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Friday, January 10, 2014

MerCruiser Engine Runs Poorly at High RPM 2001-2006

The following information contains troubleshooting testing procedures for engine runs poorly at high rpm problems on the MerCruiser 5.oL, 5.7L and 6.2L MPI gasoline 2001 2002 2003 2004 2005 2006 engines. Testing and diagnosis helps determine problems and possible causes. Its recommended you use a factory manual when performing repairs on your inboard engine, additional safety precautions, or technical data maybe included.

SYMPTOMS: Engine runs poorly at high rpm

CAUSES

1.0 Crankcase overfilled with oil

1.1 Anti-siphon valve restricting fuel supply

1.2 Plugged fuel tank vent

1.3 Improper fuel supply

1.4 Incorrect rotor location

1.5 Low grade of fuel or water in the fuel

1.6 Spark plugs fouled, burned, cracked porcelain or incorrect heat range

1.7 Spark plug wires broken or poorly insulated

1.8 Distributor cap or rotor dirty or cracked

1.9 Coil damaged or malfunctioning

1.10 Excessive play in distributor shaft

1.11 Engine overheating

1.12 Low compression - worn valves, rings or seals

1.13 Restricted exhaust

ACTIONS NEEDED

1.0 Check the oil level with the boat at rest in the water. Drain the oil if necessary to obtain the correct level.

1.1 Check fuel flow rates and repair, replace or remove anti-siphon valve as necessary.

1.2 Clean the fuel tank vent.

1.3 Inspect fuel supply system. Repair or replace as necessary.

1.4 Reset rotor location.

1.5 Drain the fuel tank and refill with the correct fuel.

1.6 Inspect the spark plugs and service or replace.

1.7 Replace the spark plug wires.

1.8 Inspect the distributor cap for cracks or marks. Replace the distributor cap and the rotor if necessary.

1.9 Replace the coil.

1.10 Replace distributor.

1.11 Check cooling water supply or coolant level.

1.12 Perform the cylinder compression check to determine which cylinder has low compression. Replace the rings, the valves or the pistons.

1.13 Clean the exhaust system.

MerCruiser RPM Information

mercruiser lifter noise high 3500 rpm
1995 3l mercruiser engine runs rough at 3000 rpm
1999 mercruiser 4.3 high rpm after changing belt and pulley
2001 mercruiser 5.0 litre runs hot at 4000 rpms
2003 mercruiser 5.7 bravo 2 overheating at high rpms or under load
2005 mercruiser 4.3 not reaching wot rpm
2005 mercruiser 5.7 mpi wont turn rpms
3.0 4 cyl mercruiser overheating at high rpm/hot water going out intake
3.0 liter mercruiser running rough at high rpm
3.0 mercruiser high rpm wide open and over heat
350 magnum fuel cooler engine running hot at 4500 rpm
350 magnum mercruiser overheats only at low rpms
350 mercruiser boat overheating at high rpms
350 mercruiser rough running at 3600 rpm
5.7 mercruiser engine miss at hi rpm
5.7 mercruiser overheats above 2000 rpms

These service procedures apply to: 2001 2002 2003 2004 2005 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Multiport Injection Engine. 5.0L MPI Alpha and Bravo, 350 Alpha and Bravo, 350 MAG MPI Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Tow Sports (MIE), 350 MAG MPI, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports.

The following information contains troubleshooting testing procedures for engine surges problems [i.e. engine surges, low or lack of top speed power, poor performance when engine is cold, engine stalls or engine misses] on the MerCruiser 5.oL, 5.7L and 6.2L MPI gasoline engines. Testing and diagnosis helps determine problems and possible causes. Its recommended you use a factory manual when performing repairs on your inboard engine, additional safety precautions, or technical data maybe included.

SYMPTOMS: Engine Surges

CAUSES

1.0 Leaking idle air control (IAC), intake manifold or throttle body gaskets

1.1 Throttle valves worn or damaged

1.2 Worn or leaking IAC hose or vacuum hose to the pressure regulator

ACTIONS NEEDED

1.0 Find and replace the leaking gaskets.

1.1 Inspect the throttle valves. Replace the throttle body if necessary.

1.2 Find and replace the leaking hose.

MerCruiser Low Top Speed/Lack Of Power

SYMPTOMS: Low top speed or lack of power

CAUSES

Leaking idle air control (IAC), intake manifold or throttle body gaskets

ACTIONS NEEDED

Find and replace the leaking gaskets.

MerCruiser Poor cold engine operation

SYMPTOMS: Poor cold engine operation

CAUSES

3.0 Engine is not reaching normal operating temperature

3.1 Faulty engine temperature sensor (ECT)

3.2. Fuel PSI too high or too low

3.3 Throttle valves worn or damaged

3.4 Engine flooding

ACTIONS NEEDED

3.0 Replace thermostat or thermostat housing gasket.

3.1 Replace the ECT.

3.2 Determine the cause and repair.

3.3 Inspect the throttle valves. Replace the throttle body if necessary.

3.4 Check the fuel pressure. If too high, find cause and correct. Clean the flame arrestor. Perform the cylinder balance test.

MerCruiser Engine stalls

SYMPTOMS: Engine Stalls

CAUSES

4.0 Idle rpm too low

4.1 Engine flooding

4.2 Leaking idle air control (IAC), intake manifold or throttle body gaskets

ACTIONS NEEDED

4.0 Clean the flame arrestor. Test the IAC to see if it opens and closes properly.

4.1 Check the fuel pressure. If too high, find cause and correct. Inspect the fuel pressure regulator. Inspect the injectors.

4.2 Find and replace the leaking gaskets.

MerCruiser Engine Misses

SYMPTOMS: Engine Misses

CAUSES

Fault in the ignition system

ACTIONS NEEDED

Check the spark plugs. Check the spark plug wires. Check the distributor cap for cracks or marks. Check the ignition coil operation. Replace the faulty component.

These service procedures apply to: 2001 2002 2003 2004 2005 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Gasoline Multiport Injection Engine.5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Tow Sports (MIE), 350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports.

MerCruiser Overheating - Merc Cruiser Troubleshooting Guide

Troubleshooting can determine faults and help correct mechanical or cooling system problems. This troubleshooting guide will focus on actions needed to correct engine overheating issues for MerCruiser Inboard motors.

Components my differ depending on MerCruiser year, these guidelines are typical for most model MerCruisers for 1998 1999 2000 2001 2002 2003 2004 2005 2006. Since these are general guidelines, the following years may be relevant: 1989 1990 1991 1992 1993 1994 1995 1996 1997.

The following is a check list of probable causes, but keep in mind, more than one of these conditions could be present.

Engine Overheats Mechanical:

IMPORTANT: First, verify if the engine is actually overheating, the temperature gauge or sender could be faulty.

IMPORTANT: Best way to test the gauge or sender is just to replace it.

Key features of interest will be focused on overheating due to mechanical problems:

Engine laboring
Timing
Distributor
Spark plug wires
Fuel mixture
Spark plugs
Exhaust
Valve timing
Head-gasket
Lubrication

1. The engine rpm is below specifications at WOT (wide open throttle), this could be do to a damaged or incorrect propeller. Check for excessive growth on the bottom of the boat. Is bilge working? Check to see if the hull is filled with water causing excessive drag (engine laboring). Also, excessive air bubbles due to growth on bottom hull could cause the sea water pick-up insufficient water for cooling (if equipped), see engine overheats cooling system. These issues can cause an engine to overheat.

2. Worn down ignition timing, check to see if the timing is retarded or possibly to far advanced.

3. Inspect the distributor advance weights to see if there sticking.

4. Spark plug wires can be transversed (wrong firing order), make sure spark plug wires are in correct order.

5. Lean fuel mixture.

6. Incorrect heat range for spark plugs.

7. Restriction in exhaust system.

8. Is the timing off? Possibly the timing chain has jumped or installed improperly.

9. Blown head gasket, a compression test will not reveal if the head gasket is blown. Typically, an engine will not overheat until the engine has reached speeds above 3000 rpm. For engines that are sea water cooled: use a clear plastic hose, inspect for air bubbles between seawater pump and engine. If you do not notice bubbles, install the hose between the thermostat housing and manifold(s). Any bubbles detected at higher rpm is an indication of a blown head gasket.

10. Lubrication issues for moving parts. A fouled oil pun, blocked oil passages or low oil level may be the problem.

Engine Overheats Cooling System

Key features of interest will be focused on overheating due to cooling system problems:

Drive belt
Seawater shutoff valve (if equipped)
Sea strainer
Seawater pick-up (models with belt driven seawater pump only)
Seawater kinks or collapsed hose
Seawater blockage
Hull obstructions
Thermostat
Exhaust elbow
Faulty seawater pump
Obstruction in cooling system
Engine circulating pump faulty
Coolant
Antifreeze
Heat exchanger
Water hoses
Drive belt
Seawater shutoff valve

1. Possible broken or loose drive belt.

2. The seawater shutoff valve may be partially or completely closed (if equipped).

3. Incorrectly installed sea water strainer

4. Loose hose connections between seawater pickup and pump inlet, this applies only to models equipped with belt driven seawater pumps). Note: the pump will suck air. The pump may also fail to prime or will force bubbles into the cooling system.

5. The seawater inlet hose could possibly be kinked or collapsed, this may or may not be noticeable until under load.

6. Blocked or clogged sea water pick-up.

7. Obstructions on the bottom hull of boat causing to much water turbulence. If there are obstructions in front of the seawater pick-up, it could cause air bubbles to be forced into the cooling system.

8. Check thermostat for proper operation.

9. Make sure the exhaust elbow water outlet in not blocked, clogged or plugged.

10. Seawater pump may have a worn pump impeller, replace if necessary.

11. Possible obstructions in cooling system. Check items such as casting flash, salt, sand, rust, etc. Check your service manual for water flow diagram.

12. Engine circulating pump could be faulty.

13. Check coolant level.

14. Is the antifreeze mixed correctly? A good mix ratio should be 50/50 or maximum 60/40 (antifreeze = 60%, water = 40%)

15. Inspect heat exchanger for plugged cores.

16. Water hoses transversed, make sure water hoses are not reversed at the water distribution block.

17. Broken, worn or loose drive belt.

18. Seawater shut off valve fully or partially closed.

Service procedures apply to some of the following models:

mercruiser overheating at high rpm
mercruiser very high temperature at idle
mercruiser 3.0 overheating
mercruiser 470 overheating
mercruiser 4.3 overheating
470 mercruiser overheating problem
will the mercruiser impeller cause engine to run hot
1997 mercruiser 3.0 lx overheating problem
1997 mercruiser 3.0 overheating
1997 mercruiser 3.0 overheating idle
1998 7.4 mercruiser overheating
454 marine engine overheating not reaching rpm
454 mercruiser boat engines overheating issue
496 8.1 mercruiser check valves glogged causing overheating
82 mercruiser 350 engine overheating problem
89 3.0 l mercruiser alpha 1 overheating problem

MerCruiser Inboard Engine Model

496 Mag HO 8.1S Horizon HO
GM V8 454 cid 7.4L 502 cid 8.2L
4.3L MPI Alpha and Bravo
3.0L & 3.0LX
4 Cylinder
305 CID 5.0L 350 CID 5.7L 6.2L
GM V8 305-350-454-482-540 CID
D1.7L DTI
In-ine Diesel D2.8L D4.2L D-Tronic Manual
GM 6-Cylinder Engines

While this guide was written to help you diagnose problems. Its recommended you refer to the factory service manual before performing any work. Improper service or repairs can magnify existing issues. Also, MercCruiser repair manuals may contain more detail information including important safety notations or warnings.

MerCruiser Rocker Arm & Valve Pushrod Service Procedures 2001-2006

The following information contains factory service procedures for Rocker Arm & Valve Pushrods for the MerCruiser 5.oL, 5.7L and 6.2L MPI gasoline engines. Its recommended you use a factory manual when performing repairs on your inboard engine, additional safety precautions, or technical data maybe included.

REMOVAL

NOTE: When performing service to just one cylinder's rocker arms, you must bring that cylinder's piston to TDC (Top Dead Center) before you remove the rocker arms. If your performing service to all of the rocker arms, you must bring cylinder number 1 up to TDC before you remove the rocker arms.

1. Remove the valve covers.

2. Remove the rocker arm assemblies and the valve pushrods.

IMPORTANT: You must organize the rocker arm assemblies and valve pushrods in a rack in order to reassemble them in their original and exact locations.

CLEANING

1. Use a designated cleaner to clean the rocker arm assemblies and pushrods.

2. Clean the valve pushrod oil passages.

3. Use safety glasses before proceeding to the next step.

4. You compressed air to dry parts.

INSPECTION

1. Carefully inspect all contact surfaces for excessive wear, damage or scoring.

2. Ensure the valve pushrod oil passage is not restricted.

3. Ensure the valve pushrods do not contain bends by rolling the pushrod on a flat surface.

4. Replace any damaged parts or parts that do not meet factory specifications.

INSTALLATION

1. Lubricate the ends of the valve pushrods and the outer surfaces.

2. Reinstall the valve pushrods in their exact location they were in upon removal. Make sure the pushrods seat in the lifter socket.

3. Apply lubrication to the rocker arm ball contact surfaces and the rocker arm.

4. Apply lubrication to the threads of the valve rocker arm studs.

5. Reinstall the rocker arms, rocker arm balls and rocker arm nuts in their original and exact locations they were in upon removal.

6. Last, adjust the valve clearance.

LUBRICANTS REQUIRED

A. Johnson EP lube or equivalent, the EP lube is used for lubricating valve pushrods, rocker arm and rocker arm ball contact surfaces.

B. 80W gear lube, this lube is used to lubricate the rocker arm ball stud, this material can be obtained at local marine service centers.

These service procedures apply to: 2001 2002 2003 2004 2005 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Engine.5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Tow Sports (MIE), 350 MAG, 350 MAG Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG Tow Sports.

MerCruiser Runs Rough or Poor Performance V8 305 350 454 482 540 CID

Troubleshooting can determine faults and help correct mechanical or electronic system problems. This troubleshooting guide will focus on actions needed to correct engine runs poorly issues for MerCruiser Inboard motors.

Components my differ depending on MerCruiser year, these guidelines are typical for most model MerCruiser for 1998 1999 2000 2001 2002 2003 2004 2005 2006. Since these are general guidelines, the following years may be relevant: 1989 1990 1991 1992 1993 1994 1995 1996 1997.

Key features of interest will be focused on:

Oil
Anti-Siphon (if equipped)
Fuel vent tank
Fuel
Timing
Fuel contamination
Spark plugs
Spark plug wires
Distributor cap or rotor
Overheating
Compression
Exhaust

While this guide was written to help you diagnose problems. Its recommended you refer to the factory service manual before performing any work. Improper service or repairs can magnify existing issues. Also, MerCruiser repair manuals may contain more detail information including important safety notations or warnings.

The following is a check list of probable causes, but keep in mind, more than one of these conditions could be present.

Troubleshooting Checklist:

Check crankcase to see if its overfilled with oil. Its best to check the oil level while the boat is in the water.
Anti-Siphon valve (if equipped), possibly restricting or blocking the fuel supply. Inspect to make sure its not clogged.
Possible plugged fuel tank vent
Completely check all fuel supply components and lines.
Ignition timing may be incorrect.
Low grade fuel, check for contaminations. Is fuel contaminated with water?
Broken, burnt, cracked porcelain, fouled, spark plugs. Make sure plugs are not covered in oil.
Broken spark plug wires or poorly insulated wires.
The distributer cap or rotor may be dirty or cracked. Replace if necessary.
Check coil.
Check for excessive shaft play on distributor.
Engine running hot, check for overheating issues.
Possible worn valves, cylinders, piston rings, etc. Do a compression check.
Check the exhaust system for possible restrictions.

Common Terminology

Poor boat performance
Mer Cruiser Mercury low power
MerCruiser Troubleshooting
Troubleshooting MerCruiser Inboard

MerCruiser Inboard Engine Models

496 Mag HO 8.1S Horizon HO
GM V8 454 cid 7.4L 502 cid 8.2L
4.3L MPI Alpha and Bravo
3.0L & 3.0LX
4 Cylinder
305 CID 5.0L 350 CID 5.7L 6.2L
GM V8 305-350-454-482-540 CID
D1.7L DTI
In-ine Diesel D2.8L D4.2L D-Tronic
GM 6-Cylinder

MerCruiser Valve Cover Removal Cleaning Installation 5.0L 5.7L 6.2L MPI

The following information contains factory service procedures for valve cover removal, cleaning and installation for the MerCruiser 5.oL, 5.7L and 6.2L MPI gasoline engines. Its recommended you use a factory manual when performing repairs on your inboard engine, additional safety precautions, or technical data maybe included.

REMOVAL

NOTE: On some models, you may need to remove the exhaust manifold before removing the valve cover.

1. Disconnect crankcase ventilation hoses.

2. Remove all items that may interfere while removing the valve cover.

3. Remove the valve cover.

CLEANING AND INSPECTION

1. Clean the gasket material from all of the sealing surfaces.

2. Use a degreaser to clean sealing surfaces on cylinder head and valve cover.

NOTE: Use safety glasses to protect your eyes from cleaners and small debris.

INSTALLATION

1. Apply the new valve cover gasket to the valve cover.

2. Install the valve cover and torque bolts.

Valve Cover Bolt Torque Specifications: Nm 12, lb-in. 106

3. Replace any components removed during removal process.

4. Re-connect the crankcase ventilation hoses.

5. Supply cooling water to the power package.

6. Start engine and inspect for any oil leaks.

These service procedures apply to: 2001 2006 2002 2005 2003 2004 MerCruiser 5.0L, 5.7L, 6.2L MPI, 5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Tow Sports (MIE), 350 MAG MPI, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports.

MerCruiser Valve Cover Information

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Thursday, January 9, 2014

MerCruiser Wiring Diagrams 5.0L 5.7L Inboard Engine 2001-2006

5.0L (305 cid)
5.7L (350 cid)

Model Years: 2001 2002 2003 2004 2005 2006

General Information

Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection. 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. Lanyard stop switch lead and neutral safety switch leads must be soldered and covered with shrink tube for a water proof connection. If an alternate method of connection is made, verify connection is secure and sealed for a water proof connection.

1 Audio Warning Alarm
2 Tachometer
3 Oil Pressure
4 Water Temperature
5 Battery Meter
6 Ignition Switch
7 Trim Indicator
8 Read/Observe NOTE 1 and 2.
9 Read/Observe NOTE 3.
10 To Engine Wiring Harness

Power Trim System

1 - 20 Amp Fuse
2 - Ground Bolt (Floor Mount)
3 - UP Solenoid
4 - 110 Amp Fuse
5 - DOWN Solenoid
6 - Trailer Switch
7 - Neutral Switch to Instrument Wiring Harness
8 - Trim Limit Switch

Wire Colors

BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LT OR LIT = LIGHT
DRK = DARK

MerCathode System Wiring Diagram

1 - Controller
2 - 20 Amp Fuse
3 - Electrode
4 - BLACK Wire - With Engine Harness or Separate

Wire Colors

BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LT OR LIT = LIGHT
DRK = DARK

MerCruiser Wire Information

2006 mercuriser 5.0 red wire with purple stripe
bad spark plug wire symptoms mercruiser
coil wire for 92 mercruiser
ground wire diagram for 5.0l mercurcruser
mercruiser 5.7l purple yellow wire 2005
mercruiser 3.0 trim solenoid green wire
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mercruiser 350 mag wire harness
mercruiser 350 wire diagram
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mercruiser 5.0 black wire
mercruiser 5.0 chevy plug wireing
mercruiser 5.0 efi green white wire
mercruiser 5.0 ground wires
mercruiser 5.0 mpi coil wire 2005 parts
mercruiser 5.0 mpi manual 2001wireingdiagram for engine
mercruiser 5.0 mpi tach wire color
mercruiser 5.0 plug wire recommendation
mercruiser 5.0 spark plug wires
mercruiser 5.0 temperature switch yellow wire black wire
mercruiser 5.0 white blue wire ignition
mercruiser 5.0l mpi wire harness schematic
mercruiser 5.0l replacement spark plug wires
mercruiser 5.0l spark plug wires
mercruiser 5.7 ground wire
mercruiser 5.7 hour meter wire
mercruiser 5.7 plug wire routing
mercruiser 5.7 starter wires
mercruiser 5.7 towsports spark plug wires
mercruiser 6.2 mpi spark plug wires test

MerCruiser Throttle Body Factory Service Reference 5.0 5.7 6.2

The following information covers factory service procedures for servicing the throttle body on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 2001 2002 2003 2004 2005 and 2006 models.

STERNDRIVE MCM

5.0L V8 MPI Alpha and Bravo
350 MAG MPI Alpha and Bravo
MX 6.2L MPI Horizon
350 Mag MPI Alpha and Bravo Horizon
MX 6.2L MPI

INBOARD AND TOW SPORTS (MIE)

350 MAG MPI Inboard
MX 6.2 MPI Horizon Inboard
350 MAG MPI Horizon Inboard
MX 6.2 MPI Inboard
350 MAG MPI Tow Sports

Testing and diagnosis helps determine problems and possible causes. Its important to perform extensive testing and troubleshooting prior to any major tear down or repair work. This ensures that the full extent of the problem is understood beforehand and may prevent any unnecessary repair work. Its recommended you use a factory repair manual when performing repairs on any vehicle, additional safety precautions, or technical data maybe included.

THROTTLE BODY REMOVAL

1. Take off the engine cover and the flame arrestor.

2. Detach the throttle linkage from the throttle body.

3. Detach the harness connector from the throttle position sensor.

4. Take off the IAC hose from the throttle body.

5. Take off the throttle body attaching studs.

6. Remove the throttle body.

7. Take off the throttle body sealing ring and discard it.

IMPORTANT: Place a clean towel over the opening of the intake manifold to prevent items or debris from entering the hole of the engine.

CLEANING AND INSPECTION

IMPORTANT: Never use any cleaners that contain methyl ethyl ketone.

IMPORTANT: Avoid getting any cleaners or solvents on the TPS (throttle position sensor).

IMPORTANT: Avoid damaging the throttle body or adapter when removing any gasket material from the throttle body and adapter.

1. Carefully remove any gasket material from throttle body and adapter, be sure not to damage the sealing surface.

2. Take off the IAC muffler.

3. Clean all of the throttle body parts thoroughly. Make sure that all of the passages are free of burrs, dirt and debris.

4. Carefully check the sealing surfaces for damage that may effect the gasket from sealing.

5. Inspect the throttle body casting for damage or cracks.

6. Check the linkage, throttle plates and other components for wear, damage and foreign material.

INSTALLATION

1. Reinstall a new throttle body sealing ring into the grove in the throttle body.

2. Reinstall the throttle body onto the upper intake manifold and align the dowels.

3. If your going to be reusing the fasteners, first apply adhesive (Loctite 242, part number 92-809821) to the threads of the throttle body attaching studs.

4. Reinstall the throttle body attaching studs and torque the studs to 9 Nm 80 lb-in.

5. Reinstall the IAC muffler.

6. Reinstall the throttle cable bracket.

NOTE: Make sure that the stud and nut are threading properly. Torque the throttle cable bracket nut to 19 Nm 168 lb-in.

7. Reinstall the IAC plug to the IAC hose.

8. Reinstall the flame arrestor and torque the flame arrestor retainer bracket nut to 12 Nm 108 lb-in.

9. Reinstall the engine cover.

MerCruiser Throttle Information

2001 mercusier 6.2 mpi trottle body gasket
mercruiser 5.0 trottle body diagram
1988 mercruiser 4.3l throttle lever
1988 mercruiser quicksilver throttle control for alpha 1
1992 mercruiser 5.0 overheats when full throttle
1992 mercruiser throttle control replacement
4.3 mercruiser runs hot at full throttle
how do i adjust the throttle on a 1998 sea ray 4.3l mercruiser alpha 1
how does the linkage for a mercruiser throttle body go together
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mercruiser 3.0 overheating when opening up throttle
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mercruiser 5.0 efi throttle body fuel pressure sensor
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mercruiser 6.2 problems when throttle
mercruiser controller 1995 4x3l throttle control how to remove?
mercruiser horizon 8.1 throttle position sensor
mercruiser iac throttle body connector
mercruiser inboard throttle
mercruiser overheating at full throttle
mercruiser throttle control alpha one gen 2
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mercruiser5.7 surge in throttle

Wednesday, January 8, 2014

MerCruiser Inboard Starter Service & Repair 2001-2006 5.0L 5.7L 6.2L

The following information covers factory service procedures for servicing the starter on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 2001 2002 2003 2004 2005 and 2006 models.

INBOARD AND TOW SPORTS (MIE)

350 MAG MPI Inboard
350 MAG MPI Horizon Inboard
MX 6.2 MPI Inboard
MX 6.2 MPI Horizon Inboard
350 MAG MPI Tow Sports

STERNDRIVE MCM

5.0L V8 MPI Alpha and Bravo
350 MAG MPI Alpha and Bravo
350 Mag MPI Alpha and Bravo Horizon
MX 6.2L MPI
MX 6.2L MPI Horizon

STARTER REMOVAL

WARNING: Always disconnect both the battery cables from the battery before serving your engine. Removing battery cables can prevent electrical shock and a ignition source for collecting fumes.

1. Remove the battery cables from the battery.

2. Remove the wires from the solenoid terminals.

3. Remove the mounting bolts from the starter.

4. Remove the starter assembly from the engine.

SOLENOID SWITCH

The solenoid switched on the starter can be removed if it is damaged or defective. Replace if necessary.

1. To remove the solenoid switch, take off the three fasteners that retain the solenoid. Then, remove the solenoid from the drive housing.

INSPECTION

The solenoid and cranking motor are enclosed in the drive housing, this prevents moisture and debris from entering. However, its important to routinely inspect it in the following order:

1. Check the terminals for tightness and corrosion.

2. Check for damaged or frayed wires and any bad insulated wires.

3. Inspect the starter mounting bolts and make sure there tightened.

INSTALLATION

NOTE: On some models, a special mooting shim may be equipped. Install the mounting shim between the engine block and starter motor.

1. Align the starter motor into position and reinstall the bolts.

Torque Specifications: Starter motor mounting bolts 41 Nm (30 lb-ft)

2. Attach the yellow/red wire to the upper solenoid terminal. Attach the red wire, the orange wire and the battery cable to the lower solenoid terminal. Apply sealant (Liquid Neoprene, part number 92-25711-3) to the terminals and install the battery cable boot, if equipped.

Torque Specification PG 260 Series:

Battery Terminal: 9.5 Nm (84 lb-in)
Switch Terminal: 2.3 Nm (20 lb-in)
Resistor Terminal 2.3 Nm (20 lb-in)
External Thru-bolt 4.6 Nm (41 lb-in)
All Other Fasteners: Tighten Securely

Torque Specification 14MT:

Battery Terminal: 10.3 Nm (91 lb-in)
Switch Terminal: 2.3 Nm (20 lb-in)
Resistor Terminal: 2.3 Nm (20 lb-in)
All Other Fasteners: Tighten Securely

3. Reconnect the positive (+) battery cable to the positive (+) battery terminal and tighten down the cable clamp.

4. Reconnect the negative (-) battery cable to the negative (-) battery terminal and tighten down the clamp.

MerCruiser Starter Repair Manuals

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MerCruiser Engine Wont Start - Troubleshooting Manual

MerCruiser troubleshooting can determine faults and help correct mechanical or electrical system problems. This troubleshooting guide will focus on actions needed to correct engine won't start issues for MerCruiser Inboards.

The following is a check list of probable causes, but keep in mind, more than one of these conditions could be present.

MerCruiser Wont Crank Over

Key features of interest will be focused on failure to start due to:

Remote control lever
Battery
Circuit breaker
Fuse
Ignition switch
Slave solenoid
Safety switch
Starter solenoid
Starter motor
Engine malfunction

1. Check the remote control lever to assure its not set in the neutral position.

2. Battery may not be charged properly, check charge. Inspect for damaged wiring, corrosion or corroded terminals and loose electrical connections.

3. Inspect the circuit break to see if its been tripped.

4. Examine fuses for a blown fuse.

5. Examine for bad or faulty ignition switch.

6. Check slave solenoid.

7. Check for a faulty natural safety switch, possible open circuit.

8. Is the starter solenoid bad? Replace if necessary.

9. Is the starter motor bad? Replace if necessary.

10. Thoroughly check for any other mechanical engine malfunctions.

Other Symptoms may include:

mercruiser wont turn over
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boat will not start

MerCruiser Inboard Engine Models

GM V8 305-350-454-482-540 CID
D1.7L DTI
In-ine Diesel D2.8L D4.2L D-Tronic Manual
496 Mag HO 8.1S Horizon HO
GM V8 454 cid 7.4L 502 cid 8.2L
4.3L MPI Alpha and Bravo
3.0L & 3.0LX
4 Cylinder
305 CID 5.0L 350 CID 5.7L 6.2L
GM 6-Cylinder Engines

While this guide was written to help you diagnose problems with wont start issues. Its recommended you refer to the factory service manual before performing any work. Improper service or repairs can magnify existing issues. Also, MercCruiser repair manuals may contain more detail information including important safety notations or warnings.

MerCruiser Starting Issues

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2000 mercruiser 5.7 starter wiring diagram
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MerCruiser Electronic Control Module (ECM) 2001-2006 5.0 5.7 6.2

The following information covers factory service procedures for electronic control module (or ECM) on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 2001 2002 2003 2004 2005 and 2006 models.

STERNDRIVE MCM

5.0L V8 MPI Alpha and Bravo
350 MAG MPI Alpha and Bravo
350 Mag MPI Alpha and Bravo Horizon
MX 6.2L MPI
MX 6.2L MPI Horizon

INBOARD AND TOW SPORTS (MIE)

350 V8 5.7L MAG MPI Inboard
350 V8 MAG MPI Horizon Inboard
MX 6.2 Multi-Port Injection Inboard
MX 6.2 MPI Horizon Inboard
350 MAG MPI Tow Sports

ECM REMOVAL

IMPORTANT: The ECM is a very sensitive piece of electrical equipment and is subject to electrostatic damage. Never touch the connector pins when installing or removing the electronic control module.

1. Detach the electrical connectors on the ECM. Never touch the connector pins.

2. Take off the ECM from the module bracket.

ECM CLEANING AND INSPECTION

1. Clean the outer exterior of the ECM with a dry and clean shop towel. Do not touch the touch or come in contact with the connector pins.

2. Check the outer housing for signs of excessive wear, corrosion or damage.

3. Carefully inspect the electrical pins at both ends of the ECM for corrosion and straightness.

4. Carefully inspect the wiring harness connectors for signs of corrosion and terminals for loose connections.

NOTE: The ECM is a designed to be a sealed electrical device, if the item appears to be damaged, replace the ECM.

ECM INSTALLATION

1. Install the ECM back on the module bracket using the existing washers and brackets.

2. Reconnect the ECM wiring harness connectors, never touch the connector pins.

ECM MerCruiser

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MerCruiser Alternator Service & Repair 3.7 4.3 5.0 5.7 6.2L

The following information covers factory service procedures for servicing the alternator on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 and 2006 models.

STERNDRIVE MCM

5.0L V8 MPI Alpha and Bravo
350 MAG MPI Alpha and Bravo
350 Mag MPI Alpha and Bravo Horizon
MX 6.2L MPI
MX 6.2L MPI Horizon

INBOARD AND TOW SPORTS (MIE)

350 MAG MPI Inboard
350 MAG MPI Horizon Inboard
MX 6.2 MPI Inboard
MX 6.2 MPI Horizon Inboard
350 MAG MPI Tow Sports

ALTERNATOR REMOVAL

WARNING: Always remove both battery cables from the battery before servicing your engine. Failure to remove cables can lead to shock and ignition of accumulated ignitable fumes or materials.

1. Remove the positive and negative cables from the battery.

2. Remove the lead and ground wires.

3. Remove the excitation wire.

4. Remove the drive belt.

5. Take off the alternator mounting bolts including washers.

6. Take off the alternator.

ALTERNATOR BRACKET REMOVAL

1. Drain the cooling system fluid.

2. Take off the water circulating pump hose.

3. Take off the bracket.

ALTERNATOR BRACKET INSTALLATION

1. Reinstall the alternator bracket.

Torque Specifications: Alternator Mounting Bracket 41 Nm (30 lb-ft)

2. Reinstall the water circulating pump hose and tighten the hose clamps securely.

ALTERNATOR INSTALLATION

1. Reinstall the idler brace.

2. Place the alternator in the alternator mounting bracket.

3. Reinstall the mounting bolts and torque to specifications.

Torque Specifications: Mounting Bolts M8 x 1.25 11 Nm (8 lb-ft)

4. Reinstall the alternator drive belt on the pulleys and adjust the tensioner.

5. Connect the wiring harness to the alternator.

6. Reconnect both the negative and positive cables to the battery.

7. Fill the cooling system with the proper fluid.

MerCruiser Alternator Searches

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MerCruiser Water In Engine Crankcase Oil

The following information contains testing procedures for water in the engine on MerCruiser 5.oL, 5.7L and 6.2L MPI gasoline engines. Testing and diagnosis helps determine problems and possible causes. Its recommended you use a factory manual when performing repairs on your inboard engine, additional safety precautions, or technical data maybe included.

Important Information

IMPORTANT: First determine the location of the water in the 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 the pistons, water in the crankcase oil and when both of those conditions occur simultaneously.

After locating the water, remove all the water from the engine by removing all the spark plugs and cranking the engine over to pump out the cylinders.
Change the oil and the filter.
Start the engine and see if the problem can be duplicated. If the problem can be duplicated, a mechanical error exists. If the problem can not be duplicated, the problem is either an operator error or a problem that exists only under certain environmental conditions.

If the water is contained to the cylinders only, it is usually entering through the intake system, the exhaust system or the head gasket.

If the water is contained to the crankcase only, it is usually caused by a cracked or porous block, a flooded bilge or condensation.

If the water is located in both the cylinders and the crankcase, it is usually caused by water in the cylinders getting past the rings and valves or complete submersion.

Checking for rust in the intake manifold or the exhaust manifolds is a good idea. Rust is a clue that the water entered these areas.

WATER IN CRANKCASE OIL

CAUSES:

2.0 Water in boat bilge

2.1 Water seeping past the piston rings or valves

2.2 Engine operating cold

2.3 Intake manifold leaking near a water passage

2.4 Cracked or porous casting

ACTIONS NEEDED

2.0 Drain the water from the bilge. 2.1 Replace the piston rings or the valves

2.2 Replace the thermostat.

2.3 Inspect the intake manifold for cracks. Check the gaskets.

2.4 Check the cylinder head, the cylinder block and the intake manifold for cracks or porosity.

These service procedures apply to: 2001 2002 2003 2004 2005 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Gasoline Multi-port Injection Engine.5.0L MPI Alpha and Bravo, 350, MX 6.2 MPI Horizon, Inboard and Tow Sports (MIE), 350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI MAG MPI Tow Sports.

MerCruiser Water in Crankcase Searches

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MerCruiser Engine Identification 5.0 5.7 6.2L 2001 2002 2003 2004 2005 2006

The Mercury/MerCruiser engine model can be determined by examining the last two or three letters of the engine code. The engine code (also known as the identification/serial number) is typically located on the front top face (slightly to the left) of the engine. This code is stamped on all Mercury MerCruiser power packages and replacement partial engines, but not replacement engine block assemblies.

If the motor serial number and/or model decals are missing or removed, the engine code letters will provide a clue in determining the engine model. The following information is a list of Mercury MerCruiser motors and their respective GM code letters.

STERNDRIVE (MCM) CODE

5.0L MPI Alpha and Bravo - 2ZB
350 MAG MPI Alpha and Bravo - 2MN
350 MAG MPI Alpha and Bravo Horizon - 2MN
MX 6.2 MPI - 2MNB
MX 6.2 MPI Horizon - 2MNB

INBOARD (MIE) CODE

350 MAG MPI Inboard - 2ML
350 MAG MPI Horizon Inboard - 2ML
MX 6.2 MPI Inboard - 2MLB
MX 6.2 MPI Horizon Inboard - 2MLB

TOW SPORTS CODE

350 MAG MPI Tow Sports - 2MN

MerCruiser application: 2001 2002 2003 2004 2005 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Gasoline Fuel Injection Engine, 5.0L MPI, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Tow Sports (MIE), 350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports.

MerCruiser Serial Number Identification

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MerCruiser Power Trim Wiring Diagram 3.0 5.0L 5.7L 6.2L

The following power trim system wiring diagram details is for 2001 2002 2003 2004 2005 and 2006 MerCruiser 5.0L, 5.7L and 6.2L MPI engines. Some models may differ. Always use are repair manual anytime your servicing your MerCruiser or components.

Models these procedures apply to:

Sterndrive (MCM)

5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon

Inboard and Tow Sports (MIE)

POWER TRIM SYSTEM WIRE DIAGRAM

350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard, 350 MAG MPI Tow Sports.

20 Amp Fuse

The solid red wire is attached to the 20 amp fuse and leads to the DOWN solenoid. From the DOWN solenoid the red wire leads to the 12V battery.

Ground Bolt (Floor Mount)

The solid black wire connects to the floor mounted ground bolt. It also leads to the UP and DOWN solenoid and the 12 V battery.

UP Solenoid

The solid black wire leads into the UP solenoid and the down solenoid. Also attaches to the 12 V battery and the floor mounted ground bolt. One blue/white wire comes out of the UP solenoid and travels to the the trim limit switch. The blue/white also travels to the forward, neutral and reverse control handle.

110 Amp Fuse

A green/white wire comes out of the 110 amp fuse and travels to the forward, neutral and reverse control handle.

DOWN Solenoid

A green and white/white comes out of the DOWN solenoid and travels to another component not directly related to the function of the DOWN solenoid.

Trailer Switch

Trailer switch wires likely purple/white, red/purple, green/white and blue/white. Green/white leads to 110 amp fuse. Red/purple leads to 20 amp fuse. Blue/white leads to trim switch and DOWN solenoid.

Neutral Switch to Instrument Wiring Harness

Yellow/red wire leads to instrument wiring harness.

Trim Limit Switch

Two black wires come out of the trim limit switch which lead to connectors that attach the blue/white wires, and the other connection connects the black wire from trim limit switch to purple/white wire.

MerCruiser Power Trim Diagram Searches

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