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Mercury Mercruiser Sterndrive Service Repair Manual 1964-2006
Mercury Mercruiser Sterndrive Service Repair Manual 1964-2006
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Mercury Mercruiser Sterndrive 1964 - 2006 Service Repair Manual
Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. Read and print pages, or copy the entire manual to your hard drive.
1770 Pages
MODEL YEAR:
1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
MANUAL COVERS:
SECTION 1 – 1964-1991
Type 1, MR
Alpha and Bravo I and II – Carburator and Fuel Injected
Page: 2-600
SECTION 2 – 1992-2000
Gasoline Engines
Alpha, Bravo, Blackhawk and
All Inboard Transmissions
Page: 602-1186
SECTION 3 – 2001-2006
Gasoline Engines and Drives
Including Inboards and Transmissions
Page: 1188-1770
MANUAL COVERS:
1 SAFETY
INTRODUCTION
CLEANING, WAXING,
AND POLISHING
CONTROLLING CORROSION
PROPELLERS
FUEL SYSTEM
LOADING
FLOTATION
EMERGENCY EQUIPMENT
COMPASS
STEERING
ANCHORS
MISCELLANEOUS EQUIPMENT
NAVIGATION
2 TUNING
INTRODUCTION
TUNING FOR PERFORMANCE
MECHANICAL TASKS
IGNITION
FUEL SYSTEM
Adjusting Idle Speed
and Mixture
3 ENGINE
INTRODUCTION/CHPT. COVERAGE
GENERAL PRINCIPLES
Piston Strokes & Combustion
Valve Timing
Engine Types
TROUBLESHOOTING
Cranking System
Ignition System
Compression Test
Mechanical Problems
Excessive Oil Consumption
ENGINE REMOVAL, INSTALLATION
AND ALIGNMENT
PAN INSTALLATION -- All Models
INTAKE MANIFOLD SERVICE
EXHAUST MANIFOLD SERVICE
CYLINDER HEAD SERVICE
Removal
Head Disassembling
Cleaning & Inspecting
Valve Mechanism Service
Valve Guide
Valve Seats
Valves
Valve Springs
Hydraulic Lifters
Head Assembling
Head Installation
PISTON, RING, & ROD SERVICE
Removal
Cleaning & Inspecting
Assembling
CYLINDER BLOCK SERVICE
Piston & Rod Installation
VALVE LASH ADJUSTMENTS
Mercury Marine Engines
GMC 4- & 6-Cyl. In-Line
GMC V6 & V 8
Ford V 8 Only
TIMING CHAIN, GEAR
AND CAMSHAFT
GMC 4- & 6-Cyl. In-Line
GMC V6 & V8
Early Mercury Marine
Mercury Marine & Ford
CAMSHAFT BEARING SERVICE
ALL UNITS
Lift Measurement GMC Only
Lift Measurement Mercury
OIL PUMP SERVICE -- All Models
Marine & Ford
3 ENGINE (CONTINUED)
CRANKSHAFT ROD & MAIN BRGS.
GMC 4- & 6-Cyl. In-Line
GMC V6 & V8
Mercury Marine & Ford
Crankshaft Installation
4 FUEL
INTRODUCTION/CHPT. COVERAGE
TROUBLESHOOTING
Excessive Fuel Consumption
Engine Surge
Rough Engine Idle
FUEL PUMPS AND FILTERS
Single-Diaphragm Pump
Dual-Diaphragm Pump
Pump Pressure Test
Pump Volume Test
Fuel Line Test
Fuel Pump Removal/Installation
Fuel Filter Replacement
Flame Arrestor Cleaning
Water Separating Filter
MODERN FUELS
"Sour" Fuel
CARBURATORS, GENERAL INFO.
ROCHESTER BC
Removal/Disassembling
Assembling
Adjusting
CARTER RBS
Description & Operation
Disassembling
Assembling
Bench Adjustments
Synchronizing Dual Carbs.
ROCHESTER 2GC & MerCarb
Disassembling
Assembling
Bench Adjustments
ROCHESTER 4MV AND 4MC
Description
Disassembling
Assembling
Bench Adjustments
HOLLEY CARBURETORS
TWO-BARREL - 2300C
FOUR-BARREL - 4150, 4160 & 4011
Description 6:Operation
Disassembling - 2300C,
4150 & 4160
Cleaning 8 Inspecting
Assembling
Tuning Adjustments
Disassembling - 401 1
Cleaning & Inspecting
Assembling
Tuning Adjustments
EFI (ELECTRONIC FUEL
INJECTION)
Description & Operation
Manifold Pressure
ECU (Electronic Control)
Fuel Pump & Routing
Air Temperature Sensor
Auxiliary Air Valve
Manifold Absolute Pressure
(MAP) Sensor
Coolant Temperature Sensor
Throttle Position Sensor
Fuel Injectors
Fuel Rail
Fuel Pressure Regulator
Oil Pressure Sensor
Throttle Shutter
Electric High Pressure
Fuel Pump
Water Separating Filter
RPM Sensor
Electronic Control (ECU)
Troubleshooting EFI
Installed Injector Test
Voltage t o Electric Pump Test
Testing Fuel Pump Pressure
Testing Injector Harness
Testing Fuel Injectors
Air Temp. Sensor Check
Coolant Temp. Sensor Test
Throttle Position Sensor Test
EFI Maintenance
Leaded Gasoline & Gasohol
SERVICING EFI
Removal
Cleaning & Inspecting
Installation
Special Timing Words
5 IGNITION
DESCRIPTION
Standard Ignition System
Ballast Resistor
Shift Cutout Switch
Ignition Timing
Thunderbolt IV System
TROUBLESHOOTING
Compression
General Tests
Condenser Test
Secondary Circuit Test
Ignition Voltage Tests
Spark Plug Troubleshooting
Spark Plug Evaluation
Polarity Check
DISTRIBUTOR SERVICE
Removal
SERVICING A DELCO-REMY
Disassembling - from a
4- o r 6- cylinder engine
Assembling
Disassembling from a
GMC V8
Assembling
SERVICING A MALLORY
Disassembling from
a V8 engine
Assembling
SERVICING A MERCURY MARINE
Disassembling from a V8
Assembling
SERVICING AN AUTOLITE
OR PRESTOLITE
Disassembling from a V8
Assembling
ADJUSTING POINT GAP
ALL DISTRIBUTORS 5-27
DISTRIBUTOR INSTALLATION
MCM 185 229 CID
All Other Engines
Adjusting Dwell
Adjusting Timing
DDIS (DIGITAL DISTRIBUTORLESS
IGNITION SYSTEM)
6 ELECTRICAL
INTRODUCTION
BATTERIES
JUMPER CABLES
DUAL BATTERY INSTALLATION
GAUGES AND HORNS
Oil and Temperature Gauges
Warning Lights
Fuel Gauges
Troubleshooting
Tachometer
Horns
CHARGING SYSTEM
Alternator
Troubleshooting
Servicing Charging System
with Separate Regulator
Servicing Delcotron Alternator
Servicing Valeo Alternator
Troubleshooting
Removal
Cleaning & Testing Brushes
Testing Alternator
Assembling & Installation
CRANKING SYSTEM
Troubleshooting
Delco-Remy Cranking Motor
Description & Operation
Servicing
Testing
Assembling
Autolite Cranking Motor
Description & Operation
Disassembling
Bench Tests
Assembling
Prestolite Cranking Motor
Description & Operation
Disassembling
Assembling
7 REMOTE CONTROLS
INTRODUCTION
SHIFT/STEERING CABLE
EARLY TYPE SHIFT CABLE
SERVICE -- PRIOR T O 1973
7 REMOTE CONTROLS (CONTINUED)
EARLY TYPE SHIFT (Continued)
Attaching Shift Cable Mounted
on Starboard Side
Adjusting Shift Cable Mounted
on Starboard Side
Attaching Shift Cable Mounted
on Port Side
Adjusting Shift Cable Mounted
on Port Side
LATE TYPE SHIFT CABLE SERVICE
1973 TO 1982
Installation Dimensions
Shift Cable Installation
Shift Cable Adjustment
SHIFT CABLES SINCE 1983
MODELS R, MR, AND ALPHA
Upper Shift Cable Installation
Lower Shift Cable Installation
BRAVO SHIFT CABLE SERVICE
Shift Cable Adjustment
Stern Drive Removed
Shift Cable Adjustment
Stern Drive Installed
Cut-Out Switch -- Lever
Position Adjustment
Reverse Lock Valve Adjustment
COMMANDER CONTROL
SHIFT BOX
Removal/Disassembling
Cleaning & Inspecting
Assembling
STEERING SYSTEMS
DIRECTIONAL INDICATOR SYS.
Disassembling
Cleaning & Inspecting
Assembling
ROTARY STEERING SERVICE
Disassembling
Cleaning & Inspecting
Assembling
POWER STEERING
DESCRIPTION & OPERATION
SYSTEM MAINTENANCE
Adding Hydraulic Fluid
Bleeding System
Belt Adjustment
Actuator Valve Adjustment
POWER STEERING COOLER
INTRODUCTION
MECHANICAL TILT MECHANISM
HYDRAULIC SYSTEM
System Operation
UP Circuit
UP and DOWN Circuit
Trailer ingllaunching
GENERAL SERVICE INSTRUCTIONS
TROUBLESHOOTING
Mechanical Problems
Electrical Problems
TESTING SYSTEM COMPONENTS
PURGING AIR ("BLEEDING") SYS.
Early Model Systems -- Both
Hoses Connected t o Fwd.
End of Cylinder
L a t e Model Systems -- One
Hose connected to Each
End of Cylinder
TRIM SENDER SYSTEMS
Disassembling
Assembling
L4djustrnents
REVERSE LOCK VALVE
Description
Disassembling
Assembling
Adjustment
PUMP MOTOR
Troubleshooting
Disassembling
Cleaning & Testing
9 COOLING
DESCRIPTION
TROUBLESHOOTING
SERVICE
DRAINING 6
In-Line Engines w/Std. Sys.
In-Line Engines w/Closed Sys.
V8 Engines w/Std. Sys.
V8 Engines w/Closed Sys.
WATER PUMP
THERMOSTAT
HEAT EXCHANGER
In-Line Engines
V8 Engines
FILLING SYSTEM
EXHAUST MANIFOLD
GMC In-Line Engines
470 Engine
Ford V8 Engines
GMC V8 Engines
EXHAUST SHUTTER
STERN DRIVE WATER PUMP
Lower Unit Removal
Pump Installation
Lower Unit Installation
BRAVO WATER PUMP ON ENGINE
Disassembling
Cleaning & Inspecting
Assembling
STERN DRIVE
NOTE
PAGES 10-2 THRU 10-58 COVER
ALL UNITS, EXCEPT BRAVO
PAGES 10-58 THRU 10-110 COVER
BRAVO STERN DRIVE
INTRODUCTION
OPERATION
TROUBLESHOOTING
SERVICE PRECAUTIONS
PROPELLER REMOVAL
TRIM CYLINDER REMOVAL
STERN DRIVE REMOVAL
UPPER GEAR HOUSING
Disassembling
Cleaning & Inspecting
U-Joint, Drive Gear
and Bearing Disassembling
Assembling
Upper Gear Housing Assembling
Upper Driveshaft and Driven
Gear Assembling
Adjustments
Bearing Preload Adjust.
Driven Gear Shimming
U-Joint Bearing & Bearing
Assembly Installation
Drive Gear Shimming
LOWER UNIT
Housing Removal
Disassembling
Cleaning & Inspecting
Reverse Bearing Carrier
Propeller Shaft
Lower Unit Assembling
Forward Gear Backlash
Reverse Gear Backlash
Pinion Gear Shimming
Forward & Reverse
Gear Shimming
Water Pump Installation
Lower Unit Installation
UPPER GEAR HOIJSING T O
LOWER UNIT ASSEMBLING
STERN DRIVE INSTALLATION
TRIM CYLINDER INSTALLATION
PROPELLER INSTALLATION
STERN DRIVE LUBRICATION
BRAVO STERN DRIVE
INTRODUCTION
OPERATION
TROUBLESHOOTING
BRAVO SERVICE
Propeller Removal
Braining Lubricant
Separating Stern Drive
From Bell 1-Iousing
Separating Upper Gear C a s e
Housing From Lower Unit
Upper Gear C a s e Service
Rear & Top Cover Removal
Bearing Removal
U-Joint Shaft Removal
Clutch Disassembling
Shifter Bushings & Seal
Cleaning & Inspecting
Assembling
Bearing & Sleeve Instl.
Shifter Bushing & Seal
Clutch Assembly
U-Joint Shaft Assembly
Spacer & Rolling Torque
Lower Unit Service
Disassembling
Bearing Carrier and
Propeller Shaft
Driveshaft
Propeller S h a f t Bearing
Cleaning & Inspecting
Assembling Lower Unit
Driveshaft
Bearing Carrier
Drive Gear & Bearing
Driveshaft Bearing Races
Drive Gear & rives shaft
10 STERN DRIVE (CONTINUED)
BRAVO LOWER UNIT Continued)
Shimming 10-102
Pinion Gear Height
Driveshaft Preload
Backlash & Rolling Torque
Mating Lower Unit To
Upper Gear C a s e Housing
Mating Stern Drive t o
Bell Housing
Propeller Installation
Stern Drive Lubrication
11 BELL HOUSING
INTRODUCTION
TROUBLESHOOTING
GIMBAL HOUSING & TRANSOM
PLATE INSTALLATION
CONNECTING HYDRAULIC HOSES
In-Line Engines
V8 Engines 13 ENGINE REMOVAL/INSTALLATION
INTRODUCTION
REMOVAL
INSTALLATION
In-Line Engine
Throttle Cable Installation
and Adjustment
V8 Engine
Throttle Cable Installation
and Adjustment
SERVICE PROCEDURES
14 MAINTENANCE
GIMBAL HOUSING BALL BEARING
Removal
Installation
TRANSOM SHIFT CABLE
Removal
Installation
EXHAUST BELLOWS
Removal
Installation
U-JOINT BELLOWS
Removal
Installation
BELL HOUSING
Removal
Disassembling
GIMBAL RING
Removal
Disassembling
Cleaning & Inspecting
Assembling 2 Installation
BELL HOUSING
Assembling & Installation
12 GIMBAL HOUSING
INTRODUCTION
TRANSOM PLATE
Removal
Cleaning & Inspecting
INTRODUCTION
ENGINE SERIAL NUMBERS
STERN DRIVE IDENTIFICATION
AND SERIAL NUMBERS
SHIFT IDENTIFICATION ALL UNITS,
EXCEPT BRAVO
BELOW WATERLINE SERVICE
ENGINE FLUIDS
OFF-SEASON STORAGE
STE RN DRIVE LUBRICATION
Filling/Draining
Models 1, IA, 18, 1 C
All Others, Incl. Bravo
PRE-SEASON PREPARATION
APPENDIX
CONVERSIONS
Metric
Drill Size
TORQUE VALUES
TUNE-UP SPECIFICATIONS
CARBURETOR SPECIFICATIONS
ENGINE SPECIFICATIONS
MCM888/225S/223/250/260/320
l5O/l6O/l65 6-Cyl. In-Line
APPENDIX (CONTINUED)
ENGINE SPECIFICATION (Continued)
MCM11011201120MR 4-Cyl.
MCM140 6-Cyl. In-Line
MCM140/140MR 4-Cyi.
UPPER DRIVESHAFT GEAR RATIO
LOWER UNIT BACKLASH
WIRE IDENTIFICATION AND ROUTING
Instrument Cluster
with Warning Light
Thunderbolt Ignition
Instrument Panel
Model 120, 140, 165
(Check Serial Numbers)
Model 898
Model 888, 225-S, 233
(Check Serial Numbers)
Model 470 & 485 w/air-cooled
voltage regulator
Model 470 & 485 w/water-cooled
voltage regulator
Model 120R/140R
MCM 120R/140R & 3.0 Litre
without fuse
MCM 120R/140R & 3.0 Litre
with fuse
MCM 4701488
MCM 470R/488R w/o fuse
MCM 470R/488R with fuse
MCM 898R/228R/260R/230
also 5.0 & 5.7 Litre
MCM 200 and 898R with fuse
MCM 165/170MR/180/190MR
MCM 185/185R V6
MCM 20 5 V6
MCM 230/228R/260R, also
5.0 & 5.7 Litre with fuse
MCM 320 with EFI
MCM 330 Sc 7.4 Litre w/o fuse
MCM 330 & 7.4 Litre with fuse
DDIS (DIGITAL DISTRIBUTORLESS
IGNITION SYSTEM
Power Trim circuit
double solenoid
Power Trim Circuit
w/one solenoid
Power Trim w/late push button
w/two solenoids A-62
Presto lite Power Trim
Oil Dyne Series IV
Since 1983
Com mander side mount controls
w/power trim/tilt
This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.
Language: English
Format: PDF - Indexed and Searchable
COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.)
Windows/Mac/Tablet/Phone Friendly
We do not accept returns or cancel for change of mind. We only offer returns for items that are faulty or damaged.
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