MOE merCruiser SERVICE MANUAL Number 2 Stern Drive Units and Marine Engines Sections 1 thru 10 Printed in U.S.A.OMa __, OUTLINE - merCruIzef SERVICE MANUAL Section 1 - General Information 1A - General Information 1B - Tuneup 1C - Lubrication Section 2 - Removal/installation/Alignment 2A - MerCruiser 120-140-165-470 2B - MerCruiser V-8 I-Drive Models 2C - MerCruiser I-TR and II-TRS Stern Drive 2D - General Installation Section 3 - Electrical System 3A - Starting System 38 - Ignition System 3C - Alternator System 3D - Instrumentation 3E - Wiring Diagrams Section 4 - Fuel System 4A - Fuel Pumps 48 - Carburetors Section 5 - Engine 5A - Engine Mechanical, In-Line 5B - Engine Mechanical, V-8 Ford 5C - Engine Mechanical, V-8 GM 5D - Engine Mechanical, 470 Model Section 6 - Drive Systems 6A - MerCruiser I Drive Unit 68 - MerCruiser II-TR Drive Unit 6C - MerCruiser I-TRS Drive Unit 6D - Direct Drive Transmission 6E - MerCruiser I-TR and I-TRS Transmission Section 7 - Accessories 7A - Power Trim System 7B - Steering Systems 7C - Remote Controls 7D - Cooling 7E - General Accessories Section 8 - Specifications 8A - Tune-Up and General B - Internal Engine &C - Torqure Specs 8D - Propeller Chart Section 9 - 400 Jet Drive Section 10 - TroubleshootingMODELS COVERED IN THIS MANUAL MERCRUISER STERN DRIVE ENGINES (MCM) TRANSOM ASSEMBLY AND STERN DRIVE UNITS Model ‘Serial Number Model Serial Number MCM 420 3770650 - 4952700 MC 120/140 3780850 - 4893604 MCM 140 3771645 - 4918569 MC 165 [___3780850 - 4890450 MCM 165 374865 - 4884834 MC 470 4893834 and Below MCM 470 4886619 and Below MC 888 3784975 and Above MCM 888 3777490 and Above MC 225 5) All MCM 698 4887829 and Below MC 233 All MOM 225 § (Ford) All MC 898/228 4898729 and Below MOM 225TR (Ford) 379775 and Above MO 250 ‘Al MCM 228 4902304 and Below MC TR 13787240 - 5009866 MCM 228TR. All Mo TRS, 4895289 and Below MOM 233. All MC Jet Drive All MCM 250 (350 CID) ‘4768000 and Above MOM 255 (Ford) ‘3838788 and Above MOM 25 (GM) 4175500 and Above CM 280 All MCM 330. 4889679 and Below 400 Jet All MERCRUISER INBOARD ENGINES (MIE) Model Serial Number Mie 198 All MIE 225 (Ford) 3750508 and Above MIE 228 4931099 and Below MIE 233 All MIE 255 (Ford) 3839488 and Above MIE 255 (G.M.) 4924564 and Below MIE 330 4890179 and Below MIE 350 AllNotice to Users of This Manual This service manual has been written and published by the service department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein Itis assumed that these personnel are familiar with the servicing procedures of these products, or like or sim- ilar products manufactured and marketed by Mercury Marine. That they have been trained in the recom- mended servicing procedures of these products which includes the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers. ‘We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses 4 service procedure and/or tool, which is not recom- mended by the manufacturer, first must completely satisfy himself that neither his nor the product's safety will be endangered by the service procedure selected. All information, illustrations and specifications con- tained in this manual are based on the latest product information available at time of publication It should be kept in mind, while working on the pro- duct, that the electrical system and ignition system is capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note that, during any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of the metric bolts and on surfaces of metric nuts indi- cate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfuction, or possibly per- sonal injury. Therefore, fasteners removed should be saved for re-use in the same locations whenever possi- ble. Where the fasteners are not satisfactory forre-use, care should be taken to select a replacement that ‘matches the original.Replacement Parts AWARNING Electrical, ignition and fuel system components on MerCruiser Engines and Stern Drives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel sys- tems, it is extremely important that all components are properly installed and tightened. If not, any electrical orignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Engine Mechanical Components Many of the engine mechanical components are de- signed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle opera~ tion, therefore, require heavy-duty components. Spe- cial marine engine parts have design and manufactur- ing specifications which are required to provide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of saltor brackish water that will rust or corrode standard auto- motive parts within a short period of time. Failure to use recommended Quicksilver service re- placement parts can result in poor engine performance and/or durabiltiy, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replace- ment parts will void the warranty on those parts which are damaged as a result of the use of other than recommended parts.GENERAL INFORMATION ee MERCRUISER Section 1 See, a WERE MRE 0 Grew a te rata Card UTABLE of CONTENTS How to Use This Manual Page Numbering Directional References ....... Engine Rotation Terminology Engine Identification .. Engine Serial Number Location Stern Drive Serial Number Location. Flushing Cooling System .. Winter Storage-Marine Engines . Winter Storage of Batteries ... Returning Engineto Service Winter Storage ~Stern Drive Units . PowerTrim Operation. . Pre-ignition and Detonation TrimTab . MerCruiser Fuel System . Propellers .. Tune-Up ....-. : Description Compression Test Spark Plugs Ignition System aa Carburetor Adjustment .. Throttle Cable Adjustments, Fuel Pump Pressure Test . Battery and Battery Cables. Valve Adjustment . Manifold . Crankcase Ventilation . Lubrication . Lubricant ang Maintenance Chart. Stern Drive Lubricant Capacities Engine Lubrication Oil Selection Draining Engine Oil Filling Engine Crankcase . Maintaining Oil Level . OilFitter . Components ... Stern Drive Lubrication . Checking Lubricant Level Draining and Filling Drive Unit .. Points of Lubrication ......SECTION 1 - GENERAL INFORMATION = merCruizer PART A - GENERAL INFORMATION 1 7 ™* A BRUNSWICK COMPANYINDEX Page How to Use This Manual me At Page Numbering z 1A Directional References . en 1A2 Engine Rotation Terminology ...... 1A2 Engine Identification = 1A2 Engine SerialNumber Location... 13 120-140-165 oes eeeeesee Pe er) 888 and 225-S 1A 233, 225 IF-TR and 255 IL-TR and 256 I-TRS with Serial No. 4175499.and Below .... 14-3 255 (Serial No. 4175500 and Above), 390, 360 and 400 Series Jet . = 1A8 470 : Be. 10-8 898, 228, 228-TR, 250 (Serial No. 4657551 and Above), 280-TRS, 330-TR, 330-TRS. vases TAA Stern Drive Serial Number Location. 1A EDrive . 1A I-TRandI-TRS 1A Flushing Cooling System 1AS MerCruisers with Water Pump Located in Drive Unit | 1A-S MerCruisers with Engine Driven Pickup Water Pump. 1A-5 Winter Storage-Marine Engines... 1A6 120-140-165 1A6 V-8 Models emit cee TAS: Winter Storage of Batteries ........... sss se sce TAT Returning Engine toService............200+ 1A? Winter Storage-Stern Drive Units ... 1A8 EDrive a a As TETRangI-TRS ssc sc. 1A8 Power Trim Operation 1A8 Operating 3-Switch Control 1A Operating 2-Switch Control ........... = 1A8 Indicator Readjustment 1A8 Pre-Ignition and Detonation m5 = 110 Pre-ignition ....... ee 1As10 Pro-ignition Causes . = 1A10 Detonation .. Ags sees TAO Other Causes of Detonation... 1A10 Trim Tab 1A-10 Removaland Replacement. 1A40 ‘Trim Tab Adjustment 3 1A MerCruiser Fuel System ; i 1A Fuel Tank- Cautions : 1A Fuel Lines-Length and Sizes . oe 1A Propellers .. = tAn2 How Does Propeller Work? . rer) Rotation 1As2 Propeller Diameter . 1As2 Propeller Pitch ES ooh 1A12 PropellerSlip .........0+ seo WAM, Cavitation 2 WA12 Cupped Propeller . ee 1A12 Twoand Three-BladePropellers.......s0. 000... TAN Correct Propeller? ..... 1A13