Instruments40
- Remote Control40
- Visual Inspections40
- Seawater Pump41
- Steering System Lubrication41
- Corrosion Prevention42
- Maintaining Ground Circuit Continuity42
- Mercathode44
- Power Package Exterior Surfaces44
- Cleaning the Seawater Strainer, if Equipped45
- Seawater System45
- Air Actuated Single-Point Drain System (Closed Cooling, Inboard Models)46
- Checking the Seawater Pickups46
- Draining the Raw Water46
- Draining the Seawater System46
- Air Actuated Single-Point Drain System (Standard Cooling)49
- Air Actuated Single-Point Drain System-Bravo Seawater Cooling52
- Draining the Sterndrive54
- Air Actuated Single-Point Drain System (Closed Cooling)55
- Draining the Raw Water55
- Draining the Seawater System55
- Air Actuated Single-Point Drain System (Closed Cooling, Inboard Models)58
- Flushing the Power Package61
- Flushing the Power Package (Bravo)61
- Seacore Power Package Flushing Procedure64
- Cold Weather or Extended Storage67
- Preparing Power Package for Storage-MPI Models67
- Power Package Recommissioning68
Important Information, Maintenance, and 171
- Before You Begin Troubleshooting72
- General Troubleshooting Guidelines72
- Introduction72
- Situational Awareness72
- Visual/Physical Check73
- Diagnostic Roadmap74
- Emission Control Fault Indicators74
- Chart R1: Engine System Fails to Power75
- Chart R2: OBD-M Lamp Does Not Self-Test76
- Chart R3: Crankshaft Fails to Rotate77
- Chart R4: Engine Cranks over but will Not Start78
- Chart R5: Hard Start79
- Chart R6: Engine Stalls80
- Chart S1: Engine Surges81
- Chart S2: Lack of Power, Sluggish, or Spongy81
- Diagnosis by Symptom81
- Chart S3: Detonation or Spark Knock82
- Chart S4: Hesitation, Sag, or Stumble84
- Chart S5: Engine Misses85
- Chart S6: Rough, Unstable, or Incorrect Idle and Stalling86
- Chart S7: Poor Fuel Economy86
- Chart S8: Dieseling or Run87
- Chart S9: Backfire88
- Chart T1: Main Power Relay Test89
- Troubleshooting Tests89
- Chart T2: Fuel System Electrical Test90
- Chart T3: Fuel System Diagnosis90
- Chart T4: Ignition System Test91
- CDS G3 Service Tool92
- Connecting and Starting G392
- Default Sensor Values92
- Fault Conditions92
- Introduction92
- OBD-M Faults92
- PCM 112 Calibration Information92
- Sticky and Nonsticky Faults92
- Troubleshooting Shift Problems92
- CDS G3 Service Tool Home Screen Overview94
- CDS G3 Fault List95
Removal and Installation 297
- Disconnecting the Fluid Systems98
- Fuel Hose98
- Preparation98
- Steering Hoses (Sterndrive)98
- Gear Lube Monitor (Sterndrive)99
- Seawater Hoses99
- Disconnecting the Shift Cable and Throttle Cable100
- Disconnecting the Electrical Components101
- Continuity Wire Removal (Sterndrive)102
- Removing the Engine102
Removal and Installation 2105
- Preparation107
- Torque Specifications107
- Engine Installation and Alignment (Sterndrive)108
- Shift Cable Routing108
- Bravo Seawater Inlet Fitting Connection113
- Connecting the Fluid Systems113
- Gear Lube Monitor Connection113
- Power-Assisted Steering Hoses116
- Speedometer and Pitot Connections116
- Bravo Models Remote Control Shift Cable Adjustment117
- Bravo Models Shift Cable Installation117
- Bravo Shift Cable Installation and Adjustment117
- Throttle Cable Installation119
- Connecting the Electrical Components120
- Electrical Connections120
- Engine Harness Connections120
- Continuity Wire Connection121
- Quick-Connect Mercathode System Connection121
- Battery Connection123
- Installing the Sterndrive Unit123
- Trim Position Sender Connections123
- Troubleshooting Shift Problems123
- Wire Color Code Abbreviations123
- Power Trim System124
- Boat Harness Connector to Engine125
- Boat Harness Installation Guidelines-MPI Sterndrive125
- Key Switch Connector125
- Trim Switch126
- Accessory Relay Connection127
- Additional Relay Kit127
- Lanyard Stop Switch127
- Neutral Safety Switch127
- Optional E-Stop127
- Warning Horn127
- CAN P (CAN 1) Connections128
- General Repower Information128
- Transom Ground Connection129
- Transom Harness-Dts/Mechanical Shift129
- Bravo Sterndrive Shift Check (Engine Running)130
- Engine Installation and Initial Engine Alignment-Towsport, Inboard131
- Engine Mount Preadjustment131
- Models with 8 Degree Down-Angle Transmissions134
- Models with V-Drive Transmissions134
- Final Engine Alignment-Towsport, Inboard135
- Exhaust System Guidelines-Towsport137
- Exhaust System Guidelines-Inboard Models138
- Exhaust Hose Connections-Inboard139
- General Information140
- Measuring Exhaust Elbow Height-Towsport140
- Boat Requirements141
- Loading Requirements142
- Loading the Boat (Boats with a Capacity Plate)142
- Loading the Boat (Boats Without a Capacity Plate)144
- Clear Hose Measurement Method146
- Audio Warning Temperature Switch Installation-Inboard147
- Electrical Connections-Towsport, Inboard147
- Boat Harness and Instrumentation Connections-Inboard148
- Audio Warning System Connections-Towsport, Inboard149
- Smartcraft Product149
- Service Engine Light and OBD-M MIL Kit150
- Testing the OBD-M Malfunction Indicator Lamp (MIL)150
- Battery Cables Connection151
- Propeller Selection151
- Shaft Log Seal Connection151
- 6.2L Maximum RPM Specification152
- Adaptive Speed Control (ASC) Propping with G3152
- Boat-In-The-Water Tests152
- Engine Idle Speed152
- Wide-Open Throttle Propping Without G3 Test154
- Checking Shift Operation155
Engine Mechanical 3157
- Engine Block Codes158
- Identification158
- Kent-Moore159
- Tools159
- Precautions160
- External Engine Components161
- Torque Specifications161
- Crankcase Oil Dipstick Measurements162
- Engine Rotation162
- General Information162
- Repair Guidelines162
- Front Mounts163
- Rear Mounts163
- Sterndrive Engine Mounts163
- Cylinder Head and Rocker Cover Components164
- Engine Components164
- Timing Chain and Front Cover Components166
- Crankshaft and Camshaft168
- Piston and Connecting Rod170
- Intake Manifold and Fuel Rail (MPI)172
- Oil Pan and Oil Pump174
- Remote Oil Filter176
- Removal178
- Rocker Arm Cover178
- Rocker Arms and Valve Pushrods178
- Finding Top Dead Center (TDC)179
- Method 1179
- Method 2179
- Intake Manifold Assembly180
- Removal180
- Exploded View181
- Hydraulic Valve Lifters181
- Removal181
- Special Information181
- Oil Pump Drive182
- Removal182
- Flywheel and Housing183
- Flywheel Housing Removal183
- Flywheel Removal183
- Oil Pan184
- Removal184
- Front Engine Cover185
- Removal185
- Removal187
- Timing Chain and Sprockets187
- Camshaft188
- Removal188
- Cylinder Head189
- Removal189
- Valve Spring Assembly Exploded View190
- Valve Spring Assembly Removal191
- Connecting Rod, Bearings, and Piston Assembly192
- Exploded View192
- Removal192
- Disassembly193
- Rear Oil Seal194
- Removal194
- Disassembly195
- Oil Pump195
- Removal195
- Crankshaft, Main Bearings, and Engine Block196
- Exploded View196
- Removal196
- Engine Block198
Engine Mechanical 3203
- General Specifications204
- Cylinder Bore205
- Engine Specifications205
- Oil Pump205
- Piston Bore Clearance205
- Piston Rings205
- Connecting Rod206
- Crankshaft206
- Piston Pin206
- Valve206
- Camshaft208
- Clean and Inspect208
- Flywheel208
- Timing Chain208
- Cylinder Reconditioning209
- Cylinder Boring210
- Cylinder Honing210
- Piston Selection210
- Camshaft Bearings211
- Engine Block Plugs214
- Cleaning216
- Crankshaft and Pistons216
- Main Bearing Inspection217
- Crankshaft Installation219
- Main Bearing Clearance, Plastigauge Method222
- Crankshaft End Play223
- Piston Inspection224
- Preliminary Inspection224
- Assembly226
- Piston Ring Gap Inspection226
- Piston and Rod Installation227
- Piston/Connecting Rod Assembly227
- Connecting Rod Bearing Clearance, Micrometer Method231
- Connecting Rod Bearing Clearance, Plastigauge Method232
- Inspection234
- Installation234
- Oil Pump234
- Camshaft235
- Inspection235
- Installation236
- Assembly237
- Inspection237
- Timing Chain237
- Checking Timing Chain Deflection238
- Crankcase Front Cover239
- Installation239
- Rear Seal Installation240
- Inspection241
- Oil Pan241
- Installation242
- Core Plug Installation245
- Cylinder Head245
- Inspection246
- Repair249
- Cylinder Head Reassembly251
- Installation253
- Inspection256
- Lifters256
- Inspection257
- Installation257
- Lifter Installation257
- Oil Pump Drive257
- Inspection258
- Rocker Arms and Pushrods258
- Installation259
- Installation261
- Intake Manifold261
- Intake Manifold Assembly261
- Cleaning and Inspection264
- Flywheel264
- Installation264
- Rocker Arm Cover264
- Cleaning267
- Flywheel Housing267
- Inspection267
- Installation267
- Oil Lines268
- Crankcase Front Cover Oil Seal (Without Removing Front Cover)269
- Installation269
- Removal269
- Installation270
- Main Bearings, Without Crankshaft Removed270
- Valve Spring Assembly Exploded View271
- Valve Spring Assembly Removal271
- Valves and Seals (Without Removing Head)271
Engine Mechanical 3273
- Troubleshooting with a Vacuum Gauge274
- Vacuum Gauge Troubleshooting Guide274
- Measuring Vacuum275
- Mechanical Engine Noise275
- Normal Condition276
- Used Spark Plug Analysis276
- Chipped Insulator277
- Cold Fouling277
- Wet Fouling (Oil Deposits)277
- High Speed Glazing278
- Overheating278
- Scavenger Deposits278
- Preignition Damage279
- Reversed Coil Polarity279
- Splashed Deposits279
- Mechanical Damage280
- Piston Inspection280
- Starter Motor will Not Crank Engine, or Cranks Slowly281
- Engine Overheat282
- Engine Runs Rough, Misses, or Backfires282
- Engine will Not Start or Is Hard to Start282
- Poor Performance282
- Important Information283
- Low Engine Oil Pressure283
- Low Engine Temperature283
- Water in the Engine283
- Compression Gauge Testing284
- Leak-Down Testing284
Electrical System295
- Precautions296
- Starter Specifications297
- Wire Color Code Abbreviations297
- Starter Motor Exploded View298
- Starter Motor Circuit300
- Starter Solenoid Circuit300
- Starting System Electrical Diagrams300
- Battery Cables for Mercruiser Models301
- Starter Relay301
- Starting Circuit Overload Protection301
- Hot Stud302
- Inspection302
- Starter302
- Starter Removal303
- Starter Solenoid303
- Water and Corrosion Inspection303
- Starter Installation304
- Low Voltage Tests305
- Starting System Tests305
- Voltage Drop Test306
Electrical System307
- Precautions308
- Ignition Components309
- Waste Spark System Specifications309
- Inspection310
- Installation310
- Removal310
- Spark Plug Removal, Inspection, and Installation310
- Spark Plug Wires310
- Wire Color Code Abbreviations310
- Ignition Coil311
- Ignition Coil Voltage Test311
- Ignition Coil Resistance Test312
- Removal312
- Installation313
Electrical System315
- Precautions316
- Specifications316
- Alternator and Brackets Exploded View318
- Alternator Removal320
- Periodic Maintenance320
- Alternator Installation321
- Serpentine Drive Belt321
- Sterndrive Models322
- Replacing323
- Before You Begin324
- Charging Output Tests324
- Troubleshooting324
- Voltage Drop Test (Alternator Circuit)325
- Sensing and Excitation Circuits326
- Battery will Not Recharge327
- Battery Isolator Diagrams328
Electrical System331
- General Information332
- Precautions332
- Analog Gauges333
- Cleaning the Gauges333
- Configuring the PCM Tachometer Signal (Non-DTS)333
- Gauge Lighting Options333
- Installation333
- Removal333
- Analog Gauge Testing334
- Oil Pressure, Fuel Level, and Coolant Temperature Gauges334
- Battery or Voltage Gauge335
- Cruiselog (Engine Hour Meter)335
- Smartcraft Instrumentation336
- Speedometer336
- Tachometer336
- Boat Harnesses and Installation Connections337
- Boat Wiring337
- CAN Bus Overview337
- Engine Harness and Accessory Power Supply337
- Termination Resistors337
- Boat Harness Installation Guidelines-MPI Sterndrive338
- Service Engine Light and OBD-M MIL Kit344
- System Link Gauge Connections344
- System Link Gauge Extension Harness Installation344
- System Link Gauges344
- Warning System344
- Audio Warning System345
- Guardian Strategy346
- Transom Harness-MPI346
- Wiring Diagrams346
- Helm Mechanical350
- Analog Gauge Harness352
- Mercruiser Remote Control Only to the Harness Assembly (Control Harness Assembly)353
- Power Trim System with a Mercruiser Remote Control354
- Power Trim System with an Outboard Remote Control355
- 14-Pin Engine Harness Connector356
- Axius Helm Installation (if Equipped)356
- Configuring the PCM Using the CDS356
- DTS Information and Installation356
- Installation Guidelines for DTS System Components356
- Special Tools - DTS Installation356
- DTS Battery Specifications357
- Weather Caps357
- Junction Box (if Equipped)358
Electrical System359
- Engine Control and Sensor Locations360
- Front View360
- Rear View361
- Port Side View362
- PCM 112 Controller363
- PCM Removal and Installation363
- Propulsion Control Module (PCM)363
- 50-Amp Main Circuit Breaker365
- Electrical System Overload Protection365
- Fuses366
- Transom Harness368
- Transom Harness Wiring Diagram (Sterndrive)368
- Wire Color Code Abbreviations370
Fuel System371
- Precautions372
- Fuel Pressure Specifications373
- Fuel Ratings373
- Fuel Requirements373
- Using Reformulated (Oxygenated) Gasoline (USA Only)373
- Alternate Priming Procedure for Fuel System374
- Fabricating a Pressure-Relief Collection Tool374
- Gasoline Containing Alcohol374
- Priming the Fuel System374
- Priming the Fuel System376
- Important Information377
- Low Permeation Fuel Lines377
- Exploded Views378
- Fuel Rail Exploded View378
- Fuel Supply Connections378
- Fuel System Module379
- Throttle Body379
- Anti-Siphon Valve380
- FSM Removal380
- Fuel Delivery System380
- Fuel Supply Module (FSM)380
- Fuel System380
- FSM Disassembly381
- FSM Assembly385
- Throttle Body392
- Throttle Body Cleaning and Inspection392
- Throttle Body Removal392
- Fuel Rail393
- Removal393
- Throttle Body Installation393
- Installation397
- Fuel Injector Wiring Diagram399
- Fuel Rail Pressure Damper399
- Wire Color Code Abbreviations399
- Fuel Pressure Gauge Setup and Use400
- Troubleshooting400
- Checking for Restrictions/Vapor Lock Problems in Fuel Delivery Systems401
- Equipment Used to Test Fuel RVP, Fuel Temperature, or Fuel System Vacuum402
Cooling System405
- General Cooling System Information406
- Seawater Inlet Hose406
- Seawater Inlet Specifications406
- Seawater Pump Output Test407
- Water Heater Installation407
- Return Hose Connection408
- Supply Hose Connection408
- Seawater Pump (if Equipped)409
- Seawater Pump Replacement409
- Seawater Pump-Exploded View409
- Seawater Pump Disassembly410
- Cleaning and Inspection411
- Seawater Pump Assembly411
- Removal413
- Water Circulating Pump413
- Cleaning and Inspection414
- Installation414
- Air Manifold and Air Pump-Exploded View415
- Air-Actuated Drain System415
- General Information415
- Testing415
- Air Manifold416
- Drain Check Valve416
- General Information416
- Exploded View417
- Inspection and Cleaning417
- Poppet Valve418
- Poppet Valve Assembly-Exploded View418
- Poppet Valve Operation418
- Poppet Valve Replacement419
- Cleaning and Inspection420
- Removal420
- Water Distribution Housing420
- Water Distribution Housing Installation420
Cooling System429
- Specifications430
- Heat Exchanger Assembly-Exploded View431
- Bravo Models with Closed Cooling432
- Crossover for Closed Cooling-Exploded View432
- Description432
- Meeting the Minimum Seawater Flow Specifications432
- Installing the Y-Fitting433
- Installing the Seawater Supply Hose434
- Through-The-Hull Seawater Pickup System434
- Seawater Pickup435
- Seawater Strainer435
- Seacock436
- Seawater Strainer437
- Seawater Strainer Installation437
- Seawater Strainer Mounting Requirements437
- Cleaning the Seawater Strainer, if Equipped438
- Coolant438
- Coolant Recommendations438
- Maintaining Coolant Level439
- Pressure Cap Maintenance and Testing439
- Pressure Testing the System440
- Testing Coolant for Alkalinity440
- Testing the Closed-Cooling System440
- Seawater Pressure Test441
- Testing for a Cylinder Head Gasket Leak442
- Thermostat442
- Thermostat Removal442
- Thermostat Testing442
- Changing Coolant443
- Closed-Cooling Section443
- Draining the Closed Cooling System443
- Thermostat Installation443
- Cleaning the Cooling System444
- Filling the Cooling System444
- Blockage445
- Heat Exchanger Assembly445
- Heat Exchanger Removal445
- Testing-Internal Leaks445
- Cleaning and Inspection446
- Heat Exchanger Disassembly446
- Heat Exchanger Repair446
- Heat Exchanger Installation447
Cooling System449
- Bravo with Air-Actuated Drain450
- Models with Standard Cooling450
- Models with Closed Cooling452
- Seawater Circuit (All Models with Closed Cooling)452
- Glycol Circuit Towsport V-Drive454
- Glycol Circuit Inboard V-Drive456
- Glycol Circuit Inboard In-Line458
- Glycol Circuit Towsport Reverse V-Drive460
Exhaust System463
- Determining Catalyst Health464
- Exhaust System Connections464
- Exhaust System Notice464
- Preventing Contamination of the Emissions Control System464
- General Information465
- Measuring Engine Exhaust Elbow Height465
- Loading Requirements466
- Loading the Boat (Boats with a Capacity Plate)466
- Loading the Boat (Boats Without a Capacity Plate)468
- Clear Hose Measurement Method470
- Clear Hose Measurement Method from Seacock or Muffler Drain471
Exhaust System475
- Elbow-To-Manifold Gaskets476
- Exhaust Manifold and Elbow Exploded View478
- Exhaust Elbow Removal481
- Exhaust Elbows481
- Intermediate Exhaust Elbow Kit481
- Exhaust Elbow Installation482
- Exhaust Manifold Removal484
- Exhaust Manifolds484
- Exhaust Manifold Installation486
- Manifold Cleaning and Inspection486
- Oxygen Sensor489
- Exhaust Manifold Coolant Temperature (EMCT) Sensor490
- Installation490
- Removal490
Exhaust System491
- Exhaust System Components492
- 6.2L Exhaust494
- Hose Clamp Identification494
- Tridon® Hose Clamp494
- 6.2L MIE Exhaust Installation495
- Switchable Exhaust495
- General Information497
- Towsport Exhaust497
- Component Replacement498
- Exhaust Angle Measurement498
- Through-The-Propeller Exhaust498
Steering Systems501
- Power-Assisted Steering Components Exploded View504
- Hydraulic Diagrams506
- Neutral506
- Left Turn508
- Right Turn510
- Axius Steering Cylinder Clearance511
- Control Valve511
- Description511
- Power-Assisted Steering Pump512
- Power-Assisted Steering Pump Pulley512
- Power-Assisted Steering Pump Pulley-Removal512
- Power-Assisted Steering Pump Pulley-Installation513
- Power-Assisted Steering Pump Assembly514
- Steering Pump Assembly Removal514
- Steering Pump Assembly Installation515
- Filling and Bleeding516
- Power-Assisted Steering Fluid516
- Replacing the Belt and Adjusting Tension516
- Power Steering Fluid517
- High-Pressure Hose (Pump to Control Valve)518
- Power-Assisted Steering Hoses518
- Return Hose (Pump Reservoir to Fluid Cooler)520
- Return Hose (Control Valve to Fluid Cooler)521
- Power-Assisted Steering System Pressure Test522
- Power-Assisted Steering System Tests522
- Pump Pressure Test524
Steering Systems527
- Approved Hydraulic Steering Fluids528
- Important Information about Through-The-Transom Exhaust528
- Installing the Steering Cylinder528
- Introduction528
- Initial Filling530
- Purging the Hydraulic Steering System530
- Checking Fluid Level531
- Checking Fluid Level after the Initial Fill531
- Engine Warm531
- Engine Cold532
- Connecting the Clevis533
- Steering Circuit Component Diagram533
- Connecting the Hydraulic Hoses to the Tilt Steering Helm534
- Hydraulic Fluid Level535
- Maintaining Fluid Level535
- Setting Fluid Level535
- System Check535
- Important Information536
- Maintenance536
- Troubleshooting Chart536
- Troubleshooting Guide536
Transmissions539
- Identification540
- Specifications540
- 45Iv542
- Transmission and Related Parts542
- 45C DTS and 45C Mechanical543
- 45C and 63 In-Line Transmissions544
- 63A Dts544
- Engine544
- Important Information544
- Precautions544
- Propeller544
- Transmission and Propeller Rotation544
- Transmission Fluid545
- 63A Down-Angle and 63IV V-Drive Transmissions548
- Transmission Fluid548
- Transmission Removal551
- Transmission Installation552
- Shift Cable Installation554
- Shift Cable Installation and Adjustment554
- Pressure Test555

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Mercury MERCRUISER Specifications

General

Brand	Mercury
Model	MERCRUISER
Category	Engine
Language	English

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