Mercury Mercruiser Sterndrive 1964 – 2006 Service Repair Manual

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 Liter

without fuse

MCM 120R/140R & 3.0 Liter

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 Liter

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 Liter with fuse

MCM 320 with EFI

MCM 330 Sc 7.4 Liter w/o fuse

MCM 330 & 7.4 Liter 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

Commander 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