Service Manual Outline

SECTION 1 - Important Information

A - General Information
B - Maintenance
C - Troubleshooting
SECTION 2 - Removal and Installation
A - MCM (Stern Drive) Models
B - MIE (Inboard) Models
SECTION 3 - Engine
A - All Models
SECTION 4 - Electrical Systems
A - Starting System
B - Glow Plug System
C - Charging System
D - Instrumentation
E - Wiring Diagrams
SECTION 5 - Fuel System
A - Fuel Delivery Pump and Fuel Filter
B - Injection Pump
C - Fuel Injectors
SECTION 6 - Cooling System
A - Seawater Cooled Section
B - Closed Cooled Section
SECTION 7 - Intake and Exhaust System
A - Intercooler
B - Intake / Exhaust System
C - Turbocharger
SECTION 8 - Drive Systems
A - Hurth Down Angle Transmission
B - Hurth V-Drive Transmission
C - Propeller Shaft Models
SECTION 9 - Power Steering
A - Pump and Related Components

iv 90-806934 1194
Notice
Throughout this publication, “Dangers,” “Warnings”
and “Cautions” are used to alert the mechanic to spe-
cial instructions concerning a particular service or op-
eration that may be hazardous if performed incorrect-
ly or carelessly. Observe them carefully!
These “Safety Alerts” alone cannot eliminate the haz-
ards that they signal. Strict compliance to these spe-
cial instructions when performing the service, plus
“common sense” operation, are major accident pre-
vention measures.
! DANGER
DANGER - Immediate hazards which will result in
severe personal injury or death.
! WARNING
WARNING - Hazards or unsafe practices which
could result in severe personal injury or death.
! CAUTION
CAUTION - Hazards or unsafe practices which
could result in minor personal injury or product
or property damage.
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 per-
sonnel when servicing the products described here-
in.
It is assumed that these personnel are familiar with
the servicing procedures of these products, of like or
similar products manufactured and marketed by Mer-
cury Marine, and that they have been trained in the
recommended servicing procedures for these prod-
ucts which include the use of mechanic’s common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
90-806934 1194
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone
who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first
must completely satisfy himself that neither his nor
the product’s safety will be endangered by the ser-
vice 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 prod-
uct, that the electrical system is capable of violent
and damaging short circuits or severe electri-
cal shocks. When performing any work where electri-
cal terminals could possibly be grounded or touched
by the mechanic, the battery cables should be dis-
connected 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 inter-
nal damage when the engine is started.
It is important to note that, during any mainte-
nance procedure, replacement fasteners must have
the same measurements and strength as those re-
moved, whether metric or customary. Numbers on
the heads of the metric bolts and on surfaces of met-
ric nuts indicate their strength. Customary bolts use
radial lines for this purpose, while most custom-
ary nuts do not have strength markings. Mismatched
or incorrect fasteners can result in damage or mal-
function, or possible personal injury. Therefore, fas-
teners removed should be saved for re-use in the
same locations whenever possible. Where the fas-
teners are not satisfactory for re-use, care should be
taken to select a replacement that meets the
same specifications as the original.
i
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 and, therefore, require heavy-duty components.
Special marine engine parts have design and man-
ufacturing specifications which are required to pro-
vide long life and dependable performance. Marine
engine parts also must be able to resist the corrosive
action of salt or brackish water that will rust or corrode
standard automotive parts within a short period of
time.
Failure to use recommended Quicksilver service re-
placement parts can result in poor engine perform-
ance and/or durability, rapid corrosion of parts sub-
jected to salt water and possibly complete failure of
the engine.
Use of parts other than recommended service re-
placement parts, will void the warranty on those parts
which are damaged as a result of the use of other
than recommended replacement parts.
ii
Replacement Parts
! WARNING
Electrical and fuel system components on Mer-
Cruiser 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 or fuel system com-
ponents, 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 and fuel systems,
it is extremely important that all components are
properly installed and tightened. If not, any elec-
trical component opening would permit sparks to
ignite fuel vapors from fuel system leaks, if they
existed.
90-806934 1194
 In-Line Diesel Models Covered in This Manual

MCM (Stern Drive) MODEL SERIAL NUMBER

D3.0L/150 D0725150 and Above
D3.6L/180 D0850125 and Above
D4.2L/220 D0554730 and Above

MIE (Inboard) MODEL SERIAL NUMBER

D3.0L/150 D0725150 and Above
D3.6L/180 D0850125 and Above
D4.2L/220 D0554730 and Above

NOTICE
Refer to appropriate “Stern Drive Service Manual”
for Transom Assembly and Stern Drive Unit Repair.

90-806934 1194 iii

IMPORTANT INFORMATION
1
A

72000

GENERAL INFORMATION
Note: Refer to the following Service Bulletins regarding this section.

SB 97-13 Service/Repair of Electrical Test Equipment

SB 96-13 Official Recall Notification Federal Boat Safety Act
Commander 3000 Remote Control
SB 96-5 Troubleshooting Shift Problems
SB 95-2 Oildyne Trim Pump Adaptor Connectors
SB 91-14 Replacement Trim Pump for the Prestolite Style Pump

INDEX
Table of Contents
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
How to Read Parts Manual . . . . . . . . . . . . . . . . . . . . 1A-2
Directional References . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Engine Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Engine Serial Number and Identification Locations 1A-3
Propeller Information . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Water Testing New Engines . . . . . . . . . . . . . . . . . . . . 1A-4
Boat and Engine Performance . . . . . . . . . . . . . . . . . . 1A-5
Boat Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Marine Fouling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Weight Distribution . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Water in Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Elevation and Climate . . . . . . . . . . . . . . . . . . . . . . 1A-6
Recommended Operation/Duty Cycle . . . . . . . . 1A-7
Pre-Lubricating Turbocharger . . . . . . . . . . . . . . . . . . 1A-7

NOTICE
For information and procedures on troubleshoot-
ing, refer to SECTION 1C.

NOTICE
Refer to appropriate Stern Drive Service Manual
for transom assembly and stern drive unit repair.

1A – –
1A-0 GENERAL INFORMATION
GENERAL INFORMATION 90-806934 1194
INDEX
Introduction Page Numbering
This comprehensive overhaul and repair manual is Two number groups appear at the bottom of each
designed as a service guide for the models previously page. Following is an example and description.
listed. It provides specific information, including pro-
cedures for disassembly, inspection, assembly and
adjustment to enable dealers and service mechanics
to repair and tune these engines.
Before attempting repairs, it is suggested that the pro-
cedure first be read through to gain knowledge of the
methods and tools used and the cautions and warn-
ings required for safety.
90-806934 1-794

How to Use This Manual

This manual is divided into sections which represent
major components and systems.
72426
Some sections are further divided into parts which
more fully describe the component.

90-806934 1194 GENERAL INFORMATION – 1A-1

INDEX
How to Read Parts Manual
NOTE: The following is represen-
tative of a page from a MerCruiser
Parts Manual and is not intended
to be an actual page from a specif-
ic Parts Manual.

73287

a b
c CYLINDER BLOCK AND CAMSHAFT
M0033-D8
REF. d
PART NO. NO. DESCRIPTION QUAN.
841-81631 1 CYLINDER BLOCK ASSEMBLY 1
N.S.S. 2 PLUG, expansion (1-1/4″) (GM #3738306) 2
22-87238 3 DRAIN COCK, cylinder block 2
19-34270 4 PLUG, expansion - cylinder block (1-5/8″ Diameter) 8
17-35465 5 PIN, dowel - block to head (5/16″ Diameter) 4
22-72640 6 PLUG, expansion - camshaft bearing hole 1
23-85674 7 BEARING UNIT, camshaft (set) 1
72638 8 LIFTER, hydraulic valve 16
431-5943 9 CAMSHAFT 1
35378 10 CHAIN, camshaft timing 1
43-35338 11 SPROCKET, camshaft timing 1
43-48338 12 SPROCKET, crankshaft timing 1
10-34505 13 BOLT, camshaft timing sprockets (3/4″) 3
12-39167 14 WASHER, camshaft timing sprocket bolt 3

841-8163 Cylinder Block Assembly includes only standard pistons,

piston rings, crankshaft bearings and camshaft bearings.
e
A. Part Number: For part ordering - Note N.S.S. for Reference Number 2, Plug, expansion - that means Not Sold Separately by Mercury Marine; however,
in this case, the G.M. Part Number (for the plug) is given in the Description Column.
B. Reference Number: For part shown on exploded parts view.
C. Description: This is the most important column because it gives:
1) Description of Part: Ref. No. 1 is a Cylinder Block Assembly, No. 9 is a Camshaft, etc.
2) What parts are included with a certain part: Notice how the Description of Part, for Ref. Nos. 1 and 8 through 14, are at the left side of the column.
Description of Part for Ref. Nos. 2 through 7 are indented under “Cylinder Block Assembly.” If Ref. No. 1 (Cylinder Block Assembly) was ordered,
all indented parts (Ref. Nos. 2 through 7) would come with the part. Ref. Nos. 8 through 14 would not come with Ref. No. 1 and would have to be
ordered separately. If two Cylinder Blocks were listed, both cylinder blocks would come with the indented parts. In some cases, an indented part
will have another part indented under it. The second indented part will come with the first indented part.
3) Serial number break: If serial number information is listed, check product serial number to ensure that correct part is ordered.
4) Special information: Many times special information will be shown after description, such as: L.H. Rotation, R.H. Rotation, Filter Up, Filter Down,
etc. This will help in selecting the correct part.
D. Quantity: Quantity that has to be ordered.
E. Special Information Block: Additional information, part numbers for gasket sets, etc.

1A-2 – GENERAL INFORMATION 90-806934 1194

INDEX
Directional References Engine Rotation
Front of boat is bow; rear is stern. Starboard side is Engine rotation is determined by observing flywheel
right side; port side is left side. In this maintenance rotation from the rear (stern end) of the engine looking
manual, all directional references are given as they forward (toward water pump end). Propeller rotation
appear when viewing boat from stern looking toward is not necessarily the same as engine rotation. When
bow. ordering replacement engine, short blocks or parts
for engine, be certain to check engine rotation. Do not
STARBOARD AFT or STERN rely on propeller rotation in determining engine rota-
(RIGHT) (REAR) tion.

FORE or BOW PORT

(FRONT) (LEFT)

72000

73330
a - Standard Left-Hand Rotation

Engine Serial Number and Identification Locations

Engine model and serial numbers are located on two plates attached on the engine where shown. Emission Certifi-
cation Decals are placed where shown.

MIE (Inboard) Engine Shown [MCM (Stern Drive) Similar]

THIS ENGINE
CONFORMS TO INT’L
BODENSEE SHIPPING D3.6L/180 TURBO AC
COMISSION STDS
CERT NO.
M12 11 3 93 _ _ c b
c
BSO:
M12 11 3 93_ _

b 71675 a 71688

d 73565

a - Riveted Serial Number Plate, and Emission Certification Decal If Applicable (Port Side of Engine Block, Near Top of Electrical Box)
b - Self-Adhesive Serial Number Plate (Applied to Top of Intercooler Duct)
c - Self-Adhesive Emission Certification Decal, If Applicable (Applied to Top of Intercooler Duct)
d - VM Serial Number (Stamped in Block)

90-806934 1194 GENERAL INFORMATION – 1A-3

INDEX
Propeller Information Water Testing New Engines
Refer to the “Propeller” section in appropriate Mer- Use care during the first 20 hours of operation on new
Cruiser Stern Drive Service Manual, or order publica- MerCruiser engines or possible engine failure may
tion P/N 90-86144-92, “Everything you need to know occur. If a new engine has to be water-tested at full
about propellers.” throttle before the break-in period is complete, follow
this procedure ONLY AFTER the engine INITIAL
Changing diameter, pitch or coupling of a propeller
BREAK-IN PROCEDURE has been completed.
will affect engine RPM and boat performance . The
blade configuration also will affect performance. Two 1. Start engine and run at idle RPM until normal op-
like propellers, same pitch and diameter, from two dif- erating temperature is reached.
ferent manufacturers also will perform differently.
2. Run boat up on plane.
It is the responsibility of the boat manufacturer and/or
3. Advance engine RPM (in 200 RPM increments)
selling dealer to equip the boat with the correct pro-
until engine reaches its maximum rated RPM.
peller to allow the engine to operate within its speci-
fied RPM range at wide-open-throttle (W.O.T.). IMPORTANT: Do not run at maximum RPM for
more than 2 minutes.
Because of the many variables of boat design and op-
eration, only testing will determine the best propeller
for the particular application.
To test for correct propeller, operate boat (with an
average load onboard) at W.O.T. and check RPM with
an accurate tachometer. Engine RPM should be near
top of the specified range so that, under heavy load,
engine speed will not fall below specifications.
If engine exceeds the specified RPM, an increase in
pitch and/or diameter is required.
If engine is below rated RPM, a decrease in pitch and/
or diameter is required.
Normally, a change of approximately 100 to 150 RPM
will be achieved for each single pitch change of a pro-
peller.
! CAUTION
If a propeller is installed that does not allow en-
gine RPM to reach the specified full-throttle RPM
range, the engine will “labor” and will not pro-
duce full power. Operation under this condition
will cause excessive fuel consumption and en-
gine overheating. On the other hand, installation
of a propeller, that allows engine to run above the
specified RPM limit, will cause excessive wear on
internal engine parts which will lead to premature
engine failure.

1A-4 – GENERAL INFORMATION 90-806934 1194

INDEX
Boat and Engine and reduces any porpoising (rhythmical bouncing)
tendency. A slight hook is often built in by the man-
Performance ufacturer. A hook also can be caused by incorrect
trailering or storing the boat with support directly un-
der the transom.
Boat Bottom
For maximum speed, a boat bottom should be as flat
as possible in a fore-aft direction (longitudinally) for
approximately the last 5 ft. (1.5 m).

72004
a - Hook

A “rocker” is the reverse of a hook. The bottom is con-

72002 vex or bulged in the fore-and-aft direction. It can
a - Critical Bottom Area cause the boat to porpoise.

For best speed and minimum spray, the corner be-

tween the bottom and the transom should be sharp.

72005

a - Rocker

Any hook, rocker or surface roughness on the bottom,

72003
particularly in the all-important center-aft portion will
a - Flat have a negative effect on speed, often several miles
b - Sharp Corner
per hour on a fast boat.
The bottom is referred to as having a “hook” if it is con-
cave in the fore-and-aft direction. A hook causes
more lift on the bottom near the transom and forces
the bow to drop. This increases wetted surface and
reduces boat speed. A hook, however, aids in planing

90-806934 1194 GENERAL INFORMATION – 1A-5

INDEX
Marine Fouling
Fouling is an unwanted build-up (usually animal-veg-
etable-derived) occurring on the boat’s bottom and
drive unit. Fouling adds up to drag, which reduces
boat performance. In fresh water, fouling results from
dirt, vegetable matter, algae or slime, chemicals, min-
erals and other pollutants. In salt water, barnacles,
moss and other marine growth often produce dramat-
ic build-up of material quickly. Therefore, it is impor-
tant to keep the hull as clean as possible in all water
conditions to maximize boat performance.
Special hull treatments, such as anti-fouling paint, will
reduce the rate of bottom fouling. However, due to the
fact that drive units (outboard or stern drive) are made
primarily of aluminum, be sure to select an anti-foul-
ing paint having a copper-free, organo-tin base. The
BIS (Tri Butyl Tin) Adipate (TBTA) base paint will not
set up a galvanic corrosion “cell” as it is completely
compatible with aluminum and avoids any electroly-
sis problems connected with many other paints.
Applied according to instructions, it also is very effec-
tive.
Weight Distribution
Weight distribution is extremely important; it affects a
boat’s running angle or attitude. For best top speed,
all movable weight - cargo and passengers - should
be as far aft as possible to allow the bow to come up
to a more efficient angle (3 to 5 degrees). On the neg-
ative side of this approach is the problem that, as
weight is moved aft, some boats will begin an unac-
ceptable porpoise.
Secondly, as weight is moved aft, getting on plane be-
comes more difficult.
Finally, the ride in choppy water becomes more un-
comfortable as the weight goes aft. With these factors
in mind, each boater should seek out what weight lo-
cations best suit his/her needs.
Weight and passenger loading placed well forward in-
creases the “wetted area” of the boat bottom and, in
some cases, virtually destroys the good performance
and handling characteristics of the boat. Operation in
this configuration can produce an extremely wet ride,
from wind-blown spray, and could even be unsafe in
certain weather conditions or where bow steering
may occur.
1A-6 – GENERAL INFORMATION
INDEX
Weight distribution is not confined strictly to fore and
aft locations, but also applies to lateral weight distri-
bution. Uneven weight concentration to port or star-
board of the longitudinal centerline can produce a se-
vere listing attitude that can adversely affect the
boat’s performance, handling ability and riding com-
fort. In extreme rough water conditions, the safety of
the boat and passengers may be in jeopardy.
Water in Boat
When a boat loses performance, check bilge for wa-
ter. Water can add considerable weight to the boat,
thereby decreasing the performance and handling.
Make certain that all drain passages are open for
complete draining.
Elevation and Climate
Elevation has a very noticeable effect on the
wide-open- throttle power of an engine. Since air
(containing oxygen) gets thinner as elevation in-
creases, the engine begins to starve for air. Humidity,
barometric pressure and temperature do have a no-
ticeable effect on the density of air. Heat and humidity
thin the air. This phenomenon can become particular-
ly annoying when an engine is propped out on a cool
dry day in spring and later, on a hot, sultry day in Au-
gust, doesn’t have its old zip.
Although some performance can be regained by
dropping to a lower pitch propeller, the basic problem
still exists. The propeller is too large in diameter for
the reduced power output. The experienced marine
dealer or a Quicksilver Propeller Repair Station can
determine how much diameter to remove from a low-
er-pitch propeller for specific high-elevation loca-
tions. In some cases, a gear-ratio change to the drive
unit to more reduction is possible and very beneficial.
It is a known fact that weather conditions exert a pro-
found effect on power output of internal combustion
engines. Therefore, established horsepower ratings
refer to the power that the engine will produce at its
rated RPM under a specific combination of weather
conditions.
90-806934 1194
Recommended Operation/Duty Cycle
It is the operator’s responsibility to operate within the
following recommended operational capability, or
duty cycle, as applicable to engine and installation:
• Pleasure Duty -
IMPORTANT: Damage caused by improper
application or failure to operate within the
operational capability, or duty cycle, will not be
covered by the MerCruiser Diesel Limited
Warranty.

1.) Operated at rated power and rated

speed for short periods of time.
• Light Duty -
1.) Operated such that full rated power at
maximum rated RPM is limited to 10% of operating
time and continuous cruising RPM is limited to
90% of Wide-Open-Throttle RPM (when propped
within specified RPM range).
2.) Annual operating time is not to exceed
500 hours.
NOTE: Pleasure duty rating applies to high
performance-type boats, or boats with planing hulls
where acceleration and top speed are of primary
importance. This rating is reserved for
privately-owned yachts, or recreational power boats
in non-revenue applications.
Pre-Lubricating
Turbocharger
IMPORTANT: After a lengthy lay-up (several
months or more), it is necessary to pre-lubricate
the turbocharger and engine. To do this, move
the “STOP” switch toggle lever DOWN and hold
in this position while you turn the key switch to
“START” position. Doing this TOGETHER turns
the engine without starting it. DO NOT engage
starter for more than 15 seconds; allow at least
one minute cool down time before re-engaging
starter for another 15 seconds. Watch that starter
does not overheat.

Light duty rating applies to planing boats where the

use of full rated power at maximum rated RPM is
limited (as stated above). Examples of Light Duty
applications include, but are not limited to: search and
rescue craft, fast patrol boats, fire boats, dive boats,
and limited season fishing boats such as sport-fish
charter boats. Application to common commercial
crafts having full-displacement or semi-displacement
hulls exceeds the recommended operational
capability, or duty cycle.

90-806934 1194 GENERAL INFORMATION – 1A-7

INDEX
IMPORTANT INFORMATION
1
B

MAINTENANCE
Note:Refer to the following Service Bulletin regarding this section.

SB 91-7 New Engine Break-In Procedure for Diesel Engines

INDEX
Table of Contents
Page Page
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Scheduled Maintenance To Be Performed By Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Owner/Operator . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Maintenance Schedule (Continued) . . . . . . . . . . . . . 1B-2 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Scheduled Maintenance To Be Performed By Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Clean/Replace Air Filter . . . . . . . . . . . . . . . . . . . . . . 1B-21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Inspect Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-21
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Replace Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Engine Water Circulating Pump Belt . . . . . . . . . 1B-22
Required Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Engine Initial Break-In Procedure . . . . . . . . . . . . . . . 1B-5 Power Steering Pump Belt . . . . . . . . . . . . . . . . . 1B-23
Engine 20-Hour Break-In Period . . . . . . . . . . . . . . . . 1B-5 D3.0L/150 and D3.6L/150 Models . . . . . . . . 1B-23
After Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 D4.2L/220 Models . . . . . . . . . . . . . . . . . . . . . 1B-24
20-50 Hour Check-up . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Vacuum Pump Belt . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 D3.0L/150 and D3.6L/150 Models . . . . . . . . 1B-25
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 D4.2L/220 Models . . . . . . . . . . . . . . . . . . . . . 1B-26
Diesel Fuel In Cold Weather . . . . . . . . . . . . . . 1B-7 Inspect/Replace Cooling System Sacrificial
Power Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27
Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Coolant Tank / Heat Exchanger Anode . . . . . . . 1B-27
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27
Recommended Oils for D3.0L/150 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27
and D3.6L/180 . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Intercooler Anode . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28
Recommended Oils for D4.2L/220 . . . . . . . . 1B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28
Coolant for Closed Cooling System . . . . . . . . . . 1B-9 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28
Maintaining Crankcase Oil Level . . . . . . . . . . . . . . . . 1B-9 Corrosion and Corrosion Protection . . . . . . . . . . . . 1B-28
Overfilled Engine Crankcase . . . . . . . . . . . . . . . . 1B-9 Check Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-29
Checking Engine Oil Level/Filling . . . . . . . . . . . . 1B-9 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-29
Changing Crankcase Oil and Oil Filter . . . . . . . . . . 1B-10 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-29
Maintaining Power Steering Pump Fluid Level . . . 1B-11 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-29
With Engine Cold . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11 Engine Coupler/U-Joint Shaft Splines . . . . . . . . 1B-30
Filling and Bleeding Power Steering System . . . . . 1B-12 Freezing Temperature and Cold Weather
Maintaining Transmission Fluid Level . . . . . . . . . . . 1B-12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-30
Maintaining Power Trim Pump Oil Level . . . . . . . . 1B-13 Saltwater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31
Maintaining Drive Unit Oil (Gear Lube Monitor) . . 1B-13 Cold Weather or Extended Storage . . . . . . . . . . . . 1B-31
Maintaining Closed Cooled Section Coolant Level 1B-14 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31
Changing (Draining) Closed Cooled Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32
Section Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Draining Instructions . . . . . . . . . . . . . . . . . . . 1B-33
Filling Closed Cooled Section . . . . . . . . . . . . . . . . . 1B-15 Battery Winter Storage . . . . . . . . . . . . . . . . . 1B-36
Flushing Seawater Cooling System . . . . . . . . . . . . 1B-16 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37
MCM Stern Drive . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
MIE Inboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Inspect Water Pickups . . . . . . . . . . . . . . . . . . . . . . . 1B-18
Stern Drive Gear Housing . . . . . . . . . . . . . . . . . . 1B-18 NOTICE
Inboard Thu-Hull Pickup . . . . . . . . . . . . . . . . . . . 1B-18 For information and procedures on troubleshoot-
Check/Clean Seawater Strainer . . . . . . . . . . . . . . . 1B-18 ing, refer to SECTION 1C.

1B – –
1B-0 MAINTENANCE
MAINTENANCE 90-806934 1194
INDEX
 Maintenance Schedule

! WARNING NOTE: Refer to appropriate Stern Drive Service

Manual for information and procedures on stern drive
Always disconnect battery cables from battery maintenance items listed.
BEFORE working around electrical system com-
ponents to prevent injury to yourself or damage
to electrical system should a wire be accidentally
shorted.

SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR

REQUIRED SERVICE INTERVAL

Check engine oil level.
Check drive unit gear lube monitor
Check transmission fluid level.
Before Operation
Check closed coolant level.
Check water pickups for marine growth or debris.
Drain fuel filter.
Check / Clean seawater strainer. Before Operation / Clean As Required
Inspect drive unit alloy anodes for erosion (Replace
Weekly or As Required
when over 50% eroded).
Flush seawater section of cooling system. Saltwater Use: After Each Use
Check power trim pump oil level.
Every 50 Hours of Use
Check power steering fluid level.
Every 50 Hours of Operation, or as Conditions
Clean air filter element.
Require
Every 50 Hours of Operation or 60 Days - Whichever
Inspect condition and check tension of drive belts.
Occurs First
Saltwater Use: Every 50 Hours of Operation or 60
Days, Whichever Occurs First
Lubricate propeller shaft.
Freshwater Use: Every 100 Hours of Operation or
120 Days, Whichever Occurs First
Every 100 Hours of Operation or Once A Year,
Replace fuel filter.
Whichever Occurs First
Every 200 Hours of Operation, or Once a Year,
Replace air filter element.
Whichever Occurs First
Check sacrificial anode (in heat exchanger) -
Replace when over 50% eroded.
Check sacrificial anode (in intercooler) - Replace
when over 50% eroded). Once a Year

Spray power package exterior surfaces with Quicksil-

ver Corrosion Guard.
Clean and paint power package exterior surfaces. As Necessary
Check battery fluid level. Refer to Battery Manufacturer Specifications

90-806934 1194 MAINTENANCE – 1B-1

INDEX
 Maintenance Schedule (Continued)
SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER

REQUIRED SERVICE INTERVAL

After First 20 Hours, But Not Later Than 50 Hours, of Op-
20-50 Hour Checkup (See NOTE 1.).
eration
After First 100 Hours of Operation or First Operating
Retorque cylinder heads
Season, Whichever Occurs First
After 20-Hour Break-In Period, Then, for Pleasure-
craft Use: Every 100 Hours of Use or 120 Days,
Change engine oil and filter. Whichever Occurs First ; and for Light Duty Use:
Every 50 Hours of Use or 60 Days, Whichever Oc-
curs First (See NOTE 2.)
Lubricate engine coupling and universal joint shaft Every 50 Hours of Operation or 60 Days, Whichever
splines. Occurs First
Check engine alignment and mounting hardware.
Every 100 Hours of Operation
Change transmission fluid
Change Stern Drive Unit oil including gear lube moni- Every 100 Hours of Operation or 120 Days, Whichev-
tor oil. er Occurs First
Retorque gimbal ring clamping U-bolt to 50 - 55 lb. ft.
(67 - 74 N·m). Every 100 Hours of Operation or Once a Year,
Clean, inspect and test the closed cooling system Whichever Occurs First
pressure cap.
Replace coolant (using only Quicksilver Premixed
Marine Engine Coolant). Every 200 Hours of Operation or Once a Year,
Clean heat exchangers. Whichever Occurs First

Lubricate universal joint cross bearings

Check and adjust idle RPM. Once a Year
Clean intercooler core.
Every 500 Hours of Operation
Replace drive belts.
Inspect cooling system hoses and clamps.
Inspect engine exhaust system externally for dam-
age, deterioration and restrictions. Check clamps for
tightness.
Inspect and lubricate shift/throttle cables and linkage . Saltwater use: Every 50 hours of operation or 60
days, Whichever Occurs First.
Check electrical system for loose or damaged wiring.
Freshwater use: Every 100 hours of operation or
Lubricate transom gimbal bearing 120 days, Whichever Occurs First.
Lubricate and inspect steering system for loose, dam-
aged or missing parts.
Ground Wire Circuit continuity - Check components
for loose connections, broken or frayed wires.
Whenever Insufficient Seawater Flow is Suspected (If
Disassemble and inspect seawater pump. Operating Temperature Exceeds Normal Range) or
At Least Once yearly
Clean fuel tank. Every 1000 Hours of Operation
NOTE 1: For a list of 20-50 Hour Checkup maintenance items to be performed, see “IMPORTANT INFORMATION, SECTION
1A” of this manual.
NOTE 2: For an explanation of Pleasure Craft and Light Duty usage refer to SECTION 1A -“Recommended Operation/Duty
Cycle”.

1B-2 – MAINTENANCE 90-806934 1194

INDEX
Specifications
Engine
SPECIFICATION
ITEM
D3.0L/150 D3.6L/180 D4.2L/220
Crankshaft Horse- MCM (Stern Drive) 150 ( 112 ) 180 ( 134 ) 220 ( 164 )
power (Kilowatts) 1 MIE (Inboard) 2 150 ( 112 ) 180 ( 134 ) 220 ( 164 )
Propeller Shaft MCM (Stern Drive) 140 ( 104 ) 170 ( 127 ) 200 (149 )
Horsepower
(Kilowatts) 1 MIE (Inboard) 2 150 ( 112 ) 180 ( 134 ) 210 (156 )
In-Line 5 Cylinder In-Line 6 Cylinder
Engine Type
Diesel Diesel
Displacement 183 cu. in. ( 3.0 L ) 219 cu. in. ( 3.6 L ) 254 cu. in. ( 4.2L )
Firing Order 1-2-4-5-3 1-5-3-6-2-4
Bore 3.622 in. ( 92mm ) 3.700 in. ( 94 mm )
3.937 in.
Stroke 3.543 in. ( 90mm )
( 100 mm )
Compression Ratio 22 : 1 21.5 : 1
Valve Clearance ( Intake / Exhaust ) .012 in. ( 0.30 mm )
Maximum Pressure Difference Between Cyl. 72 PSI ( 500 kPa )
Maximum Governed WOT RPM 4300 ± 50 4200 ± 50
Maximum WOT RPM 3800 3600
Idle RPM in Forward Gear 700
750 RPM 22-36 PSI [ 1.5 - 2.5 bar ( 152-248 kPa ) ]
Oil Pressure:
3600 RPM 50-58 PSI [ 3.5 - 4 bar ( 345-400 kPa ) ]
Oil Temperature 212° - 230° F ( 100° - 110° C )
Water: 1 at temperature: 160° F ( 70° C )
Thermostats:

(2 for Water) 1 at temperature: 180° F ( 82° C )

(1 for Oil)
Oil: 195°° F ( 90°° C )
Coolant Temperature 176° - 185° F ( 80° - 85° C )
Electrical System 12-volt Negative ( – ) Ground
Alternator Rating 949W, 14.6v, 65A
Recommended Battery Rating ( Minimum ) 12v, 750cca, 950mca, 180Ah
Starter ( Bosch ) 12v, 2.7 kW
1 Power rated in accordance with NMMA Procedure - ISO 3046 (Technically Identical to ICOMIA 28-83).
2 Engine rated with Hurth 8 degree Down-Angle transmission. Power output with other transmissions will vary.

90-806934 1194 MAINTENANCE – 1B-3

INDEX
Fluid Capacities
NOTICE
All capacities are approximate fluid measures
in U.S. Quarts (Litres).

SPECIFICATION - MIE ( INBOARD )

ITEM ITEM
D3.0L/150 D3.6L/180 D4.2L/220
Total Oil-filling Capacity 1 9-1/2 ( 9 ) 10-1/2 ( 10 ) 12-3/4 ( 12 )
from oil pan 7-1/2 ( 7 ) 8-1/2 ( 8 ) 10-3/4 ( 10 )
Oil Drainage from oil filter 1(1)
from oil cooler 1(1)
Transmission - Hurth - 630A 8° Down Angle 1 4-1/4 ( 4 )
Transmission - Hurth - 630V-Drive 1 5 ( 4-3/4 )
Round Monitor 3-1/4 ( 3 )
Bravo One
Drive Unit Oil Capacity, with Gear Square Monitor 2-1/4 ( 2 )
Lube Monitor Round Monitor 3-3/4 ( 3-1/2 )
Bravo Two
Square Monitor 3-1/4 ( 3 )
Closed Cooling Circuit 11-1/2 ( 11 ) 12-3/4 ( 12 ) 13-3/4 ( 13 )
1 Always use dipstick to determine exact quantity of oil or fluid required.
2 Seawater cooling system capacity information is for cold weather or extended storage use only.

Required Coolant: Quicksilver Premixed Marine Engine Coolant

IMPORTANT: This contains special low silicate ethylene glycol, special additives, and purified water. Use
of other coolant may cause fouling of the heat exchangers, and overheating of the engine.

1B-4 – MAINTENANCE 90-806934 1194

INDEX
Engine Initial Break-In 3. DO NOT exceed 75% of full throttle during the first
10 hours except during the Engine Initial Break-In
Procedure Procedure. During the next 10 hours, occasional
operation at full throttle (5 minutes at a time maxi-
It is especially important that the following procedure
mum) is permissible.
be used on new and rebuilt diesel engines. This
break-in procedure allows the proper seating of the 4. AVOID full throttle accelerations from stopped po-
pistons and rings, which greatly reduces the likeli- sition.
hood of problems. 5. DO NOT operate at full throttle until engine reach-
IMPORTANT: It is recommended that the boat not es normal operating temperature.
be accelerated hard until this procedure has been 6. OBSERVE INSTRUMENTATION carefully. If an
completed. abnormal reading occurs, stop engine immedi-
IMPORTANT: Never operate the starter motor longer ately and determine cause.
than 15 seconds at a time, to avoid overheating the
7. FREQUENTLY CHECK crankcase oil level and
starter motor. If engine does not start, wait 1 minute to
add oil if necessary. It is normal for oil consump-
allow the starter motor to cool; then, repeat starting
tion to be somewhat high during the break-in peri-
procedure.
od.
Initial Break-In Procedure is as follows: 8. AT END OF THE 20-HOUR BREAK-IN PERIOD,
1. Refer to owner’s manual and start engine. Allow drain oil from crankcase and replace oil and filter.
engine to idle until engine has reached normal op- Fill crankcase with correct grade and viscosity oil.
erating temperature.
2. Run engine in gear for 3 minutes at each of the fol-
lowing RPMs: 1200 RPM, 2400 RPM and 3000 After Break-in Period
RPM.
To help extend the life of your MerCruiser power
3. Run engine in gear for 3 minutes at each of the fol- package, the following recommendations should be
lowing RPMs: 1500 RPM, 2800 RPM and 3400 considered;
RPM.
• Use a propeller that allows the engine to operate
4. Run engine in gear for 3 minutes at each of the fol- at or near the top of the maximum RPM range (See
lowing RPMs: 1800 RPM, 3000 RPM and Maxi- “Specifications” section) when at full throttle with
mum Rated Wide-Open-Throttle RPM. a normal boat load.
• Operation at 3/4 throttle setting or lower is recom-
mended. Refrain from prolonged operation at
Engine 20-Hour Break-In maximum (full throttle) RPM.
Period
IMPORTANT: The first 20 hours of operation is the
engine break-in period. Correct break-in is essen-
tial to obtain minimum oil consumption and maxi-
mum engine performance. During this break-in
period, the following rules must be observed:
The first 20 hours of operation is the engine (new or
rebuilt) break-in period. During this period, it is ex-
tremely important that the engine is operated as out-
lined in the following.
1. DO NOT operate engine below 1500 RPM for ex-
tended periods of time during the first 10 hours.
During this period, shift into gear as soon as pos-
sible after starting engine and advance throttle so
that RPM is above 1500 (provided that conditions
permit safe operation at this speed).
2. DO NOT operate at any one constant speed for
extended periods of time.
90-806934 1194 MAINTENANCE – 1B-5
INDEX
20 Hour Checkup
After 20 hours of operation, but no later than 50 hours, an Authorized MerCruiser Dealer should be contacted for
the following services, checks, and adjustments. (Note: Some items may not apply to your specific power
package.)
The product owner is responsible for any charges. A copy of the dealer service work order must be kept by the
product owner.
Service, check or adjust as indicated.
BEFORE RUNNING (ENGINE COLD) - CHECK OR ADJUST
Not
Applicable Completed
Torque turbocharger fasteners [31 lb. ft. (42 N·m)] and exhaust manifold
fasteners [24 lb. ft. (32 N·m)] (V-8 Diesel models only)
Tighten cooling and exhaust system hose clamps
Throttle, shift and steering system fasteners tight and/or properly secured
Drive mounting fasteners are tight
Check that both front engine mount locknuts are tightened securely.
Then, check to ensure that tab washers are bent down over adjusting nuts.
Check that rear engine mounts are torqued to 35-40 lb. ft. (47-54 N⋅m).
(stern drive models only)
Drain fuel filter and check for water
Check condition and tension of all drive belts
Check closed cooling system coolant level *
Retorque gimbal ring clamping bolt to 50 - 55 lb. ft. (67 - 74 N·m)
(stern drive models only)
Power steering system fluid (stern drive models only)*
Drive unit lubricant level (stern drive models only)*
Transmission fluid level (inboard models only)*
Power trim pump oil level (stern drive models only)*

ON-WATER TESTING (ENGINE RUNNING/OPERATING TEMPERATURE) - CHECK OR ADJUST

Adjust idle RPM in forward gear♦
All gauges and indicator lamps proper readings♦
Fuel, oil, water, coolant and exhaust leaks
Remote control operation--forward, neutral and reverse
Steering operation throughout range
Power trim operation (stern drive models only)
Maximum RPM in forward gear -- change propeller if necessary♦

AFTER-WATER TESTING - SERVICE

Change crankcase oil and filter
♦ - Refer to “Specifications - Engine” Chart in this manual.

* - Use only factory approved coolant and fluids.

1B-6 – MAINTENANCE 90-806934 1194

INDEX
Fluid Specifications Sulphur content of the above fuel is rated at 0.50% by
weight, maximum (ASTM). Limits may vary in coun-
tries outside of the United States.
Diesel Fuel On intermittent use engines, high sulphur content die-
sel fuel will greatly increase:

! WARNING • Corrosion of metal parts.

• Deterioration of elastomer and plastic parts.
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause • Corrosion and extensive damage, and excessive
serious bodily injury or death. Careful periodic in- wear of internal engine parts, particularly bear-
spection of entire fuel system is mandatory, par- ings.
ticularly after storage. All fuel components in-
• Starting and operating difficulties.
cluding fuel tanks, whether plastic, metal or
fiberglass, fuel lines, primers, fittings, and fuel fil-
ters should be inspected for leakage, softening, DIESEL FUEL IN COLD WEATHER
hardening, swelling or corrosion. Any sign of Unaltered diesel fuels thicken and “gel” in cold tem-
leakage or deterioration requires replacement peratures, unless treated. Virtually all diesel fuels are
before further engine operation. “climatized” to allow their use in the particular region
for that time of the year. If it becomes necessary to fur-
! WARNING ther treat diesel fuel, it is the owner/operator’s re-
sponsibility to add a commercial “standard brand”
Under no circumstances should gasoline, gaso- “anti-gel” diesel fuel additive, following that product’s
hol and/or alcohol be mixed with diesel fuel for directions.
any reason. This mixture of gasoline, gasohol
and/or alcohol with diesel fuel is highly flam-
mable and produces a significant risk to the user. Power Steering Fluid
Use Quicksilver Power Trim and Steering Fluid, or au-
IMPORTANT: Use of improper or water-contami- tomatic transmission fluid (ATF), Dexron, Dexron II.
nated diesel fuel will damage your engine seri-
ously. Use of improper fuel is considered misuse
of engine, and damage caused thereby will not be
covered by warranty.
Transmission Fluid
Use automatic transmission fluid (ATF) Dexron II.
Grade 2-D diesel fuel is required, meeting ASTM
Standards D975 (or fuel rated Diesel DIN 51601), and
having a minimum cetane rating of 45.
The cetane number is a measure of the ignition quali-
ty of diesel fuel. Increasing the cetane number will not
improve overall engine performance, but it may be
necessary to raise the cetane rating for low tempera-
ture or high altitude use.
NOTE: If your engine suddenly becomes noisy after
a fuel fill, you possibly received substandard fuel with
a low cetane rating.

90-806934 1194 MAINTENANCE – 1B-7

INDEX
Crankcase Oil
To help obtain optimum engine performance and to
provide maximum protection, the engine requires en-
gine oil with rating of HD-SAE-API-SG/CD, and con-
forming to or exceeding military specifications of
MIL-2104 D.
If Quicksilver 4-Cycle Marine Engine Oil is unavail-
able, we recommend the use of 15W-40 CD oil for all
temperature operation, from the following list of ap-
proved oils.
These oils, approved by Mercury Marine and Marine
Power Europe, exceed MlL-2104 D standards.

We recommend the use of Quicksilver 4-Cycle Ma-

rine Engine Oil, a specially blended 25W-40 SG/CD
oil with Marine Additives.

RECOMMENDED OILS FOR D3.0L/150 AND D3.6L/180

ALL TEMPERATURE OPERATION - USE 15W-40 CD

AGIP SIGMA TURBO CHEVRON DELO 450 MOTOR OIL FANAL INDOL X
ARAL OL P 327 MULTIGRADE FINA KAPP LDO
AUTOL VALVE-SHP DEUSOL TURBOMAX FUCHS TITAN TRUCK 1540
AVIATICON TURBO DIVINOL MULTIMAX EXTRA GULF SUPERFLEET SPECIAL
BP VANELLUS C3 EXTRA DUKCHAMS HYPERGRADE IP TAURUS M
CALTEX RPM DELO 450 OIL ECUBSOL OIL CD PLUS MOBIL DELVAC 1400 SUPER
CASTROL TURBOMAX ELF MULTIPERFORMANCE TOTAL RUBIA TIR
CENTURY SHPD ESSO HESSOL TURBODIESEL VALVOLINE SUPER HD LD

RECOMMENDED OILS FOR D4.2L/220

ALL TEMPERATURE OPERATION - USE 15W-40 CD

AGIP SIGMA TURBO
SHELL MYRINA
MOPAR
MOBIL DELVAC 1400 SUPER
TEXACO URSA SUPER TD
WINTERSHALL MULTI-REKORD
TOTAL RUBIA TIR
VEEDOL TURBOBOSTAR
WINTERSHALL VIVA 1

1B-8 – MAINTENANCE 90-806934 1194

INDEX
Coolant for Closed Cooling System Checking Engine Oil Level/Filling
! CAUTION IMPORTANT: ENGINE CRANKCASE OIL MUST
BE CHECKED AT INTERVALS SPECIFIED IN
Alcohol or Methanol base antifreeze or plain wa- “MAINTENANCE SCHEDULE” CHART. It is nor-
ter, are not recommended for use in fresh water mal for an engine to use a certain amount of oil in
section of cooling system at any time. the process of lubrication and cooling of the en-
We require that the coolant section of closed cooling gine. The amount of oil consumption is greatly
system be filled with Quicksilver Premixed Marine dependent upon engine speed, with consump-
Engine Coolant. tion being highest at wide-open-throttle and de-
creasing substantially as engine speed is re-
IMPORTANT: Quicksilver Premixed Marine En- duced.
gine Coolant contains special low silicate ethy-
lene glycol, special additives, and purified water. Check engine oil daily before first start-up.
Use of other coolant may cause fouling of the If it becomes necessary to check oil level during oper-
heat exchangers, and overheating of the engine. ation, stop the engine and allow 5 minutes for oil to
drain into pan.
! CAUTION
Maintaining Crankcase Oil
Avoid possible injury, or damage to oil dipstick
Level and internal engine components. Do not remove
crankcase oil dipstick when engine is running.
Stop the engine completely before removing or
Overfilled Engine Crankcase inserting dipstick.
Overfilled crankcases (oil level being too high ) can 1. Remove dipstick. Wipe clean and reinstall into
cause a fluctuation or drop in oil pressure on Mer- dipstick tube.
Cruiser engines. The over-full condition results in the
engine crankshaft splashing and agitating the oil, a
causing it to foam (become aerated). The aerated oil
causes a loss of engine performance and an increase
in crankcase backpressure. An extreme overfill
condition could result in backpressure sufficient to
cause large amounts of oil to be pulled over into the
intake.
Care must be taken when checking engine oil level.
Oil level must be maintained between the MINIMUM
mark and the MAXIMUM mark on the dipstick. To en-
sure that you are not getting a “false reading,” make
sure the following steps are done before checking the
oil level.
• Boat “at rest” in the water, or
• If boat is on a trailer, raise or lower bow until the
boat is setting at the approximate angle that it a - Dipstick
would be if setting “at rest” in the water.
• Allow sufficient time for oil to drain into the crank-
case if engine has just been run or oil has just been
added.

90-806934 1194 MAINTENANCE – 1B-9

INDEX
2. Remove dipstick and observe oil level. Oil must Changing Crankcase Oil and
be between MIN and MAX marks on dipstick. If
necessary, add oil as follows. Oil Filter
a IMPORTANT: Change oil when engine is warm
from operation. Warm oil flows more freely, carry-
ing away more impurities. Use only recom-
mended motor oil (see SPECIFICATIONS).
1. Start engine and allow it to warm up to normal op-
erating temperature.
2. Stop engine and allow some time for oil to drain
into oil pan (approximately 5 minutes).
3. Loosen hose clamp and disconnect crankcase
vent oil return hose from oil return tube.
c 4. Install crankcase oil pump (Quicksilver Part Num-
ber - 90265A2) onto threaded fitting of oil return
tube.
71382

b
71380

a - Dipstick
b - Minimum Oil Level Mark
c - Maximum Oil Level Mark
3. Remove oil filler cap. Add specified oil to bring lev-
el up to, but not over, “MAX” mark on dipstick. Re- d
install oil filler cap.
b
a

a
73325
e

d c
c
70571

a - Hose Clamp
b - Vent Oil Hose
c - Oil Return Tube
d - Threaded Fitting
e - Crankcase Oil Pump Drain Assembly
73322
5. Pump oil out of crankcase into drain pan. When
a - Oil Filler Cap crankcase is empty, remove pump and reinstall
crankcase oil return hose to oil return tube. Tight-
en hose clamp securely.

1B-10 – MAINTENANCE 90-806934 1194

INDEX
6. Remove and discard oil filter and sealing ring. Maintaining Power Steering
Coat sealing ring on new filter with oil and install
filter. Hand tighten only, do not use a filter Pump Fluid Level
wrench.

a With Engine Cold

1. Stop engine and position drive unit so that it is
straight back.
2. Remove fill cap/dipstick from power steering fluid
b
reservoir and note fluid level.
IMPORTANT: Use only Quicksilver Power Trim
and Steering Fluid or automatic transmission
fluid (ATF) Dexron, or Dexron II in power steering
system.
3. Add Automatic Transmission Fluid (ATF) as re-
quired to bring the level between the MINIMUM
mark and FULL COLD mark on dipstick.

72706

a - Oil Filter
b - Sealing Ring (Not Visible In This View)
7. Remove oil fill cap and refill engine with new oil
(refer to “Specifications” for quantity and grade of
oil).
a c
IMPORTANT: When refilling engine with oil al- d
ways use dipstick to determine how much oil is
required. 71

! CAUTION b
Avoid possible injury or damage to oil dipstick
and internal engine components. Do not remove
crankcase oil dipstick when engine is running.
Stop the engine completely before removing or
inserting dipstick.

IMPORTANT: After oil change, pre-lubricate tur- 73326

bocharger and engine. To do this, move the a - Fill Cap/Dipstick
“STOP” switch toggle lever DOWN and hold in b - Power Steering Reservoir
this position while you turn the key switch to c - Full Cold Mark
“START” position. Doing this TOGETHER turns d - Minimum Mark
the engine without starting it. DO NOT engage 4. If fluid is not visible in reservoir, a leak exists in the
starter for more than 15 seconds; allow at least power steering system. Find the cause and cor-
one minute cool down time before re-engaging rect. Refer to “Filling and Bleeding Power Steer-
starter for another 15 seconds. Watch that starter ing System” as outlined later in this section.
does not overheat.
5. Install fill cap.

90-806934 1194 MAINTENANCE – 1B-11

INDEX
Filling and Bleeding Power Maintaining Transmission
Steering System Fluid Level
IMPORTANT: Power steering system must be IMPORTANT: To accurately check fluid level, en-
filled exactly as explained in the following to be gine MUST BE run at 1500 RPM for 2 minutes im-
sure that all air is bled from the system. All air mediately prior to checking level.
must be removed, or fluid in pump may foam dur-
1. Start engine and run at 1500 RPM for 2 minutes
ing operation and be discharged from pump res-
to fill all circuits, lines, and cooler.
ervoir. Foamy fluid also may cause power steer-
ing system to become spongy, which may result
in poor boat control.
1. With engine stopped, position drive unit so that it
is straight back. Remove fill cap/dipstick from
power steering pump. Add Quicksilver Power
Trim and Steering Fluid or automatic transmis-
sion fluid (ATF), Dexron, or Dexron II, as required,
to bring level up to FULL COLD mark on dipstick. a

IMPORTANT: Use only Quicksilver Power Trim b

and Steering Fluid or automatic transmission
fluid (ATF), Dexron, or Dexron II in power steering
system.
2. With engine NOT running, turn the steering
wheel, at a moderate rate, back-and-forth to end 71383
of travel in each direction pausing each time at
end of travel for a few seconds to allow any air to a - Maximum Fluid Level
bubble from pump reservoir. Do this a minimum b - Minimum Fluid Level
of 5 complete cycles, then recheck fluid level and
Typical Hurth Transmission Shown
add fluid, if necessary.
3. Install reservoir fill cap.
IMPORTANT: Be sure to push dipstick all the way
! CAUTION down into dipstick tube when checking fluid lev-
el.
DO NOT operate engine without water being
supplied to seawater pickup pump, or pump im- 2. Stop engine and quickly check level before fluid
peller may be damaged and subsequent over- drains back into transmission. Add fluid if neces-
heating damage to engine may result. sary.

4. Position boat in the water and/or see that water is 3. If fluid level is extremely low, check transmission
supplied to seawater pickup holes. Start engine case, cooler, and hoses for leaks.
and run AT IDLE. During this time, turn steering IMPORTANT: Use automatic transmission fluid
wheel back and forth to end of travel in each direc- (ATF) Dexron II.
tion several times.
5. Position drive unit so that it is straight back and
stop engine. Remove fill cap from pump reservoir.
Allow any foam in pump reservoir to disperse,
then check fluid level. DO NOT OVERFILL. Rein-
stall fill cap securely.
IMPORTANT: Drive unit must be positioned
straight back to accurately check fluid level.
6. If fluid is still foamy (in Step 5), repeat Steps 4 and
5 until fluid does not foam and level remains con-
stant.

1B-12 – MAINTENANCE 90-806934 1194

INDEX
Maintaining Power Trim 3. Observe oil level. Level must be up to, but not
over, bottom of fill neck. Add Quicksilver Power
Pump Oil Level Trim and Steering Fluid if required (or SAE
10W-30 motor oil if Quicksilver Power Trim and
1. Place drive unit in full down/in position.
Steering Fluid is unavailable) to bring level to bot-
IMPORTANT: Trim pump reservoir fill cap has a tom of filler neck. Replace fill cap, and tighten
small vent hole in it. Occasionally check to en- when finished with checks.
sure vent is not restricted.
2. Unscrew fill cap.

a - Fill Neck 73184

b - Fill Cap
a
73182

a - Fill Cap
b - Fill Cap Vent Hole
NOTE: New trim pumps have a shipping “caplug” in
the reservoir fill neck. Check to ensure that this ca-
plug is NOT present in filler neck. DISCARD caplug
if present.
Maintaining Drive Unit Oil
(Gear Lube Monitor)
Check gear lube monitor oil level; keep oil level at or
near FILL line. Check for water at bottom of monitor,
and/or if oil appears a milky-tan. Both conditions indi-
cate a water leak somewhere in the drive unit.

a IMPORTANT: If more than 2 oz. (57 grams) of

Quicksilver High Performance Gear Lube are re-
quired to fill drive unit, a seal may be leaking.
Damage to unit may occur due to lack of lubrica-
tion.

73183

a - Caplug

73185

Round Monitor Bottle Square Monitor Bottle

90-806934 1194 MAINTENANCE – 1B-13

INDEX
Maintaining Closed Cooled
Section Coolant Level
1. Check coolant level in coolant recovery bottle.
Coolant level should be between the ADD and FULL
marks on coolant recovery reservoir with the engine
at normal operating temperature. Add specified cool-
ant as required.
a
72520
a - Coolant Recovery Reservoir
NOTE: Coolant recovery system is considered to be
functioning properly when coolant level in heat ex-
changer/coolant tank remains at bottom edge of its
filler neck.
! WARNING
Allow engine to cool down before removing pres-
sure cap. Sudden loss of pressure could cause
hot coolant to boil and discharge violently. After
engine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
turn cap all the way off.
1B-14 – MAINTENANCE
INDEX
2. Periodically, to ensure that coolant recovery sys-
tem is functioning properly, you should allow engine
to cool and then slowly and carefully remove coolant
tank cap. Coolant level must be to the bottom edge of
the tank filler neck. If coolant is low, add coolant as
necessary to bring up to proper level. Refer to “Speci-
fications” for proper coolant.
IMPORTANT: When installing pressure cap, be
sure to tighten it until it contacts stop on filler
neck.
Changing (Draining) Closed
Cooled Section Coolant
! WARNING
Allow engine to cool before removing pressure
cap. Sudden loss of pressure could cause hot
coolant to boil and discharge violently. After en-
gine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
turn cap all the way off.
IMPORTANT: A wire should be inserted into drain
holes to ensure that foreign material is not ob-
structing the drain holes.
IMPORTANT: Engine must be as level as possible
to ensure complete draining of cooling system.
IMPORTANT: Closed cooled section must be kept
filled year round with recommended coolant. If
engine will be exposed to freezing temperatures,
make sure closed cooled section is filled with an
ethylene glycol antifreeze and water solution
properly mixed to protect engine to lowest tem-
perature to which it will be exposed.
IMPORTANT: Do not use Propylene Glycol Anti-
freeze in the closed cooled section of the engine.
NOTE: Drain coolant into a suitable container. Dis-
pose of old coolant properly.
90-806934 1194
1. Allow engine to cool down. Slowly and carefully
remove pressure cap from coolant tank.
2. Drain coolant from intake/exhaust manifold by
opening the petcock.
3. Drain coolant from the engine block by opening
the petcock.
4. After coolant has drained completely, securely
close petcocks.
5. Remove coolant recovery bottle from mounting
bracket and pour out coolant.
6. If required, clean system as outlined in “Cleaning
System.”
7. Fill system with required coolant, as outlined in
“Filling Closed Cooled Section.”

Changing (Draining) Closed Cooled Section

a
d

71381

71364 72706

a - Pressure Cap
b - Drain Petcock on Intake/Exhaust Manifold
c - Drain Petcock on Engine Block
d - Coolant Recovery Bottle
Typical
NOTICE
For instructions on Draining Seawater Section refer to “Cold Weather or Extended Storage” in this SEC-
TION 1B.

90-806934 1194 MAINTENANCE – 1B-15

INDEX
Filling Closed Cooling
Section
1. Remove pressure cap from heat exchanger and
fill section with Quicksilver Premixed Marine En-
gine Coolant through heat exchanger fill neck.
Continue filling until coolant level is 1 in. (25 mm)
below filler neck.
MCM Stern Drive
NOTE: If flushing seawater cooling system with boat
in water, raise drive unit to TRAILER position, install
flushing attachment and lower drive unit to full down/
in position.
1. Install Quicksilver flushing attachment (or equiva-
lent) over water intake openings in gear housing.

! CAUTION
Avoid seawater pickup pump impeller damage and
subsequent overheating damage to stern drive unit.
DO NOT operate engine without water being supplied
to seawater pickup pump.
2. With pressure cap off, start engine and run at fast
idle (1500-1800 RPM). Add coolant solution to
heat exchanger, as required, to maintain coolant
level 1 in. (25 mm) below filler neck.
3. After engine has reached normal operating tem-
perature (thermostats are fully open), and coolant
level remains constant, fill heat exchanger to bot-
tom of filler neck.
4. Observe engine temperature gauge to make sure
that engine operating temperature is normal. If
gauge indicates excessive temperature, stop en- 72012
gine immediately and examine for cause.
Typical
5. Install pressure cap on heat exchanger.
2. Attach a garden hose between the flushing at-
6. Remove cap from coolant recovery reservoir and
tachment and a water tap.
fill to a level between the ADD and FULL marks
with coolant solution. Reinstall cap. 3. Lower drive unit to full IN position.
7. With engine still running, check hose connec- ! CAUTION
tions, fittings and gaskets for leaks. Repeat
Step 4. Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump
may collapse flushing hose, causing engine to
overheat.
Flushing Seawater Cooling
! CAUTION
System Watch temperature gauge on dash to ensure that
If engine is operated in salty, polluted, or mineral-lad- engine does not overheat.
en water, flush cooling system (preferably after each
use) to reduce corrosion and prevent the accumula- 4. Partially open water tap (approximately 1/2 maxi-
tion of deposits in the system. Thoroughly flush cool- mum capacity). DO NOT use full water pressure.
ing system prior to storage. 5. Place remote control in neutral, idle speed posi-
tion, and start engine.
! WARNING 6. Operate engine at idle speed in neutral for 10 min-
utes, then stop engine.
When flushing, be certain the area around propel-
ler is clear, and no one is standing nearby. To 7. Shut off water tap.
avoid possible injury, remove propeller. 8. Raise drive unit to TRAILER (full-UP) position, if
boat is in the water.
9. Remove garden hose and flushing attachment.

1B-16 – MAINTENANCE 90-806934 1194

INDEX
MIE Inboard
! CAUTION
If boat is in the water, seacock (water inlet valve),
if so equipped, must be closed until engine is to
be re-started, to prevent water from flowing into
the boat and/or back into the cooling system. If
boat is not fitted with a seacock, water inlet hose
must be disconnected and plugged (to prevent
water from flowing into the boat and/or back into
the cooling system). As a precautionary mea-
sure, attach a tag to the ignition switch or steering
wheel of the boat with the warning: Open seacock
or reconnect water inlet hose before starting en-
gine.
IMPORTANT: If a seacock is to be installed for the
purpose of draining or flushing the seawater sys-
tem, the valve used must have an internal
cross-sectional area equal to or greater than wa-
ter inlet hose to prevent restricting water flow
during normal operation. A 1-1/2 in. (38 mm), or
larger, brass ball valve or gate valve is recom-
mended.
1. Shut off seacock or plug seawater inlet hose to
prevent seawater from entering boat, if boat is in
the water.
2. Remove inlet hose from seawater pump.
a if so equipped, must remain closed until engine
b
73522
a - Seawater Pump
b - Inlet Hose
D3.6L/180 Shown (All Similar)
90-806934 1194
INDEX
3. Using an adaptor, connect a garden hose from a
water tap to seawater pump inlet.
4. Partially open water tap (approximately 1/2 maxi-
mum). Do not use full water pressure.
5. Place the remote control lever in neutral position
and start engine.
! WARNING
When flushing, be certain the area around propel-
ler is clear, and no one is standing nearby. To
avoid possible injury, remove propeller.
! CAUTION
Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump
may collapse flushing hose, causing engine to
overheat.
! CAUTION
Watch temperature gauge on dash to ensure that
engine does not overheat.
6. Operate engine at idle speed in neutral for 10 min-
utes, or until discharge water is clear. Stop en-
gine.
7. Shut off water tap. Remove garden hose and
adaptor from pump inlet and reconnect water inlet
hose. Be sure to tighten hose clamp securely.
! CAUTION
If boat is in the water, seacock (water inlet valve),
is to be re-started, to prevent water from flowing
back into cooling system and/or boat. If boat is
not fitted with a seacock, water inlet hose must be
disconnected and plugged (to prevent water from
flowing back into cooling system and/or boat). As
a precautionary measure, attach a tag to the igni-
tion switch or steering wheel of the boat with the
warning: Open seacock or reconnect water inlet
hose before starting engine.
MAINTENANCE – 1B-17
Inspect Water Pickups Check/Clean Seawater
Strainer
Stern Drive Gear Housing 1. Visually inspect seawater strainer through glass
top.
Check water inlet area of gear housing to ensure that
openings are clean and not obstructed. ! CAUTION
When cleaning seawater strainer, close seacock,
if so equipped. If boat is not equipped with a sea-
cock, remove and plug seawater inlet hose to pre-
vent a siphoning action that may occur, allowing
seawater to flow from the drain holes or removed
hoses.
! CAUTION
Do not overtighten cover screws or cover will
warp and leak.
a 2. With engine off, close seacock (if so equipped) or
remove and plug seawater inlet hose if no sea-
cock exists. Remove two screws, washers, and
cover. Remove strainer, drain plug and washer.
Clean all debris from strainer housing; flush both
73186 strainer and housing with clean water. Check gas-
ket and replace when necessary (if it leaks). Rein-
stall strainer, drain plug and washer. Reattach
a - Water Inlet Holes
cover with screws and washers. After starting en-
Typical gine, check for leaks and/or air in system, which
would indicate an external leak.

Inboard Thu-Hull Pickup a

Check water inlet holes (slots) of seawater pickup to
ensure that openings are clean and not obstructed. b
f

d
e

72673
a
70355 a - Screws and Washers
b - Cover, with Glass
a - Water Inlet Holes (Slots) c - Strainer
d - Housing
Typical e - Drain Plug and Sealing Washer
f - Gasket

1B-18 – MAINTENANCE 90-806934 1194

INDEX
Fuel Filter Draining

NOTICE
Precautions Refer to “Precautions,” in this Fuel Filter
section , BEFORE proceeding.
! WARNING
Always disconnect battery cables from battery
BEFORE working on fuel system to prevent fire. NOTE: To ensure complete draining, in warm weath-
This eliminates the engine wiring as a potential er, open the drain cock before starting daily opera-
source of ignition. tions. In cold weather, when there is a possibility that
the condensed water will freeze, drain the filter shortly
after the end of daily operations.
! WARNING
Be careful when draining, filling or replacing wa- 1. The filter can be drained of water and small dirt
ter separating fuel filter; diesel fuel is flammable. particles by pressing up on the water bleed valve.
Be sure that the ignition key is OFF. DO NOT
smoke or allow sources of open flame in the area
while changing fuel system components. Wipe
up any spilled fuel immediately. DO NOT allow
fuel to come into contact with any hot surface
which may cause it to ignite.

! WARNING a

Dispose of fuel-soaked rags, paper, etc., in an ap-

propriate air tight, fire retardant container.
Fuel-soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.

! WARNING
b
Make sure no fuel leaks exist before closing en-
gine hatch.
71370

! CAUTION a - Fuel Filter

b - Water Bleed Valve
Absolute cleanliness is required for work on the
fuel injection system, since the injection pump
and fuel injectors have very close tolerances. 2. Drain until fuel is clear in appearance.
Even minute particles of dirt or small amounts of 3. Release bleed valve.
water can impair the function of the fuel injection
4. Fill fuel filter as outlined later in this section.
system.

90-806934 1194 MAINTENANCE – 1B-19

INDEX
Filling Replacing
NOTICE NOTICE
Refer to “Precautions,” in this Fuel Filter Refer to “Precautions,” in this Fuel Filter
section , BEFORE proceeding. section , BEFORE proceeding.

NOTE: Follow this procedure after installing new filter
or if fuel has been drained from filter checking for
water.
1. Loosen bleed screw on fuel filter bracket.
a b
1. Turn water bleed valve counterclockwise (when
viewed from bottom of filter element) and remove
from old filter. Note position of o-ring.
2. Install o-ring and valve on new filter. Tighten se-
curely.
3. Coat sealing ring on new filter with clean motor oil.
Thread filter onto bracket and tighten securely by
hand. Do not use a filter wrench.
a

c
71370

a - Bleed Screw
b - Fuel Filter Bracket
d

2. Move lever on pump up and down repeatedly, until

an air free stream of fuel flows from bleed screw. e

71370
b
a a - Fuel Filter Bracket
b - O-Ring
c - Fuel Filter
d - O-Ring
e - Water Bleed Valve

4. Fill fuel filter as outlined previously.

5. Start and run engine. Check filter connections for
fuel leaks. If leaks exist, recheck filter installation
and correct as needed.

73332

a - Hand Pump / Primer Lever (On Fuel Pump)

b - Bleed Screw

3. Securely tighten bleed screw.

1B-20 – MAINTENANCE 90-806934 1194

INDEX
Clean/Replace Air Filter 4. Wash element in warm water and detergent until
clean.
1. Disconnect crankcase vent hose from end of air in-
take screen housing. IMPORTANT: No treatment (such as partial oil sat-
uration) is required or recommended on air clean-
er foam element prior to use. Use element clean
and dry for proper filtration.

5. Allow element to completely dry before use and

install around air intake screen.
a
6. Connect crankcase vent hose to end of air clean-
er. Tighten hose clamp securely.
7. Inspect installation to ensure engine draws in fil-
tered air only.

IMPORTANT: To prevent unfiltered air from enter-

ing the engine be certain that all of the air intake
screen is covered by the foam element when in-
stalled.
b
73323

Inspect Drive Belts

a - Air Cleaner
b - Crankcase Vent Hose
! WARNING
2. Carefully remove air cleaner foam element from Make sure engine is stopped and ignition key is
around air intake screen housing mounted on tur- removed.
bocharger inlet.
1. Visually inspect all drive belts for cracks, glazing,
b fraying or separation.
2. Check drive belts for proper tension by pressing
at center point between pulleys. Belt(s) must not
deflect more than 3/16 in. (5 mm).

71267

a - Housing
b - Foam Element

3. Inspect element for tears or holes. a

73190

IMPORTANT: Replace the foam element if it is de- a - Drive Belt

teriorated or torn. (Refer to MAINTENANCE - Typical
“Maintenance Schedules” for replacement inter-
val under normal conditions.)

90-806934 1194 MAINTENANCE – 1B-21

INDEX
Replace Drive Belts
Belt and Pulley Replacement Guidelines:
• During belt assembly, do not force belt into pulley
grooves by prying with a screwdriver, pry bar, etc.
This will damage belt side cords which will cause
belt to turn over in pulley grooves and result in
complete destruction of belt.
• Do not use belt dressing.
• Always check condition of remaining belts. Re-
place belt if worn, cracked, grease- or oil-soaked.
• When replacing belt and pulley, pulley alignment
must be checked under tensioned condition
(brackets securely clamped). A misalignment that
can be detected by visual inspection is detrimental
to belt performance.
• If belt is disturbed for any reason, it must be ten-
sioned to the correct tension.
• Replace pulleys if worn, or clean if still suitable for
service.
• On some engines it may be necessary to remove
other drive belts to gain access to a particular belt
during replacement. Refer to appropriate sections
for information concerning individual drive belts
and proceed accordingly.
Engine Water Circulating Pump Belt
Refer to “Alternator Belt” instructions.
1B-22 – MAINTENANCE
INDEX
Alternator Belt
NOTE: On some engines it may be necessary to re-
move other drive belts to gain access to a particular
belt during replacement. Refer to appropriate sec-
tions for information concerning individual drive belts
and proceed accordingly.
! CAUTION
Before removing the seawater pump hoses, close
the seacock, if so equipped. If boat is not
equipped with a seacock, remove and plug the
seawater inlet hose to prevent a siphoning action
that may occur, allowing seawater to enter the
boat.
1. Close the seacock, if so equipped. If boat is not
equipped with a seacock, remove and plug the
seawater inlet hose. Remove seawater pump in-
let and outlet hoses.
a
b
73521
a - Seawater Inlet Hose
b - Seawater Outlet Hose
D4.2L/220 MCM Engine Shown (All Similar)
2. Loosen alternator mounting and tensioning fas-
teners. Pivot alternator to loosen and remove old
belt.
3. Install new alternator belt.
4. Pivot alternator to adjust belt. Approximately 3/16
in. (5 mm) deflection should be measured at mid-
point between the pulleys on the longest span.
Tighten tensioning and mounting fasteners se-
curely.
90-806934 1194
5. Install seawater pump inlet and outlet hoses. Power Steering Pump Belt
Tighten hose clamps securely.
D3.0L/150 AND D3.6L/150 MODELS

1. Loosen mounting and tensioning fasteners on

power steering pump.
2. Turn tensioning bolt with pinion, to pivot pump
and loosen belt.
c
3. Remove old power steering belt and install new
belt.
4. Turn tensioning bolt with pinion to adjust tension.
Approximately 3/16 in. (5 mm) deflection should
be measured at midpoint between the pulleys on
the longest span.
5. Tighten mounting and tensioning fasteners se-
curely.
73521

c
b

b
71443

a d
73324

a - Mounting Fastener
b - Tensioning Fastener
c - 3/16 in. (5 mm) Approximate Deflection
D4.2L/220 MCM Engine Shown (All Similar)

c
73320

a - Mounting Fastener
b - Tensioning Fastener with Pinion
c - Power Steering Pump
d - 3/16 in. (5 mm) Approximate Deflection

90-806934 1194 MAINTENANCE – 1B-23

INDEX
D4.2L/220 MODELS
NOTE: On some engines it may be necessary to re-
move other drive belts to gain access to a particular
belt during replacement. Refer to appropriate sec-
tions for information concerning individual drive belts
and proceed accordingly.
1. Loosen the two mounting screws and the tension-
ing screw on power steering pump.
2. Pivot the power steering pump to loosen belt.
4. Remove old power steering belt and install new
belt.
5. Pivot the power steering pump to adjust belt.
Approximately 3/16 in. (5 mm) deflection should
be measured at midpoint between the pulleys on
the longest span.
6. Tighten mounting screws and tensioning screw
securely.
d

a a

c
b 70113

a - Mounting Screws (One Hidden In This View)

73521
b - Tensioning Screw
c - Power Steering Pump

a a
! CAUTION
Before removing the seawater pump, close the
seacock, if so equipped. If boat is not equipped
with a seacock, remove and plug the seawater in-
let hose to prevent a siphoning action that may
c
occur, allowing seawater to enter the boat. b
70113
3. Remove or loosen the seawater pump fasteners
sufficiently to allow drive belts to fit between
crankshaft balancer. (Refer to SECTION 6A, a - Mounting Screws (One Hidden In This View)
Seawater Pump Removal.) b - Tensioning Screw
c - 3/16 in. (5 mm) Approximate Deflection

23161

a - Seawater Pump Fasteners

Typical

1B-24 – MAINTENANCE 90-806934 1194

INDEX
7. Install and tighten the seawater pump fasteners.
(Refer to SECTION 6A, Seawater Pump
Removal.)
IMPORTANT: There is an o-ring seal on the water
pump. Ensure that it is in proper position before
installing or securing the water pump. Also, be
certain the pump is keyed in slot before tighten-
ing fasteners.
a 1. Loosen the vacuum pump mounting and tension-
70243
23161
a - O-ring
b - Water Pump Nuts (4)
NOTE: Seawater pump shown removed in inset
drawing for visual clarity only.
90-806934 1194
INDEX
Vacuum Pump Belt
D3.0L/150 AND D3.6L/150 MODELS
NOTE: On some engines it may be necessary to re-
move other drive belts to gain access to a particular
belt during replacement. Refer to appropriate sec-
tions for information concerning individual drive belts
and proceed accordingly.
ing screws, behind the bracket.
2. Appropriately pry or move the vacuum pump to
loosen belt. Remove old belt.
3. Install new vacuum pump belt and adjust tension
[3/16 in. 5 mm) deflection]. Torque mounting and
tension screws to 15 lb. ft. (21 N·m).
c
a
b
74095
a - Tensioning Screw Location
b - Mounting Screw Location
c - Vacuum Pump Bracket
MAINTENANCE – 1B-25
D4.2L/220 MODELS 4. Install new vacuum pump belt and adjust tension
[3/16 in. (5 mm) deflection]. Torque mounting and
NOTE: On some engines it may be necessary to re- tensioning screws to 15 lb. ft. (21 N·m).
move other drive belts to gain access to a particular
belt during replacement. Refer to appropriate sec-
tions for information concerning individual drive belts
and proceed accordingly.
1. Remove or loosen seawater pump fasteners
sufficiently to allow vacuum pump belt to fit
between crankshaft balancer and water pump
housing. (Refer to SECTION 6A, Seawater
Pump Removal.)

a
b

74085

a a - Tensioning Screw Location

b - Mounting Screw Location

5. Install seawater pump and tighten nuts securely.

23161
2. Loosen the vacuum pump mounting and tension-
ing screws, behind the bracket.
IMPORTANT: There is an o-ring seal on the water
pump. Ensure that it is in proper position before
installing or securing the water pump. Also, be
certain the pump is keyed in slot before tighten-
ing fasteners.

c
a

70243

b
a

74085

a - Mounting Screw Location

b - Tensioning Screw Location
c - Vacuum Pump Bracket 23161

3. Appropriately pry or move the vacuum pump to a - O-ring

b - Water Pump Nuts (4)
loosen belt. Remove old belt.
NOTE: Seawater pump shown removed in inset
drawing for visual clarity only.

1B-26 – MAINTENANCE 90-806934 1194

INDEX
 REPLACEMENT
Inspect/Replace Cooling
System Sacrificial Anodes NOTE: Sacrificial anodes are available as an assem-
bly. Replace both the plug and anode, if so desired.

Coolant Tank / Heat Exchanger 1. Refer to “Inspection”, as previously outlined and

Anode remove anode plug. Then:
a. Unscrew anode from anode plug by holding
INSPECTION
plug hex head and turning anode.
The sacrificial anode is located on the starboard ,aft-
b. Clean interior threads of anode plug.
side of the heat exchanger.
c. Apply Loctite #242 to threads of new sacrifi-
1. With the engine cold, remove anode plug and in-
cial anode and install into anode plug. Tighten
spect sacrificial anode for deterioration.
securely.
2. Replace anode assembly when deteriorated
d. Install new copper sealing washer.
50%.
e. Install anode plug, with washer and sacrificial
anode, into heat exchanger. Tighten securely.
a
c b
a

71367

a - Anode Plug
b - Sacrificial Anode
c - Copper Sealing Washer

c b
73326

e d 71368

a - Heat Exchanger
b - Anode Plug and Sacrificial Anode
c - 3/4 in. (19 mm) - Length When New
d - 5/8 in. (16 mm) - Diameter When New
e - Copper Sealing Washer

90-806934 1194 MAINTENANCE – 1B-27

INDEX
Intercooler Anode b. Clean interior threads of anode plug.
c. Apply Loctite #242 to threads of new sacrifi-
INSPECTION cial anode and install into anode plug. Tighten
securely.
The sacrificial anode is located on the top of the inter- d. Install new copper sealing washer.
cooler.
e. Install anode plug, with washer and sacrificial
1. With the engine cold, remove anode plug and in- anode, into intercooler front cover. Tighten
spect sacrificial anode for deterioration. securely.
2. Replace anode assembly when deteriorated c b
50%. a

71367

a b a - 3/4 in. (19 mm) - Length When New

b - 5/8 in. (16 mm) - Diameter When New
c - Anode Plug
d - Sacrificial Anode
e - Copper Sealing Washer

Corrosion and Corrosion

Protection
73327
c
1. After first cleaning all surfaces, check all metal
surfaces and touch up with Quicksilver Paint as
necessary.
2. To maintain a corrosion protective coating on all
metal surface areas, spray with Quicksilver Cor-
e rosion
d 71368 Guard.
a - Engine Intercooler NOTICE
b - Anode Plug and Sacrificial Anode
c - 3/4 in. (19 mm) - Length When New For additional information on Drive Unit
d - 5/8 in. (16 mm) - Diameter When New corrosion protection and external corro-
e - Copper Sealing Washer sion protection refer to appropriate Stern
Drive Service Manual.
REPLACEMENT

NOTE: Sacrificial anodes are available as an assem-

bly. Replace both the plug and anode, if so desired.

1. Refer to “Inspection”, as previously outlined and

remove anode plug. Then:
a. Unscrew anode from anode plug by holding
plug hex head and turning anode.

1B-28 – MAINTENANCE 90-806934 1194

INDEX
Check Battery Shift Cable
Lubricate pivot points and guide contact surfaces with
1. Check battery connections to ensure they are SAE 30W motor oil.
clean and tight. a
2. Keep exterior surfaces of battery wiped clean with
b
a water/baking soda solution. a
3. Ensure battery is securely fastened in place.
4. Refer to battery manufacturer’s recommenda-
tions for fluid levels and charging.

Lubrication a b a
22245

Throttle Cable
a - Pivot Points
Lubricate pivot points and guide contact surfaces with b - Guide Contact Surface
SAE 30W motor oil. MCM Model (Typical) Shift Cable

a 71261 a

a - Pivot Points
b - Guide Contact Surfaces 73587
Single Cable Shown (Dual Similar)
a - Pivot Points
b - Guide Contact Surface
MIE Model (Typical) Shift Cable and Transmission
Linkage

90-806934 1194 MAINTENANCE – 1B-29

INDEX
Engine Coupler/U-Joint Shaft Splines
NOTE: Refer to MerCruiser Stern Drive Service Man-
ual for stern drive unit removal and installation.
a tionary statement above.
70559
a - Quicksilver Engine Coupler Spline Grease
a disconnected and plugged to prevent water from
a from water separator, if equipped. Fill fuel tank at
a cient to prevent freezing to the coldest tempera-
72531
a - Quicksilver Engine Coupler Spline Grease
Freezing Temperature and
Cold Weather Operation
IMPORTANT: If boat is operated during periods of
freezing temperature, precautions must be taken
to prevent freezing damage to power package.
Refer to the following and to “Cold Weather or Ex-
tended Storage” for related information and
draining instructions.
1B-30 – MAINTENANCE
INDEX
In order to operate the engine in temperatures of 32°
F (0° C) or lower, observe the following precautions
and instructions:
! CAUTION
Seawater (raw water) section of cooling system
MUST BE COMPLETELY drained for winter stor-
age or immediately after cold weather use, if the
possibility of freezing temperatures exist. Failure
to comply may result in trapped water causing
freeze and/or corrosion damage to engine.
1. At the end of each daily operation, COMPLETELY
drain seawater section of the cooling system and
the seawater strainer to protect against damage
by freezing. Refer to Section 6A, and the precau-
! CAUTION
If boat is in the water, seacock (water inlet valve),
if so equipped, must remain closed until engine
is to be re-started to prevent water from flowing
back into seawater cooling system. If boat is not
fitted with a seacock, water inlet hose must be left
flowing into cooling system and/or boat. As a pre-
cautionary measure, attach a tag to the ignition
switch or steering wheel with the warning that the
valve must be opened or the water inlet hose re-
connected prior to starting the engine.
2. At the end of each daily operation, drain water
end of daily operation to prevent condensation.
3. Closed cooling section of engine must be filled
with Quicksilver Premixed Marine Engine Cool-
ant, a mixture of antifreeze/water solution suffi-
ture of the user area.
4. Be sure to use proper cold weather lubrication oil,
and be sure the crankcase contains a sufficient
amount.
5. Make certain that the battery is of sufficient size
and is fully charged. Check that all other electrical
equipment is in optimum condition.
6. At temperatures of –4° F (–20° C) and below, it
is recommended that you use the crankcase
mounted coolant heater to improve cold starting.
7. If operating in arctic temperatures of –20° F (–29°
C) or lower, consult your dealer for information
about special cold weather equipment and pre-
cautions.
90-806934 1194
Saltwater Operation
Seawater section must be flushed after each use. Re-
fer to “Flushing Seawater Cooling System.”
Cold Weather or Extended
Storage
Precautions
! CAUTION
Seawater section of cooling system MUST BE
COMPLETELY drained for winter storage, or im-
mediately after cold weather use, if the possibility
of freezing temperatures exists. Failure to com-
ply may result in trapped water causing freeze
and/or corrosion damage to engine.
! CAUTION
If boat is in the water, seacock (water inlet valve),
if so equipped, must remain closed until engine
is to be re-started, to prevent water from flowing
back into cooling system and/or boat. If boat is
not fitted with a seacock, water inlet hose must re-
main disconnected and plugged (to prevent wa-
ter from flowing back into cooling system and/or
boat). As a precautionary measure, attach a tag to
the ignition switch or steering wheel of the boat
with the warning: Open seacock or reconnect wa-
ter inlet hose before starting engine.
90-806934 1194
INDEX
IMPORTANT: Observe the following information
to ensure complete draining of cooling system.
• Engine must be as level as possible.
• A wire should be repeatedly inserted into all
drain holes to ensure there are no obstruc-
tions in passages. Remove petcock, if neces-
sary, to insert wire completely into drain hole.
IMPORTANT: To prevent threads in cylinder
blocks from rusting out during storage, reinstall
plugs using Quicksilver Perfect Seal on threads.
Never leave drain plugs out during storage.
NOTE: If possible, place a container under drains and
hoses to prevent water from draining into boat.
! CAUTION
Closed cooling section of engine must be kept
filled with specified coolant to protect engine to
lowest temperature to which it will be exposed.
DO NOT USE PROPYLENE GLYCOL antifreeze in
closed cooling section. Seawater section, how-
ever, must be drained completely.
! CAUTION
A discharged battery can be damaged by freez-
ing.
MAINTENANCE – 1B-31
Layup 5. Drain seawater section of cooling system and
prepare for cold weather or extended storage fol-
NOTICE lowing these procedures:
Refer to “Cold Weather or Extended Storage,”
“Precautions,” in this section, BEFORE proceed- IMPORTANT: Drain only the seawater section of
ing. the cooling system.

IMPORTANT: This service should be performed IMPORTANT: Closed cooling section must be
by an authorized MerCruiser dealer. kept filled year-round with specified coolant.

! CAUTION
The engine must be prepared for long storage pe-
riods to prevent internal corrosion and severe
damage.

! WARNING
Do not remove coolant cap when engine is hot;
coolant may discharge violently causing severe
burns.

1. Slowly and carefully remove coolant tank cap

from the heat exchanger. Be certain coolant level
is to the bottom of the filler opening. If not, add
specified coolant as necessary to achieve proper
level.

IMPORTANT: If boat has already been removed

from water, before starting engine a source of wa-
ter must be supplied to water intake (inlet) open-
ings. Follow all warnings and flushing attach-
ment procedures stated in “Flushing Seawater
Cooling System.”
! CAUTION
DO NOT operate engine without cooling water be-
ing supplied to seawater pickup pump or water
pump impeller will be damaged and subsequent
overheating damage to engine may result.

2. Start engine and run until it reaches normal oper-

ating temperature. Stop engine.
3. Change crankcase oil and oil filter (refer to
“Changing Crankcase Oil and Oil Filter”). Be cer-
tain to fill engine with correct amount of recom-
mended oil. Always use dipstick to determine ex-
act amount of oil required.
4. Start engine and run at IDLE for about 15 minutes.
Check for any oil leaks and correct as necessary.

1B-32 – MAINTENANCE 90-806934 1194

INDEX
DRAINING INSTRUCTIONS 2. Do not open either of these two petcocks. They
are in the closed cooling section.
! CAUTION
If boat is to remain in the water, seacock, if so
equipped, must be closed until engine is to be re-
started to prevent water from flowing back into
seawater cooling system. If boat is not fitted with
a seacock, water inlet hose must be discon-
nected and plugged to prevent water from flow-
ing into cooling system and/or boat. As a precau-
tionary measure, attach a tag to the ignition
a
switch or steering wheel with the warning that the
valve must be opened or the water inlet hose re-
connected prior to starting the engine.
71364
IMPORTANT: Observe the following information
to ensure complete draining of seawater cooling
system.
• Engine must be as level as possible.
• A wire should be repeatedly inserted into all
drain holes to ensure there are no obstruc-
tions in passages.

1. Close seacock, if so equipped, or disconnect and

plug seawater inlet hose, if boat is to remain in the 73335
water. 73522

72706

a - Exhaust Manifold Petcock (Do NOT Open.)

b - Engine Block Petcock (Do NOT Open.)
Typical

90-806934 1194 MAINTENANCE – 1B-33

INDEX
3. Remove the end covers from BOTH port and star- 4. Follow appropriate instructions “a” or “b”:
board ends on upper and lower sections of heat
a. On MCM (Stern Drive) Engines: Disconnect
exchanger tank. Drain tank completely. Sponge-
seawater outlet hose at aft end of power
out or soak-up any water that remains in the bot-
steering fluid cooler. Lower hose and drain
tom part of each section, until all water passage
completely.
tubes are completely free of standing water.

a
! CAUTION
Avoid damage to heat exchanger and subsequent
possible engine damage. Remove all water from
heat exchanger sections. Failure to do so could
cause corrosion or freeze damage to heat ex-
changer water passage tubes.
b

72470

a - Power Steering Fluid Cooler

b - Seawater Hose
b. On MIE (Inboard) Engines: Disconnect
73326 seawater outlet hose at aft end of
b transmission fluid cooler. Lower hose and
drain completely.

a a
b

b 73335

73322 a - Transmission Fluid Cooler

b - Seawater Hose
a - Upper Section End Cover(s)
b - Lower Section End Cover(s)
NOTE: In the following it may be necessary to lower
or bend the hoses to allow water to drain completely.

1B-34 – MAINTENANCE 90-806934 1194

INDEX
5. Remove the drain plug from the aft end cover of
the intercooler.
a Tighten securely. Reconnect hoses. Tighten hose
b (22 N·m). Torque the end covers on the lower
70071
a - Drain Plug
b - Intercooler
6. Remove seawater pump outlet hose from top of
seawater pump and drain.
a Seal, and reinstall. Tighten securely. Install all
73322
a - Seawater Pump Outlet Hose
7. Repeatedly clean out drain holes using a stiff
piece of wire. Do this until entire system is
drained.
! CAUTION
Avoid water entering boat. Do not unplug seawa-
ter inlet hose unless a seacock is present and it
is closed.
8. Remove hose(s) at seawater strainer and drain
hose(s) completely. Empty seawater strainer.
(Refer to MAINTENANCE SECTION - Cleaning
Quicksilver Seawater Strainer.) Reconnect
hose(s) and tighten hose clamps securely.
90-806934 1194
INDEX
9. After seawater section of cooling system has
been drained completely, coat threads of inter-
cooler drain plug with Perfect Seal and reinstall.
clamps securely. Install all four end covers on the
heat exchanger tank (Renew end cover gaskets
if worn or deteriorated.). Torque the end covers
on the upper heat exchanger section to 16 lb. ft.
heat exchanger section to 96 lb. in. (11 N·m).
10. If not already accomplished, close seacock, if so
equipped, or disconnect and plug seawater inlet
hose, if boat is to remain in the water. Disconnect
hoses at seawater strainer (if so equipped) and
drain hoses completely. Empty and clean seawa-
ter strainer (refer to “Check/Clean Seawater
Strainer”). Reconnect hoses and tighten hose
clamps securely.
c
c
b b
a
72691
a - Seawater Strainer
b - Hoses
c - Hose Clamps
11. After seawater section of cooling system has
drained completely, coat threads of drain plugs
previously removed with Quicksilver Perfect
hoses previously removed and tighten hose
clamps securely.
IMPORTANT: MerCruiser recommends that pro-
pylene glycol antifreeze (nontoxic and biode-
gradable, which makes it friendly to lakes and riv-
ers) be used in seawater section of the cooling
system for cold weather or extended storage.
Make sure that the propylene glycol antifreeze
contains a rust inhibitor and is recommended for
use in marine engines. Be certain to follow the
propylene glycol manufacturer’s recommenda-
tions.
12. Fill a container with approximately 6 U.S. quarts
(5.6 L) of antifreeze and tap water mixed to man-
ufacturer’s recommendation to protect engine to
the lowest temperature to which it will be exposed
during cold weather or extended storage.
MAINTENANCE – 1B-35
13. Disconnect hose from seawater inlet side of sea-
water pump. Using an adaptor, temporarily con-
nect an appropriate length piece of hose to sea-
water pump and place the other end of the hose
into container of coolant.
b. Ease impeller off pump shaft with two screw-
drivers.
c. Reinstall cover for storage.
NOTE: Pump shown removed for visual clarity only.

b
e a

c d

73521
e
a - Seawater Pump Inlet Hose
MCM (Stern Drive) Engine Shown (All Similar)

! CAUTION
It is good practice to ventilate the engine com- 71366
partment prior to servicing any engine compo- a - Seawater Pump Housing
nents to remove any fuel vapors which may cause b - Cover Screws
difficulty breathing or be an irritant. c - Cover
d - Gasket
e - Impeller
14. Start engine and run, AT IDLE SPEED, until anti-
D3.0L/150 Seawater Pump Shown (All Similar)
freeze mixture has been pumped into engine sea-
water cooling system. Stop engine.
IMPORTANT: Place a CAUTION TAG at instrument
15. Clean engine and coat with Quicksilver Corrosion panel and in engine compartment stating that
Guard or equivalent corrosion inhibiting oil. “Seawater Pump is Out - DO NOT Operate En-
16. Lubricate all items outlined in ”Lubrication.” gine.”
17. Remove and store battery in a cool, dry place. Do
not store on a concrete surface, or on the ground. ! CAUTION
Place on a dry, wood board or a thick plastic base
(Refer to battery manufacturer’s instructions.) Stern drive unit should be stored in full “down”
position. Universal Joint bellows may develop a
18. Perform all checks, inspections, lubrication and “set” if unit is stored in raised position and may
fluid changes outlined in “Maintenance Schedule” fail when unit is returned to service.
under “At Least Once Yearly.”
19. Remove seawater pump impeller for storage as 20. Place stern drive unit in the full “down” position.
follows:
a. Remove seawater pump cover mounting
screws, and remove cover and gasket.

1B-36 – MAINTENANCE 90-806934 1194

INDEX
BATTERY WINTER STORAGE c. Install the seawater pump cover mounting
Follow battery manufacturer’s instructions for stor- screws. Tighten securely.
age. If not available, use the following instructions: NOTE: Pump shown removed for visual clarity only.
1. Be certain all electrical components are off, and
ignition key is in OFF position.
2. To avoid possible electrical system damage, a
FIRST remove the NEGATIVE (–) battery cable,
and NEXT remove the POSITIVE (+) battery
cable. Remove the battery.
3. Remove dirt and grease from top surface of bat-
tery.
4. Follow battery manufacturer’s recommendations
and add distilled water, if needed.
5. Grease cable ends and bolts.
6. Store battery in a cool, dry place. Do not store on
a concrete surface, or on the ground. Place on a
dry wood board or a thick plastic base.

! CAUTION
A discharged battery can be damaged by freez-
ing.
7. Every 30 to 45 days, check water level and re-
charge battery according to manufacturer’s spec-
ifications. Do not fast charge.
If you cannot perform the above service, contact your
authorized MerCruiser dealer or local automotive
garage.
Recommissioning
NOTICE
Refer to “Cold Weather or Extended Storage,”
“Precautions,” in this section, BEFORE pro-
ceeding.
1. Reinstall seawater pump components as follows:
a. Place impeller in pump housing, turning
clockwise while simultaneously pushing firm-
ly inward onto pump shaft.
NOTE: Use new gasket. Install in correct position -
wide surface on side of cam.
b. Install pump cover with new gasket in noted
position.
e b
a
d c
71366
a - Impeller
b - Seawater Pump Housing
c - Gasket (Wide Surface on Cam Side)
d - Cover
e - Cover Screws
D3.0L/150 Seawater Pump Shown (All Similar)
2. Check that all cooling system hoses are in good
condition and connected properly, hose clamps
are tight, and all petcocks and drain plugs are in-
stalled and tight.
3. Inspect all drive belts.
4. Perform all lubrication and maintenance specified
for completion “At Least Once Yearly” in “Mainte-
nance Schedule,” except items which were per-
formed at time of engine layup.
5. Fill fuel tank(s) with fresh diesel fuel. Old fuel
should not be used. Check fuel lines and connec-
tions for leaks and general condition.

90-806934 1194 MAINTENANCE – 1B-37

INDEX
6. Replace fuel filter as outlined previously in this ! CAUTION
section.
DO NOT operate engine without water flowing
7. For drive unit, refer to appropriate Stern Drive thru seawater pickup pump, as pump impeller
Service Manual. may be damaged and subsequent overheating
damage to engine or transmission may result.
! CAUTION
10. Start engine and closely observe instrumentation
When installing battery, be sure to connect POSI-
to make sure that all systems are functioning cor-
TIVE (+) battery cable to POSITIVE (+) battery ter-
rectly.
minal FIRST, and NEGATIVE (–) battery cable to
NEGATIVE (–) battery terminal LAST. If battery 11. Carefully inspect engine for fuel, oil, fluid, water
cables are reversed, or connection order is re- and exhaust leaks.
versed, electrical system damage will result.
12. Check steering system, shift and throttle control
for proper operation.
8. Install fully-charged battery. Clean battery cable
clamps and terminals and reconnect cables (see
CAUTION listed above). Secure each cable
clamp when connecting. Coat terminals with a
battery terminal anti-corrosion spray to help re-
tard corrosion.
9. Perform all checks on OPERATION CHART in
the STARTING PROCEDURE column.

IMPORTANT: After a lengthy lay-up (several

months), it is necessary to pre-lubricate the
turbocharger. To do this, move the “STOP”
switch toggle lever DOWN and hold in this
position while you turn the key switch to “START”
position. Doing this TOGETHER turns the engine
without starting it. DO NOT engage starter for
more than 15 seconds; allow at least one minute
cool down time before re-engaging starter for
another 15 seconds. Watch that starter does not
overheat.

1B-38 – MAINTENANCE 90-806934 1194

INDEX
IMPORTANT INFORMATION
1
C

TROUBLESHOOTING
Note: Refer to the following Service Bulletin regarding this section:
SB 96-9 MerCruiser Scan Tool

INDEX
Table of Contents
Page
Engine Smoking (Blue) . . . . . . . . . . . . . . . . . . . . . . . 1C-12
NOTICE Engine Smoking (White) . . . . . . . . . . . . . . . . . . . . . . 1C-12
Refer to “Precautions” BEFORE proceeding Exhaust Gas Temperature (High) . . . . . . . . . . . . . . 1C-13
with Troubleshooting. Exhaust Gas Temperature (Low) . . . . . . . . . . . . . . . 1C-13
Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Page Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Valve Cover Area . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Cylinder Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Poor Boat Performance and/or Poor Camshaft Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-16
Maneuverability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Crankshaft Area . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Improper Full Throttle Engine RPM . . . . . . . . . . . . . . 1C-3 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
RPM Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
RPM Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Engine Cranks Over but Will Not Start High Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
or Starts Hard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Excessive Oil Consumption . . . . . . . . . . . . . . . . 1C-20
Important Information . . . . . . . . . . . . . . . . . . . . . . 1C-4 Water in Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Important Information . . . . . . . . . . . . . . . . . . . 1C-21
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Water In Crankcase Oil . . . . . . . . . . . . . . . . . . . . 1C-21
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Water On Top Pistons . . . . . . . . . . . . . . . . . . . . . 1C-22
Engine Will Not Crank Over or Starter Inoperative . 1C-5 Engine Overheats (Cooling System) . . . . . . . . . . . . 1C-22
Glow Plugs Inoperative . . . . . . . . . . . . . . . . . . . . . . . . 1C-6 Engine Overheats (Mechanical) . . . . . . . . . . . . . . . 1C-24
Charging System Inoperative . . . . . . . . . . . . . . . . . . . 1C-7 Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
Noisy Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Poor, Erratic, or No Assist . . . . . . . . . . . . . . . . . . 1C-25
Engine Runs Poorly at Idle . . . . . . . . . . . . . . . . . . . . . 1C-8 Noisy Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-26
Engine Runs Poorly At High Rpm . . . . . . . . . . . . . . . 1C-9 Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-26
Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Insufficient Water Flow From Belt Driven
Engine Smoking (Black) . . . . . . . . . . . . . . . . . . . . . . 1C-11 Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Hurth Hydraulic Transmission . . . . . . . . . . . . . . . . . 1C-28

1C –– TROUBLESHOOTING
1C-0 TROUBLESHOOTING 90-806934 1194
INDEX
Precautions
! WARNING
Always disconnect battery cables from battery
BEFORE working on fuel system to prevent fire or
explosion.
! WARNING
Always disconnect battery cables from battery
before working around electrical system compo-
nents to prevent injury to yourself or damage to
electrical system.
! WARNING
Be careful when changing fuel system compo-
nents; diesel fuel is flammable. Be sure that igni-
tion key is OFF. DO NOT smoke or allow sources
of spark or flame in the area while changing fuel
system components. Wipe up any spilled fuel im-
mediately. DO NOT allow fuel to come into con-
tact with any hot surface which may cause it to ig-
nite.
! WARNING
Avoid diesel fuel fire. Improper installation of
brass fittings or plugs into fuel filter base can
crack casting and/or cause a fuel leak. Follow
specific procedure, given in Section 4 of this
manual, for all fuel line connections.
Fuel Supply Connections
! WARNING
Avoid diesel fuel fire or explosion. Improper in-
stallation of brass fittings or plugs into fuel filter
base can crack casting and/or cause a fuel leak.
• Apply #592 Loctite Pipe Sealant with Teflon to
threads of brass fitting or plug. DO NOT USE
TEFLON TAPE.
• Thread brass fitting or plug into fuel filter base un-
til finger tight.
• Tighten fitting or plug an additional 1-3/4 to 2-1/4
turns using a wrench. DO NOT OVER-TIGHTEN.
• Install fuel line. To prevent over-tightening, hold
brass fitting with suitable wrench and tighten fuel
line connectors securely.
• Check for fuel leaks.
! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
serious bodily injury or death. Careful periodic in-
spection of entire fuel system is mandatory, par-
90-806934 1194
INDEX
ticularly after storage. All fuel components in-
cluding fuel tanks, whether plastic, metal or
fiberglass, fuel lines, primers, fittings, and fuel fil-
ters should be inspected for leakage, softening,
hardening, swelling or corrosion. Any sign of
leakage or deterioration requires replacement
before further engine operation.
! WARNING
Dispose of fuel-soaked rags, paper, etc., in an ap-
propriate air tight, fire retardant container.
Fuel-soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
Make sure no fuel leaks exist before closing en-
gine hatch.
! CAUTION
DO NOT operate engine without water being supplied
to seawater pickup pump on engine, or pump impeller
may be damaged and subsequent overheating dam-
age to engine may result. Engine may be operated with
boat out of water, if instructions for running engine
with boat out of water, below, are followed.
! WARNING
When running engine with boat out of water, be
certain that area in vicinity of propeller is clear
and that no person is standing nearby. As a pre-
cautionary measure, it is recommended that the
propeller be removed.
! CAUTION
DO NOT run engine above 1500 RPM, as suction
created by seawater pickup pump may collapse water
supply hose and cause engine to overheat.
! WARNING
Be sure that engine compartment is well venti-
lated and that no diesel fuel vapors are present to
prevent the possibility of a FIRE or EXPLOSION.
! WARNING
DO NOT leave helm unattended while performing
idle speed adjustment.
! WARNING
Safety glasses should be worn while working on
fuel injection system. The fuel injection pump will
generate pressures in excess of 2000 PSI (13790
kPa). Use caution when removing injectors, injec-
tor lines, or bleeding air from injection system.
TROUBLESHOOTING – 1C-1
Poor Boat Performance and/or Poor Maneuverability
Symptom Cause
1. Bow too low 1. A. Improper drive unit trim angle
B. Improper weight distribution
C. Boat is underpowered
D. Permanent or power hook in boat bottom
E. False bottom full of water
F. Improperly adjusted trim tabs (after planes)

2. Bow too high 2. A. Improper drive unit trim angle

B. Propeller pitch too great
C. Dirty boat bottom (marine growth)
D. Poor running engine
E. Improper weight distribution
F. Rocker in boat bottom
G. False bottom full of water
H. Improperly adjusted trim tabs (after planes)

3. Propeller ventilating 3. A. Drive unit installed too high on transom

B. Dirty or rough boat bottom
C. Damaged propeller; pitch too small; diameter
too small
D. Keel located too close to propeller or too deep
in the water
E. Water pickup or accessories located too close
to propeller
F. Hook in boat bottom
G. Propeller plugged up with weeds

1C-2 – TROUBLESHOOTING 90-806934 1194

INDEX
Improper Full Throttle Engine RPM

RPM Too High

Cause Special Information
1. Propeller 1. Damaged; pitch too low; diameter too small;
propeller hub slipping

2. Boat 2. A. Water pickup or accessories mounted too

close to propeller (ventilation)
B. Keel located too close to propeller and/or too
deep in the water (ventilation)
C. Drive installed too high on transom
D. Wrong gear ratio

3. Operation 3. Unit trimmed out too far

4. Engine coupler slipping

RPM Too Low

Cause Special Information
1. Propeller 1. Damaged; pitch too great; diameter too great

2. Boat 2. A. Dirty or damaged bottom

B. Permanent or power hook in bottom
C. False bottom full of water
D. Drive installed too low

3. Operation 3. Unit trimmed in too far

90-806934 1194 TROUBLESHOOTING – 1C-3

INDEX
Engine Cranks Over but Will Not Start or Starts Hard
Important Information
Determine which engine system is causing the problem. To make an engine run, basic components - fuel, glow
plugs, and compression - are required. If all three components are present, the engine should run. If any one of the
three are missing, weak, or arriving at the wrong time the engine will not run.

Electrical
Cause Special Information
1. Battery, electrical connections, damaged wiring

2. Ignition switch

3. Glow plugs inoperative

4. Injection timing 4. May crank over hard

Fuel System
Cause Special Information
1. Empty fuel tank

2. Fuel shutoff valve closed (if equipped)

3. Cold start lever 3. To help when starting a cold engine when outside
temperature is below 50° F (10° C)

4. Anti-siphon valve stuck closed (if so equipped) 4. Restricting fuel supply

5. Mechanical engine stop lever improperly posi- 5. Reposition lever (push forward)
tioned (pushed to rear)

6. Low grade, stale fuel or water in fuel

7. Fuel waxing or frozen water separator (cold

weather)

8. Plugged fuel suction line or filter

9. Air leaks, suction side fuel line or water separator 9. Sucks air into fuel system reducing fuel volume

10. Plugged or pinched fuel line (feed or return)

11. Fuel tank vent plugged 11. Engine will start initially. After a short time
running, engine will stall and will not restart for a
period of time. Can verify if it is a vent problem by
running engine with filler cap loose. Filler cap will
act as a vent.

1C-4 – TROUBLESHOOTING 90-806934 1194

INDEX
Fuel System (continued)
Cause Special Information
12. Injection pump solenoid valve

13. Fuel supply pump 13. Low pump pressure

Miscellaneous
Cause Special Information
1. Low grade or stale fuel

2. Water in fuel

3. Incorrect starting procedure 3. Refer to Owners Manual

4. Internal mechanical damage (bent rods, etc.)

5. Low compression 5. Worn valves, rings, cylinder, or head gasket

6. Valve timing incorrect 6. Timing gears improperly installed or cam slipped

in drive gear

7. Restricted or plugged exhaust

Engine Will Not Crank Over or Starter Inoperative

Cause Special Information
1. Remote control lever not in neutral position

2. Battery charge low; damaged wiring; loose electri-

cal connections

3. Circuit breaker tripped

4. Blown fuse

5. Ignition switch

6. Slave solenoid

90-806934 1194 TROUBLESHOOTING – 1C-5

INDEX
Engine Will Not Crank Over or Starter Inoperative (continued)
7. Faulty neutral start safety switch 7. Open circuit

8. Starter solenoid

9. Starter motor

10. Engine mechanical malfunction

Glow Plugs Inoperative

Cause Special Information
1. Battery discharged

2. Circuit breaker tripped 2. On dash or in electrical box

3. Poor battery connections

4. Glow plug(s) defective (burned out)

5. Controller defective or inoperative 5. In electrical box

6. Pre-glow circuit of controller inoperative 6. In electrical box

7. Water temperature sender inoperative

8. Ignition switch inoperative

9. Broken or disconnected wire in glow plug circuit

1C-6 – TROUBLESHOOTING 90-806934 1194

INDEX
Charging System Inoperative
Cause Special Information
1. Loose or broken drive belt

2. Engine RPM too low on initial start 2. Rev engine to 1500 RPM

3. Loose or corroded electrical connections

4. Faulty battery gauge 4. Best way to test is to replace gauge

5. Battery will not accept charge 5. Low electrolyte or failed battery

6. Faulty alternator or regulator

7. Refer to “Charging System” SECTION for com-

plete diagnostic procedures

Noisy Alternator
Cause Special Information
1. Loose mounting bolts

2. Drive belt 2. Worn, frayed, loose

3. Loose drive pulley

4. Worn or dirty bearings

5. Faulty diode trio or stator

6. Faulty armature 6. Rubbing, broken wire

90-806934 1194 TROUBLESHOOTING – 1C-7

INDEX
Engine Runs Poorly at Idle
Cause Special Information
1. Clogged air cleaner

2. Improper idle fuel mixture adjustment

3. Plugged fuel suction line or filter

4. Air leaks: suction side fuel line, water separating

fuel filter or loose intake manifold

5. Water in fuel 5. Refer to Sections 1A and 5A

6. Low grade or stale fuel

7. Fuel waxing or frozen water separating fuel filter

(cold weather)

8. Valve timing 8. Cam slipped in drive gear

9. Restricted or plugged exhaust

10. Injectors not functioning properly 10. Refer to Section 5C

11. Injection pump timing incorrect

12. Low compression 12. Also check for defective (blown) head gasket

13. Water leaking into cylinders 13. Defective head gasket, exhaust manifold, cracked
head or valve seat

14. Loose or broken engine mounts

1C-8 – TROUBLESHOOTING 90-806934 1194

INDEX
Engine Runs Poorly At High Rpm
Cause Special Information
1. Also refer to “Poor Boat Performance” 1. See “Table of Contents”

2. Crankcase overfilled with oil 2. Check oil level with boat at rest in the water

3. Anti-siphon valve (if equipped) 3. Restricting fuel supply

4. Plugged fuel tank vent

5. Low fuel supply

6. Clogged fuel filter

7. Low grade of fuel or water in the fuel

8. Obstructed fuel lines

9. Injectors not functioning properly 9. Refer to Section 5C

10. Engine overheating 10. Refer to “Engine Overheats”

(See “Table of Contents”)

11. Low compression 11. Worn valves, rings, cylinders, etc.

12. Restricted or plugged exhaust

90-806934 1194 TROUBLESHOOTING – 1C-9

INDEX
Poor Fuel Economy
Cause Special Information
1. Fuel leaks

2. Operator habits 2. Prolonged idling; slow acceleration; failure to cut

back on throttle once boat is on plane; boat over
loaded; uneven weight distribution

3. Engine laboring 3. Bent, damaged, or wrong propeller. Water test

boat for proper operating RPM at wide open
throttle

4. Clogged air cleaner

5. Engine compartment sealed too tight 5. Not enough air for engine to run properly

6. Boat bottom 6. Dirty (marine growth), hook, rocker

7. Turbocharger malfunction

8. Improper fuel

9. Crankcase ventilation system not working

10. Engine running too hot or too cold

11. Plugged or restricted exhaust

12. Engine 12. Low compression

13. Injectors not functioning properly

14. Injection pump timing incorrect

1C-10 – TROUBLESHOOTING 90-806934 1194

INDEX
Engine Smoking (Black)
Cause Special Information
1. Overload

2. Clogged air cleaner

3. Excessive fuel delivery 3. Refer to Section 5A

4. Faulty injector(s) 4. Refer to Section 5C

5. Restricted or plugged exhaust

6. Insufficient coolant temperature

7. Excessive idle time (slobber)

8. Inoperative glow plug system 8. Refer to Section 4B

9. Leaking head gaskets

10. Worn piston rings

90-806934 1194 TROUBLESHOOTING – 1C-11

INDEX
Engine Smoking (Blue)
Cause Special Information
1. Insufficient load 1. Check propeller

2. Low fresh water temperature (faulty thermostat) 2. Check temperature of oil and water

3. Worn piston rings 3. Check compression

4. Sticking piston rings 4. Check compression

5. Oil leakage from compressor side of turbocharger 5. Check turbocharger

6. Crankcase overfilled - incorrect dipstick reading

7. Leaking head gaskets

Engine Smoking (White)

Cause Special Information
1. Injection pump timing incorrect 1. Refer to Section 5B

2. Faulty injector(s) 2. Refer to Section 5C

3. Low compression

4. Plugged fuel suction line or filter

5. Air leaks, suction side fuel line or water separat-

ing fuel filter

6. Questionable fuel quality

7. Restricted fuel return/excessive return line pres-

sure

8. Leaking head gaskets

1C-12 – TROUBLESHOOTING 90-806934 1194

INDEX
Exhaust Gas Temperature (High)
Cause Special Information
1. Excessive load

2. Injection pump timing incorrect 2. Refer to Section 5B

3. Wrong assembly - timing device - pressure regu-

lating valve

Exhaust Gas Temperature (Low)

Cause Special Information
1. Injection pump timing incorrect 1. Refer to Section 5B

2. Excessive idling time/light loads

3. Heater system air locked

Fuel Injection Nozzle

Cause Special Information
1. Nozzle turning blue 1. Faulty installation or tightening; insufficient
cooling

2. Nozzle opening pressure too high 2. Incorrect shim adjustment; nozzle valve dirty or
sticky; seized nozzle

3. Nozzle opening pressure too low 3. Shim/spacer wear; nozzle valve spring weak or
broken; nozzle seat worn

4. Nozzle valve seat leakage 4. Nozzle leaks because of excessive carbon de-
posits or sticking nozzle valve; defective nozzle

90-806934 1194 TROUBLESHOOTING – 1C-13

INDEX
Turbocharger
Make certain that troubles are not due to engine components, especially to injection system, before troubleshoot-
ing turbocharger and/or carrying out corrective action on turbocharger.

Cause Special Information

1. Smoke from exhaust 1. A. Not enough air getting to engine air intake
B. Clogged air filter
C. Boost pressure too low
D. Refer to “Engine Smoking (Black, Blue and/or
White)” in previous troubleshooting chart

2. Loss of power 2. A. Not enough air getting to engine air intake

B. Clogged air cleaner
C. Boost pressure too low
D. Poor lubrication of turbocharger
E. Low oil pressure at turbocharger
F. Defective wastegate valve
G. Rubbing of compressor or turbine impellers
against housing
H. Defective engine gaskets allowing air or fuel
escape into exhaust or intake system

3. Unusual noises and vibrations at turbocharger 3. A. Poor lubrication of turbocharger

B. Low oil pressure at turbocharger
C. Rubbing of compressor or turbine impellers
against housing
D. Defective engine gaskets allowing air or fuel
escape into exhaust or intake system

4. Rubbing of compressor or turbine impellers 4. A. Poor lubrication of turbocharger

against housing
B. Low oil pressure at turbocharger
C. Defective bearings in turbocharger

5. Oil leakage from compressor side 5. A. Clogged air cleaner

B. Boost pressure too low

1C-14 – TROUBLESHOOTING 90-806934 1194

INDEX
Engine Noise
IMPORTANT INFORMATION 4. Try to isolate the noise to location in engine: front
to back, top to bottom. This can help determine
No definite rule or test will positively determine source
which components are at fault.
of engine noise; therefore, use the following informa-
tion only as a general guide to engine noise diagno- 5. Sometimes noises can be caused by moving
sis. parts coming in contact with other components.
Examples are: flywheel or coupler; exhaust flap-
1. Use a timing light to determine if noise is timed
pers rattling against exhaust pipe; crankshaft
with engine speed or one-half engine speed.
striking (pan, pan baffle, or dipstick tube); rocker
Noises timed with engine speed are related to
arm striking valve cover; and loose flywheel cov-
crankshaft, rods, pistons, piston pins, and fly-
er. In many cases if this is found to be the problem,
wheel. Noises timed to one-half engine speed are
a complete engine teardown is not necessary.
valve train related.
6. When noise is isolated to a certain area and com-
2. The use of a stethoscope can aid in locating a
ponent, removal and inspection will be required.
noise source; however, because noise will travel
Refer to proper sections of service manual for in-
to other metal parts not involved in the problem,
formation required for service.
caution must be exercised.
7. If noise cannot be distinguished between engine
3. If you believe noise is confined to one particular
and drive unit, remove drive from boat. Run a wa-
cylinder, ground spark plug leads, one at a time.
ter supply directly to engine. Run engine without
If noise lessens noticeably or disappears, it is iso-
the drive to determine if noise is still there.
lated to that particular cylinder.

Valve Cover Area

Location Possible Cause
1. Valve cover area, timed to one-half engine 1. A. Rocker arm striking valve cover
speed, noise could be confined to one cylinder
or may be found in any multitude of cylinders
B. Rocker arm out of adjustment
C. Worn rocker arm
D. Bent push rod
E. Worn camshaft
F. Sticking valve

Cylinder Area
Location Possible Causes
1. Cylinder area, may be confined to one cylinder 1. A. Sticking valve
or found in more than one cylinder, timed to
engine speed
B. Carbon build-up
C. Connecting rod installed wrong
D. Bent connecting rod
E. Piston
F. Piston rings
G. Piston pin
H. Cylinder worn

90-806934 1194 TROUBLESHOOTING – 1C-15

INDEX
Cylinder Area (continued)
Location Possible Causes
2. Engine knocking 2. A. Faulty injector (white smoke)
B. Worn delivery valve
C. Wrong injection timing
D. Incorrect valve clearance
E. Loose pre-combustion chamber
F. Tight piston pin

Camshaft Area
Location Possible Causes
1. Camshaft area, front of engine, timed to engine 1. A. Camshaft timing gear
speed
B. Injection pump
C. Fuel pump
D. Valve lifter - camshaft wear
E. Cam bearings

2. Camshaft area, center of engine, timed to 2. A. Fuel pump

engine speed
B. Valve lifter - camshaft wear
C. Cam bearings

3. Camshaft area, rear of engine, timed to engine 3. A. Valve lifter - camshaft wear
speed
B. Cam bearings

4. Camshaft area, throughout engine, timed to 4. A. Loss of oil pressure

engine speed
B. Valve lifter - camshaft wear
C. Cam bearings

1C-16 – TROUBLESHOOTING 90-806934 1194

INDEX
Crankshaft Area
Location Possible Causes
1. Crankshaft area, front of engine, timed to engine 1. A. Crankshaft timing gear
speed
B. Oil Pump
C. Rod bearing
D. Main bearing

2. Crankshaft area, center of engine, timed to 2. A. Crankshaft striking pan or pan baffle
engine speed
B. Rod bearing
C. Main bearing

3. Crankshaft area, rear of engine, timed to engine 3. A. Loose flywheel cover

speed
B. Loose coupler or drive plate
C. Loose flywheel
D. Rod bearing
E. Main bearing

4. Crankshaft area, throughout engine, timed to 4. A. Loss of oil pressure

engine speed
B. Rod bearings
C. Main bearings

Miscellaneous
1. Hissing 1. A. Vacuum leak
B. Leaking exhaust (manifolds or pipes)
C. Loose cylinder heads
D. Blown head gasket

2. Whistle 2. A. Vacuum leak

B. Dry or tight bearing in an accessory

3. Squeaks or squeals 3. A. Drive belt slipping

B. Dry or tight bearing in an accessory
C. Parts rubbing together

4. Rattling in exhaust pipe area 4. A. Exhaust shutters

90-806934 1194 TROUBLESHOOTING – 1C-17

INDEX
Oil Pressure
Item Special Information
1. Measuring oil pressure 1. Use a good automotive oil pressure test gauge.
Do not rely on the oil pressure gauge in the boat.

2. Check engine oil level with boat at rest in the 2. Oil level should be between the ADD and FULL
water marks

3. Oil level in crankcase above FULL mark 3. May cause loss of engine RPM, oil pressure
gauge fluctuation, drop in oil pressure, and
hydraulic valve lifter noise at high RPM

4. Oil level in crankcase below ADD mark 4. Low oil pressure; oil pressure gauge fluctuation;
internal engine noise and/or damage

5. Change in oil pressure 5. This may be a normal condition. Oil pressure may
read high in the cooler times of the day, and when
engine is not up to operating temperature. As the
air temperature warms up and engine is running
at normal opening temperature, it is normal for oil
pressure to drop.

6. Low engine oil pressure at idle
6. With modern engines and engine oils, low oil
pressure readings at idle do not necessarily mean
there is a problem. If valve lifters do not “clatter”
(at idle), there is a sufficient volume of oil to
lubricate all internal moving parts properly. The
reason for the drop in oil pressure is that engine
heat causes an expansion of the internal
tolerances in the engine and, also, the oil will thin
out somewhat from heat.

7. Low engine oil pressure at idle after running at a 7. Refer to No. 5 and 6, preceding
high RPM

8. Boats with dual engines 8. It is not uncommon to see different oil pressure
readings between the two engines, as long as
both engines fall within specifications. Differences
in oil pressure can be attributed to differences in
engine tolerances, gauges, wiring, senders, etc.

9. Boats with dual stations 9. Refer to No. 8. preceding

1C-18 – TROUBLESHOOTING 90-806934 1194

INDEX
Low Oil Pressure
Cause Special Information
1. Low oil level in crankcase

2. Defective oil pressure gauge and/or sender 2. Verify with an automotive test gauge.

3. Thin or diluted oil 3. Oil broken down; contains water or fuel; wrong
viscosity; engine running too hot or too cold;
excessive idling in cold water (condensation)

4. Oil pump 4. Relief valve stuck open; pickup tube restricted;

worn parts in oil pump; air leak on suction side of
oil pump or pickup oil tube

5. Oil leak can be internal or external 5. Oil passage plugs leaking, cracked or porous
cylinder block

6. Excessive bearing clearance 6. Cam bearings, main bearings, rod bearings

High Oil Pressure

IMPORTANT: Oil pressure slightly higher than normal does not always indicate a problem. Oil viscosity,
and weather conditions could cause high oil pressure.

Cause Special Information

1. Oil too thick 1. Wrong viscosity, oil full of sludge or tar

2. Defective oil pressure gauge and/or sender 2. Verify with an automotive test gauge

3. Clogged or restricted oil passage

4. Oil pump relief valve stuck closed

90-806934 1194 TROUBLESHOOTING – 1C-19

INDEX
Excessive Oil Consumption
Cause Special Information
1. Normal consumption 1. One quart of oil consumed in 5-15 hours of
operation at wide-open-throttle (especially in a
new or rebuilt engine) is normal

2. Oil leaks 2. Clean bilge, run engine with clean white paper on
bilge floor, locate oil leak(s)

3. Oil too thin 3. Oil diluted or wrong viscosity

4. Oil level too high

5. Drain holes in cylinder head plugged 5. Oil will flood valve guides

6. Defective valve stem seals (if so equipped)

7. Worn valve stems or valve guides

8. Defective oil cooler (if so equipped) 8. Crack in cooler tubes

9. Defective piston rings 9. Glazed, scuffed, worn, stuck, improperly installed;

ring grooves worn; improper break-in; wrong end
gap

10. Defective cylinders 10. Out of round, scored, tapered, glazed; excessive
piston to cylinder clearance; cracked piston

11. Excessive bearing clearance

1C-20 – TROUBLESHOOTING 90-806934 1194

INDEX
Water in Engine
IMPORTANT INFORMATION
IMPORTANT: First determine location of water in
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 pis-
tons, water in crankcase oil, water in crankcase
oil and on top of pistons.”
The first step, after locating water, is to remove all the
water from the engine by removing all spark plugs
and pumping cylinders out by cranking engine over.
Next change oil and filter. Now, start engine and see
if problem can be duplicated. If problem can be dupli-
cated, there more than likely is a mechanical prob-
lem. If the problem cannot be duplicated, the problem
is either an operator error or a problem that exists only
under certain environmental conditions.
Water In Crankcase Oil
Cause
1. Water in boat bilge
2. Water seeping past piston rings or valves
3. Engine running cold
4. Intake manifold leaking near a water passage
5. Cracked or porous casting
90-806934 1194
INDEX
If water is contained to cylinder(s) only, it is usually en-
tering through the intake system, exhaust system, or
head gasket.
If the water is contained to 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 cylinder(s) and the
crankcase, it is usually caused by water in the cylin-
ders getting past the rings and valves, or complete
submersion.
Checking for rust in the intake manifold or exhaust
manifolds is a good idea. Rust in these areas will give
clues if the water entered these areas.
Special Information
1. Boat has been submerged or bilge water was
high enough to run in through dipstick tube
2. Refer to “Water in Engine” (“Water On Top of
Pistons”)
3. Defective thermostat, missing thermostat; pro-
longed idling in cold water
5. Check cylinder head, cylinder block, and intake
manifold
TROUBLESHOOTING – 1C-21
Water On Top Pistons
Cause Special Information
1. Rain water running onto air cleaner 1. Hatch cover

2. Backwash through the exhaust system

3. Improper engine or exhaust hose installation 3. Refer to exhaust specifications

4. Cracked exhaust manifold

5. Improper manifold to elbow gasket installation

6. Loose cylinder head bolts

7. Blown cylinder head gasket 7. Check for warped cylinder head or cylinder block

8. Cracked valve seat

9. Porous or cracked casting 9. Check cylinder heads, cylinder block, and intake
manifold

Engine Overheats (Cooling System)

Cause Special Information
IMPORTANT: The first step is to verify if the en-
gine is actually overheating or the temperature
gauge or sender is faulty

1. Seacock (seawater shutoff valve) partially or

fully closed (if so equipped)

2. Low coolant level

3. Antifreeze not mixed properly 3. Use Quicksilver Premixed Marine Engine

Coolant. DO NOT mix water with Quicksilver
Premixed Marine Engine Coolant.

4. Loose or broken drive belt

5. Clogged or improperly installed sea strainer

1C-22 – TROUBLESHOOTING 90-806934 1194

INDEX
Engine Overheats (Cooling System) (continued)
Cause Special Information
6. Loose hose connections between seawater 6. Pump will suck air. Pump may fail to prime or will
pickup and seawater pump inlet force air bubbles into cooling system.

7. Seawater inlet hose kinked or collapsed 7. Inlet hose must be wire reinforced to prevent col-
lapsing, and positioned to prevent kinks or restric-
tions.

8. Seawater pickup clogged

9. Obstruction on boat bottom causing water 9. Obstruction will be in front of seawater pickup,
turbulence causing air bubbles to be forced into cooling
system

10. Defective thermostat(s)

11. Exhaust elbow water outlet holes plugged

12. Insufficient seawater pump operation 12. Worn pump impeller

13. Obstruction in cooling system such as casting 13. Refer to water flow diagram for engine type being
flash, sand, rust, salt, etc. serviced

14. Engine water circulating pump defective

18. Heat exchanger cores plugged

15. Also refer to “Engine Overheats (Mechanical)”

90-806934 1194 TROUBLESHOOTING – 1C-23

INDEX
Engine Overheats (Mechanical)
Cause Special Information
1. Engine RPM below specifications at wide- 1. Damaged or wrong propeller; growth on boat
open-throttle (engine laboring) bottom; false bottom full of water

2. Incorrect injection pump timing 2. Injection pump timing too far advanced or
retarded

3. Seawater pump impeller slipping

4. Exhaust restriction

5. Valve timing off 5. Jumped timing chain, or gears improperly

installed

6. Insufficient lubrication to moving parts of engine 6. Defective oil pump, plugged oil passage, low oil
level

1C-24 – TROUBLESHOOTING 90-806934 1194

INDEX
Power Steering

Poor, Erratic, or No Assist

Cause Special Information
1. Drive belt 1. Worn, broken or out of adjustment

2. Low fluid level

3. Air in system 3. Air leak in lines, pump, or air from installation.

Refer to Section 9A for bleeding procedure.

4. Leaking hoses 4. Refer to Section 9A for bleeding procedure.

5. Steering cables and/or steering helm 5. Cable or helm partially frozen from corrosion or
rust; cable over-lubricated; improper cable
installation

6. Binding in stern drive unit 6. Refer to appropriate Stern Drive Service Manual

7. Restriction in hydraulic hoses 7. Causes a loss of pressure

8. Control valve not positioned properly, not

balanced properly, or the mounting nut is loose

9. Mounting bracket adjusting screw loose or mount

ing tube is loose

10. Faulty pump 10. Flow control valve may be sticking

11.Worn piston ring or scored housing bore in 11. Causes loss of pressure
cylinder

12. Leaking valve body or loose fitting spool

90-806934 1194 TROUBLESHOOTING – 1C-25

INDEX
Noisy Pump
Cause Special Information
1 Drive belt 1. Check belt tension

2. Low fluid level

3. Air in fluid 3. Air leak in lines, pump, or air form installation

4. Faulty Pump 4. Use stethoscope to listen for noise in pump

5. Restricted fluid passages 5. Kinks or debris in hoses or debris in passages

6. Stop nut adjusted improperly 6. Refer to appropriate Stern Drive Service Manual

7. Steering cables installed that do not meet BIA 7. Refer to appropriate Stern Drive Service Manual
standards

Fluid Leaks
Cause Special Information
1. Loose hose connections 1. Refer to Section 10A for bleeding instructions

2. Damaged hose

3. Oil leaking from top of pump 3. System overfilled; fluid contains water; fluid
contains air

4. Cylinder piston rod seal

5. Faulty seals in valve

6 Faulty seals in o-rings in pump

7. Cracked or porous metal parts

1C-26 – TROUBLESHOOTING 90-806934 1194

INDEX
Insufficient Water Flow From Belt Driven Seawater Pump
Cause Special Information
1. Drive belt 1. Loose, worn or broken

2. Seawater shutoff valve partially or fully closed

3. Clogged or improperly installed sea strainer

4. Loose hose connections between seawater pick 4. Pump will suck air, pump may fail to prime or will
up and seawater pump inlet force air bubbles into cooling system

5. Seawater inlet hose kinked or plugged

6. Seawater pickup plugged

7. Obstruction on boat bottom causing water 7. Obstruction will be in front of seawater pickup,
turbulence causing air bubbles to be forced into cooling
system

8. Faulty seawater pump

90-806934 1194 TROUBLESHOOTING – 1C-27

INDEX
Hurth Hydraulic Transmission
Trouble Possible Cause
1. Transmission gears 1. A. Shifting lever loose
cannot be shifted
B. Remote control does not
permit lever travel required for
testing
C. Remote control faulty
D. No shifting pressure available
2. Gears are shifted 2. Lever travel of remote control is
sluggishly too short; lever shift just short of
minimum traveling distance
3. Clutch is slipping; 3. A. Incorrect fluid used
propeller speed too low
as compared to engine
speed
B. Fluid contains water
C. Shifting pressure too low
D. Wear on clutch discs
E. Piston rings in clutch are
damaged
4. Transmission is blocked 4. A. Medium piston ring in input
shaft in control block is faulty
5. Output shaft turns in 5. A. Rotary slide valve in control
neutral position block is worn
B. Faulty needle bearing on input
shaft
C. Dished discs due to
overheating of slipping clutch
1C-28 – TROUBLESHOOTING
INDEX
Remedy
1. A. Tighten clamping screw on
shifting lever
B. Lift remote control off, if gears
can be shifted by hand, correct
remote control
C. Repair remote control
D. Refer to 7
2. Lift remote control off, if gears can
be shifted by hand, correct remote
control
3. A. Drain and refill with correct
fluid, flush transmission while
engine runs in neutral position,
drain fluid, refill transmission
B. Refer to 9
C. Refer to 6
D. Disassemble transmission
replace clutch discs
E. Disassemble transmission
replace clutch
4. A. Remove control block, replace
piston ring, replace control
block if worn
5. A. Replace control block
B. Disassemble transmission and
input shaft, replace bearing
C. Refer to 3
90-806934 1194
Hurth Hydraulic Transmission (continued)
Trouble Possible Cause
6. Shifting pressure too low 6. A. Fluid filter dirty
B. Fluid level in transmission is
too low
C. Fluid pump is worn out
D. Piston rings in input shaft in
control block are faulty
E. Piston rings in clutch are faulty
7. No shifting pressure 7. A. Direction of engine rotation
does not agree with arrow on
transmission
B. No fluid in transmission
C. Fluid filter is dirty
D. Fluid level in transmission is
too low
E. Fluid pump is worn out
F. Fitting key in input shaft for
fluid pump drive is broken
G. Shifting pressure relief valve
spring is broken
8. Excessive fluid 8. A. Excessive fluid in transmission 8. A. Remove excessive fluid with
temperature
B. Fluid cooler is dirty on water
side
C. Worn fluid pump in control
block
D. Faulty piston rings in input
shaft in control block
E. Clutch is slipping
F. Clutch does not open
completely due to worn clutch
discs
90-806934 1194
INDEX
Remedy
6. A. Replace fluid filter
B. Fill with fluid; check for fluid
loss in transmission,cooler and
pipelines lines for leaks also
refer to steps 10 to 13
C. Replace control block together
with fluid pump
D. Remove control block and
replace piston rings. also
replace control block
E. Disassemble transmission,
replace clutch
7. A. Replace with L.H. rotation
engine
B. Refill with fluid
C. Replace fluid filter
D. Fill with fluid; check for fluid
loss in transmission,cooler and
pipelines lines for leaks also
refer to steps 10 to 13
E. Replace control block together
with fluid pump
F. Remove control block.
Replace fitting key and any
other faulty parts
G. Replace control block
commercial fluid pump
B. Remove coolant lines and
clean fluid cooler on water
side
C. Replace control block and fluid
pump
D. Remove control block, replace
piston rings in input shaft.
Check control block and
replace if damaged from faulty
piston rings
E. Refer to 3
F. Dismount transmission,
replace inner disc all faulty
parts
TROUBLESHOOTING – 1C-29
Hurth Hydraulic Transmission (continued)
Trouble Possible Cause
8. Excessive fluid G. Clutch does not open
temperature completely due to broken
(continued) clutch cup springs
H. Low water flow from sea pump
9. Water in fluid, fluid looks 9. A. Fluid cooler faulty
milky
B. high water level in engine
compartment, water entering
at output shaft seal
10. Fluid leakage at input 10. A. Breather clogged by paint or
shaft dirt
B. Shaft seal faulty
11. Fluid leakage at output 11. A. Breather clogged by paint or
shaft dirt
B. Shaft seal faulty
12. Fluid leakage at venting 12. A. Excessive fluid in transmission 12. A. Pump out excessive fluid with
filter
13. Fluid leakage at joints or 13. A. Bolts are not tight
screw connections
B. Seals on bolts have been
reused several times
14. Fluid leakage at filter 14. A. Filter cap not flush or tight
cap or breather
B. Filter cap o-ring damaged
C. Fluid level too high
1C-30 – TROUBLESHOOTING
INDEX
Remedy
G. Disassemble transmission,
replace inner disc support
and/or clutch
H. repair or replace sea pump
9. A. Repair leakage at cooler or
replace cooler and replace
cooler
B, Remedy cause for water level
in engine compartment,
change transmission fluid
10. A. Remove dirt or paint from
breather
B. Disassemble transmission,
replace seal. If seal location on
input shaft is worn repair
surface
11. A. Remove dirt or paint from
breather
B. Disassemble transmission,
replace seal. If seal location on
input shaft is worn repair
surface
commercial hand pump
13. A. Tighten bolts to specified
torque
B. Replace seals, tighten bolts to
specified torque
14. A. Reinstall filter cap flush with
housing and tighten
B. Replace o-ring
C. Correct fluid level
90-806934 1194
Hurth Hydraulic Transmission (continued)
Trouble Possible Cause
15. Transmission noise 15. A. Fluid level too low so that
changes, becomes pump sucks in air
louder
B. Damage starting on flexible
coupling due to wear or
fatigue, possible due to
misalignment between engine
and transmission
C. Beginning damage of
bearings in transmission;
torsional vibrations, running
without fluid, overload, wrong
alignment of transmission,
excessive motor output
D. Beginning damage of
gearings; torsional vibrations,
running without, fluid, overload
E. Fluid baffle on transmission
has come loose
F. Fluid suction pipe in
transmission has come loose
16. Chattering transmission 16. A. The engine or propeller
noise mainly at low generate torsional vibrations,
speed which produce a chattering
noise in the transmission
B. Misaligned cardan shafts on
input or output shafts
90-806934 1194
INDEX
Remedy
15. A. Top off fluid to fill mark
B. Replace flexible coupling.
Check alignment between
engine and transmission
C. Disassemble transmission,
replace bearings concerned
and other faulty parts
D. Disassemble transmission,
remove faulty parts
E. Disassemble transmission,
attach baffle plate
F. Disassemble transmission, fix
fluid suction pipe
16. A. Mount a flexible coupling with
another stiffness factor
between engine and
transmission; a coupling with a
higher stiffness factor might be
sufficient
B. Mount and align cardan shaft
strictly according to
instructions issued by cardan
shaft manufacturer
TROUBLESHOOTING – 1C-31
REMOVAL AND INSTALLATION

2
A
73935

MCM (STERNDRIVE) MODEL

Note:Refer to the following Service Bulletins regarding this section.
SB 98-12 Gimbal Housing Oil Reservoir Bulkhead Fitting-Material Change
SB 97-10 Alternate Gear Ratio Sterndrive Units for High Altitude
SB 97-7 Bravo Drives and Transoms
SB 96-1 Bravo Transom Assemblies for the 1996-1/2 Model Year
SB 95-21 Bearing Cup Installation in the Bravo One Bearing Carrier
SB 95-10 MerCruiser MCM D7.3L/270 Diesel Sterndrive Replacement
SB 91-26 Bravo One Clutch
SB 91-21 Drive Unit Gear Ratio Identification
SB 91-19 Anode Material Change
SB 91-4 815471A3 Bravo Shift Cable Replacement Kit

INDEX
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Tools/Lubricants/Adhesives . . . . . . . . . . . . . . . . . . . . 2A-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Engine Preparation . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Engine Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5
Engine Connections . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Shift Cable Installation and Adjustment . . . . . . . . . . 2A-9
Throttle Cable Installation and Adjustment . . . . . . 2A-13
Engine Idle Speed Adjustment . . . . . . . . . . . . . . . . . 2A-14

NOTICE
For information and procedures on trouble-
shooting, refer to SECTION 1C.

2A- -MCM
2A-0 MCM(STERN
(STERNDRIVE)
DRIVE)MODEL
MODEL 90-806934 1194
INDEX
Torque Specifications
IMPORTANT: Listed below are the torque specifications for those fasteners which have a specific torque
value. Tighten all other fasteners (not listed) securely.

DESCRIPTION Lb. In. Lb. Ft. N·m

Drive Unit Shift Cable or Power Shift Output Cable End Guide Tighten Nut Until It Bottoms Out Against Flat
Attaching Nut Washer; then, Back Nut Off 1 Turn
Tighten Nut Until It Bottoms Out Against Flat
Remote Control Throttle Cable End Guide Attaching Nut
Washer; then, Back Nut Off 1 Turn
Remote Control Throttle and Shift Cable Barrel Attaching Nut Securely
Rear Engine Mounts 35-40 47-54
Power Steering Fluid Hose Fittings (at Control Valve) 20-25 27-34
Stern Drive Unit Fasteners 50 68
Transom Assembly Fasteners 20-25 27-34
Seawater Pickup (Inlet) Fitting (on gimbal housing) 45 5
Drive Unit Gear Lube Monitor - 90 Degree Barb Fitting 70-90 8-10
Steering Cable Pivot Bolts 25 (34)
Steering Cable Coupler Nut 35 (47)
Bravo One / Two Propeller Nut 55 MINIMUM 75

Tools/Lubricants/Adhesives
DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubricant 92-825407A12
Quicksilver Special Lubricant 101 92-13872A1
Quicksilver Liquid Neoprene 92-25711--2
Quicksilver Perfect Seal 92-34227--1
Quicksilver Engine Alignment Tool [or old tool (91-57797A3) which has
91-805475A1
been modified per OEM Service Bulletin 92-4]
Quicksilver Engine Coupler Spline Grease 91-816391A4
Engine Lifting Eye Tool 91-814412
# 592 - Loctite Pipe Sealant with Teflon Obtain Locally

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-1

INDEX
Removal
IMPORTANT: Stern drive unit must be removed
prior to engine removal. Refer to Stern Drive Ser-
vice Manual.
Engine Removal
1. Disconnect battery cables from battery.
2. Disconnect gear lube monitor bottle wires on tran-
som mounted bottles. Remove engine mounted
gear lube monitor bottle and disconnect wires.
Set the bottle aside, in the upright position.
3. Disconnect extension harness connector plugs
from engine harness connector ends.
! CAUTION
It is good practice to ventilate the engine com-
partment prior to servicing any engine compo-
nents to remove any fuel vapors which may cause
difficulty breathing or be an irritant.
! WARNING
Be careful when changing fuel system compo-
nents; diesel fuel is flammable. Be sure that the
ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled fuel
immediately. DO NOT allow fuel to come into con-
tact with any hot surface which may cause it to ig-
nite.
! WARNING
Dispose of fuel-soaked rags, paper, etc., in an ap-
propriate air tight, fire retardant container.
Fuel-soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
serious bodily injury or death.
2A-2 - MCM (STERN DRIVE) MODEL
INDEX
4. Loosen hose clamps, then disconnect and suit-
ably plug fuel lines to prevent fuel in tank from
leaking into bilge.
5. Disconnect throttle cable from injection pump
linkage on engine and retain locknuts and hard-
ware.
6. Disconnect bullet connectors of trim sender wires
(coming from transom assembly) from engine
harness.
NOTE: After wires are disconnected be sure to loos-
en them from clamps or sta-straps retaining them to
engine or hoses.
7. Disconnect MerCathode wires from MerCathode
controller mounted on engine.
8. If not already accomplished, close seacock, if so
equipped, or disconnect and plug seawater inlet
hose, if boat is to remain in the water.
! CAUTION
Before removing seawater inlet hose, close sea-
cock, if so equipped. If boat is not equipped with
a seacock, remove and plug seawater inlet hose
to prevent a siphoning action that may occur, al-
lowing seawater to flow from the drain holes or re-
moved hoses.
9. Disconnect seawater inlet hose from water inlet
fitting on engine.
10. Disconnect exhaust elbow hose from exhaust
pipe.
11. On Engines WITH Power Shift: Disconnect
vacuum hose from power shift cylinder to vacuum
pump fitting.
12. Remove both shift cables from shift plate. Retain
locknuts and hardware.
13. Disconnect any grounding wires and accessories
that are connected to engine.
14. Disconnect (and suitably plug) fluid hoses from
power steering control valve on transom.
90-806934 1194
 ! CAUTION
DO NOT allow lifting sling to hook or compress
engine components or damage will occur.
15. Support engine with suitable sling, through lifting
eyes on engine and remove front and rear engine
mounting bolts. Retain hardware.
a Disturbed: Ensure front mount adjusting
Installation
Engine Preparation
1. Follow instructions “a” or “b”:
a. On Engines Where Engine Mounts WERE
NOT Disturbed: Proceed to Step 2.
b. On Engines Where Engine Mounts WERE
nuts are positioned midway on studs so that
adequate up and down adjustment exists for
engine alignment.
2. Lubricate coupler splines with 2-4-C Marine
Lubricant.

73322

73935 a
a
73330

a - Coupler Splines
Typical

3. Attach a suitable sling to lifting eyes on engine

and adjust so that engine is level when sus-
pended. Refer to previous “Removal” section for
71706
location of engine lifting eyes.
a - Engine Lifting Eyes
b - Suitable Sling 4. Lift engine into position (in boat), using an over-
head hoist.
Typical
5. Align rear engine mounts with inner transom plate
16. Carefully remove engine. DO NOT hit power mounts and set onto front engine mounts and in-
steering control valve. ner transom plate mounts, while simultaneously
aligning exhaust elbow with exhaust tube. (Do
not relieve hoist tension.)

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-3

INDEX
IMPORTANT: Engine attaching hardware must be
installed in sequence shown.
6. Install both rear engine mounting bolts and hard-
ware as shown. Torque to 35-40 lb. ft. (47-54
N·m).
8. Remove rocker cover nut (and O-ring seal) near-
est pulley end of engine and install Engine Lifting
Eye Tool 91-814412 as shown. Tighten securely,
but do not overtighten. Attach chain and hook
from suitable hoist.

d
e
a

a
g

73328

22032

a - Rear Engine Mount

b - Inner Transom Plate Mount
c - Bolt
d - Washer
e - Spacer
f - Fiber Washer
g - Double-Wound Lockwasher
7. Relieve hoist tension and disconnect sling from
engine lifting eyes.

NOTE: Install appropriate Engine Lifting Eye Tool b

shown in following steps to help equalize load on
hoist during alignment procedure.

! CAUTION
Avoid injury or damage to product. Engine Lifting
Eye Tool must be used for alignment procedures 71730
only and is NOT to be used for installing the en-
gine in the boat. a - Rocker Cover Nut (and O-ring Seal - Not Visible Here)
b - Engine Lifting Eye Tool

2A-4 - MCM (STERN DRIVE) MODEL 90-806934 1194

INDEX
Engine Alignment
1. Align engine as follows:
! CAUTION
DO NOT use an alignment tool from another man-
ufacturer. Alignment tools other than Quicksilver
Alignment Tool, may cause improper alignment
and damage to gimbal bearing and/or engine cou-
pler.
2. Front engine mounts must rest on boat stringer.
Adjust front engine mounts until they touch
stringer.
3. Relieve hoist tension entirely and fasten front
mount assembly to boat stringer using appropri-
ate hardware (lag bolts or thru-bolts, etc.).
4. Recheck alignment with alignment tool. Tool must
enter coupler splines freely. If not, readjust front
mounts.

! CAUTION 5. When alignment is correct, tighten locknuts and

jam nuts securely. Bend tabs (if so equipped)
To avoid damage to gimbal bearing, engine cou- down on adjusting nuts.
pler, or alignment tool:
• DO NOT attempt to force alignment tool! f

• DO NOT raise or lower engine with alignment

tool inserted (or partially inserted) in gimbal a
bearing or engine coupler.
g
a. Attempt to insert the solid end of the align-
ment tool thru the gimbal bearing and into the b
e
engine coupler splines.
b. If the tool does not fit, remove it and carefully
raise or lower the front end of the engine, as
necessary, and attempt to insert the align- c
ment tool.
c. Repeat step “c” until the alignment tool installs d
easily (SLIDES FREELY WITH TWO FIN-
GERS) all the way into and out of engine cou- 23161
pler splines. Do not check by turning. a - Lock Nut
b - Bracket
22029
c - Mount Adjustment Nut – turn left to lower, right to raise
d - Lag Screws (or Bolts)
e - Clamp
f - Nuts – Loosen to Move Bracket Side-to-Side
b g - Clamp Spread-Screw
D3.0L/150. D3.6L/180, and D4.2L/220
a

6. Remove alignment tool if not already removed.

7. Remove Engine Lifting Eye Tool. Install rocker
cover nut with new o-ring seal. Torque rocker nut
to 84 lb. in. (10 N·m).

d
73794
a - Alignment Tool (use only recommended alignment tool)
b - Insert this end of Alignment Tool thru Gimbal Housing
Assembly
c - Gimbal Bearing
d - Engine Coupler
Typical

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-5

INDEX
Engine Connections 4. Connect any grounding wires and accessories
that were connected to engine.
1. Connect power steering hoses to control valve.
5. Connect seawater inlet hose to engine water inlet
IMPORTANT: Make hydraulic connections as fitting. Tighten hose clamp securely.
quickly as possible to prevent oil leakage.
IMPORTANT: Be careful not to cross-thread or
overtighten hose fittings.

a
a c
b
50226 73521
b
a - Water Inlet Fitting
b - Seawater Inlet Hose
c - Hose Clamp

74045 6. Connect coolant recovery hose to bayonet fitting

on heat exchanger and secure with tubing clamp.
a - Rear Fitting (Pressure Hose)
b - Front Fitting (Return Hose)
2. Tighten exhaust tube hose clamps securely.
3. Connect continuity circuit wire from engine to
transom assembly. Tighten screw securely.
IMPORTANT: Do not attach any accessory
ground (–) wires to transom plate ground point.
b

a
a

70548
b
a - Plastic Tubing
73567 b - Tubing Clamp

a - Flywheel Housing Screw

b - Continuity Circuit Wire
c - Inner Transom Plate Grounding Screw

2A-6 - MCM (STERN DRIVE) MODEL 90-806934 1194

INDEX
7. Connect MerCathode wires to MerCathode con-
troller mounted on engine. Apply a thin coat of
Liquid Neoprene to ALL electrical connections.
a b. On engine mounted bottles: Mount the
9. Follow gear lube monitor bottle connection
instructions “a” or “b”. In “a” and “b” the TAN/
BLUE wire connects to BLACK/GREEN wire.
BLACK wire connects to BLACK wire. Check that
bullet connectors are together tightly.
a. On transom mounted bottles: Connect
drive unit gear lube monitor bottle wires to
corresponding engine harness wires.
bottle in the engine bracket. Connect drive
unit gear lube monitor bottle wires to corre-
sponding engine harness wires.

71709

a - Controller Assembly Location

c

50027

b
c

74235

a - Transom Mounted, Round Gear Lube Monitor Bottle

b - Engine Mounted, Square Gear Lube Monitor Bottle
a b c d c - Bullet Connectors
22232
10. Connect instrument extension harness ends to
a - Orange Wire - From Electrode on Transom Assembly engine harness ends – connector collars must be
b - Red/Purple Wire - Connect (Other End) to Positive (+)
fully engaged and secure.
Battery Terminal
c - Black Wire - From Engine Harness c
d - Brown Wire - From Electrode on Transom Assembly
8. Connect the trim position sender wires bullet con- a b
nectors (coming from transom assembly) to en-
gine harness.
a b

BLU/BLK BLK
BLK/WHT BLK 71890

a - Extension Harnesses (From Instruments)

24841 b - Engine Harness and Connector Ends
c - Connector Collar(s)
a - From Engine Harness
b - From Gimbal Housing

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-7

INDEX
 ! WARNING b. Connect fuel return line to injection pump re-
turn fitting and secure with hose clamps.
Be careful when working on fuel system compo-
nents; diesel fuel is flammable. Be sure that the
ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled fuel
immediately. DO NOT allow fuel to come into con- c b a
tact with any hot surface which may cause it to ig-
nite.

! WARNING
Dispose of fuel-soaked rags, paper, etc., in an
appropriate air tight, fire retardant container.
Fuel-soaked items may spontaneously ignite and
result in a fire hazard which could cause serious 23284

bodily injury or death. a - Fuel Line

! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
serious bodily injury or death.
11. Connect fuel lines as follows:
a. Connect flexible fuel line to inlet fitting on fuel
pump and secure with hose clamps.
d 15. Connect throttle cable using retained hardware.
c Refer to “Throttle Cable Installation and Ad-
b - Hose Clamp
c - Return Fitting
12. On Engines with Power Shift: Attach vacuum
hose from power shift cylinder to vacuum pump
fitting. Tighten hose clamp securely.
13. After all wires are connected be sure to secure
them with clamps or Sta-Straps which may have
been retaining them to engine or hoses prior to
removal.
14. Connect both shift cables to shift plate using
retained locknuts and hardware. Refer to “Shift
Cable Installation and Adjustment” section
outlined later and follow instructions.
justment” section outlined later and follow
instructions.
16. Connect battery cables to engine:

b a. Make sure that grounding stud and starter so-

lenoid terminal are free of paint and any other
material that could cause a poor electrical
a connection.
b. After battery cables are connected, apply a
thin coat of Liquid Neoprene to the terminals.
71710 c. Be sure to slide rubber boot over the positive
a - Fuel Line (+) terminal after Liquid Neoprene dries.
b - Hose Clamp
c - Inlet Fitting 17. Connect battery cables to battery by FIRST con-
d - Fuel Pump necting positive (+) battery cable (usually red) to
positive (+) battery terminal. Tighten clamp se-
curely. Then, connect negative (–) battery cable
(usually black) to negative (–) battery terminal.
Tighten clamp securely.
NOTE: Spray terminals with a battery connection
sealant to help retard corrosion.

2A-8 - MCM (STERN DRIVE) MODEL 90-806934 1194

INDEX
Shift Cable Installation 3. Loosen stud and move it to dimension as shown.
Retighten stud.
and Adjustment
NOTE: Shift Cable Adjustment Tool (91-12427) al-
lows the shift cables to be installed and adjusted, b
with or without the stern drive attached.
a
IMPORTANT: When installing shift cables, be
sure that cables are routed in such a way as to
avoid sharp bends and/or contact with moving
parts. DO NOT fasten any items to shift cables.
23345
IMPORTANT: The direction of propeller rotation a - Stud
(RH or LH) for this drive unit is determined by the b - 3 in. (76mm) - Center of Pivot Bolt to Center of Stud
following method.
4. Install drive unit shift cable.
1. Determine desired propeller rotation.
a
a. RIGHT HAND PROPELLER ROTATION -
b
Control cable will have to be installed in re-
mote control so that cable end will move in di-
rection “A,” when shift handle is placed in the c
forward position.
b. LEFT HAND PROPELLER ROTATION - Con-
trol cable will have to be installed in remote
control so that cable end will move in direction
“B,” when shift handle is placed in the forward 23345
position. a - Washers (2)
b - Lock Nut - Tighten Until Contact, Then Back Off 1/2 Turn
c - Cotter Pin - Insert from Top and Spread Both Ends

5. Place adjustment tool over drive unit shift cable,

as shown. Hold tool in place, using a piece of tape
over the barrel retainer.

23242

2. Install shift cable into remote control (refer to

appropriate remote control instructions).

23242
NOTE: Shift Cable Adjustment Tool (91-12427) al-
lows the shift cables to be installed and adjusted, with
or without the stern drive attached on engines WITH-
OUT Power Shift. On engines WITH Power Shift final
adjustment must be accomplished with the drive unit
installed, and when the engine can be operated.

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-9

INDEX
6. Locate center of remote control shift cable play ! CAUTION
(backlash), or center of Power Shift output control
cable play (on engines with Power Shift). DO NOT attempt to install or remove remote con-
trol cable or Power Shift output cable barrel from
a. Remote control must be in NEUTRAL posi- stud, without first removing end guide anchor pin
tion. from shift lever, and removing cable. Attempting
b. Push in on shift cable end with enough pres- to bend cable to install or remove barrel, will
sure to remove play, and mark position “a” on place undue stress on cable end guide and shift
tube. lever, and damage to both could occur.
c. Pull out on shift cable end with enough pres-
sure to remove play, and mark position “a” on
tube.
d. Measure distance between marks “a” and “b”
and mark position “c” half-way between
marks “a” and “b.”

b c e

b
a
a d c 23242

c
a - Control/Output Cable End Guide
b - Anchor Pin
c - Backlash Center
d - Remote Control Shift Cable Barrel
e - Stud

22024
c. Remove remote control or output cable end
guide from shift lever, by removing anchor
IMPORTANT: Be sure to keep center mark “c” pin.
aligned with remote control shift cable end guide
8. Install remote control shift cable or Power Shift
edge when making the following adjustment.
output shift cable.
7. Adjust remote control shift cable or Power Shift
output cable as follows:
a. Temporarily install shift cable end guide into
shift lever, and insert anchor pin.
c
b. Adjust shift cable barrel so that hole in barrel
centers with vertical centerline of stud. En-
sure that backlash center mark is aligned
with edge of control cable end guide.
a

d
b
23242

a - Lock Nut - Tighten Until Bottomed Out

b - Washers - Both Sides of Barrel
c - Anchor Pin
d - Cotter Pin (Not Visible) - Spread Both Ends

9. Remove adjustment tool.

2A-10 - MCM (STERN DRIVE) MODEL 90-806934 1194

INDEX
10. Follow instructions “a” or “b”:
a. On Engines WITHOUT Power Shift: Shift
remote control lever into forward position.
Place end of adjustment tool in barrel retainer. a
(1) Slot (as indicated )in tool should fit over b c
shift lever stud.
• RH ROTATION – ON BRAVO ONE AND TWO : d
Rear slot in tool should fit over shift lever stud.
• LH ROTATION – ON BRAVO ONE AND TWO
MODELS: Forward slot in tool should fit over shift 23242
lever stud. LH ROTATION
(2) If slot indicated does not fit over stud, loos- a - Adjustment Tool
en shift lever stud and slide stud up or b - Barrel Retainer
c - Shift Lever Stud
down, until slot in tool fits over stud. d - Shift Lever Adjustment Slot
(3) When adjustment is correct, retighten
stud. (4) Remove adjustment tool.
(5) Lubricate shift cable pivot points with 30W
oil.
a
c
b

23242

RH ROTATION
a - Adjustment Tool
b - Barrel Retainer
c - Shift Lever Stud
d - Shift Lever Adjustment Slot

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-11

INDEX
 b. On Engines Equipped WITH Power Shift: • RH ROTATION – ON BRAVO ONE AND TWO
Final adjustment of Power Shift Assembly MODELS: Rear slot in tool should fit over shift
output cable at the shift plate cannot be ac- lever stud.
complished unless vacuum is applied to the
• LH ROTATION – ON BRAVO ONE AND TWO
Power Shift cylinder. In which case, the en-
MODELS: Forward slot in tool should fit over shift
gine must be running or vacuum must be
lever stud.
created through another source (such as an
electric vacuum pump). (6) When adjustment is correct, retighten
stud.
In any case, the following precautions apply:

! WARNING
a
If the engine is to be operated with boat out of wa-
ter, the propeller must be removed to avoid injury. c
b

! CAUTION
d
Failure to comply with the following instructions
will result in improper unit shift cable adjustment
and possible damage to stern drive shift mecha- 23242

nism. RH ROTATION
• Remove throttle cable(s) from injection pump
before checking and adjusting shift cable
when using combination shift/throttle remote
control(s). a
• Engine must be running and Power Shift oper- b c
ating when cable adjustment procedure re-
quires moving remote control handle to full
forward or full reverse positions. d

NOTE: If your remote control has separate shift and

throttle levers, it is NOT necessary to disconnect
throttle cable(s) from injection pump.
(1) Disconnect throttle cable(s) from injection
pump if using combination shift/throttle
remote control(s).
(2) Start engine. Allow engine to reach oper-
ating temperature.
(3) Shift remote control lever into full forward
position.
(4) If slot does not fit over stud, loosen shift
lever stud and slide stud up or down, until
slot in tool fits over stud.
(5) Place end of adjustment tool in barrel re-
tainer. Slot in tool (as indicated) should fit
over shift lever stud.
LH ROTATION 23242
a - Adjustment Tool
b - Barrel Retainer
c - Shift Lever Stud
d - Shift Lever Adjustment Slot
(7) Remove adjustment tool.
(8) Shift remote control lever into neutral
position. Stop engine.
(9) Lubricate shift cable pivot points with 30W
oil.
(10) Connect throttle cable(s) to injection
pump if using combination shift/throttle
remote control(s) (Refer to “Throttle
Cable Installation and Adjustment” as
previously outlined.)

2A-12 - MCM (STERN DRIVE) MODEL 90-806934 1194

INDEX
Throttle Cable Installation 5. Check to ensure injector pump lever is contact-
ing “W.O.T. Stop Screw,” DO NOT attempt to
and Adjustment adjust screw (screw is sealed). Check to ensure
that remote control and cable are providing
IMPORTANT: When installing throttle cables, be proper output.
sure that cables are routed in such a way as to
avoid sharp bends and/or avoid contact with
moving parts. DO NOT fasten any items to
throttle cables.

1. Place remote control lever(s) in neutral/idle e a

position. b
2. Lightly push on throttle cable end guide and turn
barrel to align anchor points with studs. Install
cable and secure with hardware as shown. d
3. Tighten locknuts until they bottom and back off 1
turn.

c
a
23728

a - W.O.T. Stop Screw (DO NOT ADJUST - Read “Caution”

b above)
b - Lever
c - Seal
d - Remote Control Throttle Cable Lever
c e - Contact Point - Lever/W.O.T. Stop Screw

6. Place remote control lever in neutral/idle position

c a and, if necessary, readjust throttle cable barrel.
7. Recheck that (when operated) injection pump
lever contacts “W.O.T. Stop Screw” as shown
71261 above, and idle screw as shown below.
a - Throttle Cable End Guide
b - Cable Barrel
c - Washers and Locknuts

4. Place remote control lever in full forward

wide-open-throttle (W.O.T.) position.

! CAUTION
The injector pump lever WOT-stop-screw ad-
justs the engine speed governor, and is factory
set and sealed. DO NOT readjust this setting.
Readjusting the governed speed, and operating
above the specified RPM will cause extensive b
engine damage, and/or failure. Removal of the
seal, and/or readjustment of the WOT-stop-
screw is considered misuse of engine and a d c
23728
resulting damages will not be covered by the a - Idle Screw
limited warranty. b - Lever
c - Stop
d - Jam Nut

90-806934 1194 MCM (STERN DRIVE) MODEL - 2A-13

INDEX
Engine Idle Speed c. Tighten jam-nut while preventing screw (a)
from turning.
Adjustment
! WARNING
DO NOT leave helm unattended while performing c
idle speed check. Boat MUST BE moving forward
(not tied to the dock) when checking idle speed.

Idle speed must not be lower than 750 RPM, in

gear. If necessary, proceed with the following b
readjustment.
a
1. Adjusting screw (a) is on the backside of the fuel
injector pump, and is secured by a jam-nut. Using
a 10mm crow foot wrench with extension, loosen d
jam-nut (b), while holding screw from turning.
23728
2. Using an accurate tachometer, adjust idle speed, a - Idle Adjustment Screw
as follows: b - Locknut
c - Injector Lever
a. TO LOWER IDLE SPEED - Turn screw (a) d - Idle Stop
counterclockwise (left) until idle RPM is
reached. Check that injector pump lever (c) is
touching lever stop (d). ! CAUTION
b. TO INCREASE IDLE SPEED - Turn screw The injector pump lever WOT-stop-screw ad-
(a) clockwise (right) until idle RPM is justs the engine speed governor, and is factory
reached. Check that adjusting screw (a) is set and sealed. DO NOT readjust this setting.
touching lever stop (d). Readjusting the governed RPM will cause exten-
sive engine damage, and/or failure. Removal of
the seal, and/or readjustment of the
WOT-stop-screw is considered misuse of engine
and resulting damages will not be covered by the
limited warranty.

2A-14 - MCM (STERN DRIVE) MODEL 90-806934 1194

INDEX
REMOVAL AND INSTALLATION

2
B

73322

MIE (INBOARD) MODELS

Index
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Tools/Lubricants/Adhesives . . . . . . . . . . . . . . . . . . . . . 2B-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Engine Installation and Initial Alignment . . . . . . . 2B-3
Engine Final Alignment . . . . . . . . . . . . . . . . . . . . . . 2B-5
Engine Connections . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Shift Cable Installation and Adjustment -
Hurth Transmissions . . . . . . . . . . . . . . . . . . . . . . 2B-11
Throttle Cable Installation and Adjustment . . . . 2B-15

NOTICE
For information and procedures on trouble-
shooting, refer to SECTION 1C.

Index
2B -- MIE
2B-0 MIE (INBOARD)
(INBOARD) MODELS
MODELS 90-806934 594
Torque Specifications
IMPORTANT: Listed below are the torque specifications for those fasteners which have a specific torque
value. Tighten all other fasteners (not listed) securely.

Fastener Location Lb. In. Lb. Ft. N·m

Remote Control Throttle and Shift Cable Barrel Attaching Nut Securely
Remote Control Throttle and Shift Cable End Guide Attaching Tighten Nut Until It Bottoms Out Against Flat
Nut Washer; then, Back Nut Off 1 Turn
Coupler to Flywheel 25 34
Transmission Flange to Flywheel Housing 50 67
Trunion Clamp Bolt 50 67
Front Engine Mount Bracket to Engine Block 55 75
Transmission Mount Bracket to Transmission Housing 55 75
Engine Mount Locking (Jam) Nuts 59 80
Transmission Output Flange to Propeller Shaft Coupler Bolts 50 67

Tools/Lubricants/Adhesives
Description Part Number
Quicksilver 2-4-C Marine Lubricant 92-825407A2
Quicksilver Special Lubricant 101 92-13872A1
Quicksilver Liquid Neoprene 92-25711--2
Quicksilver Perfect Seal 92-34227--1
Quicksilver Engine Coupler Spline Grease 91-816391A4
#592 - Loctite Pipe Sealant with Teflon Obtain Locally

Index
90-806934 594 MIE (INBOARD) MODELS - 2B-1
Removal
Engine Removal
! CAUTION
It is good practice to ventilate the engine com-
partment prior to servicing any engine compo-
nents to remove any fuel vapors which may cause
difficulty breathing or be an irritant.
1. Disconnect battery cables from battery.
2. Disconnect negative battery cable from engine
block. Disconnect positive battery cable from
starter solenoid.
3. Remove instrument extension harness connector
ends from engine harness ends.
! WARNING
Be careful when changing fuel system compo-
nents; diesel fuel is flammable. Be sure that the
ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled fuel
immediately. DO NOT allow fuel to come into con-
tact with any hot surface which may cause it to ig-
nite.
! WARNING
Dispose of fuel-soaked rags, paper, etc., in an
appropriate air tight, fire retardant container.
Fuel-soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
serious bodily injury or death.
4. Loosen hose clamp, then disconnect and suitably
plug fuel inlet and fuel return lines to prevent fuel
in tank from leaking into bilge.
Index
2B-2 - MIE (INBOARD) MODELS
5. Disconnect throttle cable from injection pump and
bracket anchor studs. Retain locknuts and hard-
ware.
6. Disconnect shift cable(s) from transmission.
! CAUTION
Before removing seawater strainer hose, close
seacock, if so equipped. If boat is not equipped
with a seacock, remove and plug seawater inlet
hose to prevent a siphoning action that may oc-
cur, allowing seawater to flow from drain holes or
removed hoses.
7. Close seacock, if so equipped, or disconnect and
plug seawater inlet hose, if boat is to remain in the
water.
c
a b
71362
a - Seawater Strainer
b - Seawater Inlet Hose
c - Suitable Plug (If Not Equipped With Seacock)
Typical
8. Disconnect seawater inlet hose from the seawa-
ter pump fitting.
9. Disconnect exhaust system hose.
10. Disconnect any grounding wires and accessories
that are connected to engine.
11. Disconnect coolant recovery bottle plastic hose
from heat exchanger.
12. Disconnect propeller shaft coupler from transmis-
sion output flange. On models with V-Drive trans-
missions: Remove propeller shaft coupler.
NOTE: It may be necessary to remove the propeller
shaft prior to engine removal on engines with V-Drive
transmissions.
90-806934 594
 ! CAUTION 14. Remove front and rear engine mounting bolts.
Retain hardware.
DO NOT allow lifting sling to hook or compress
engine components or damage to them will
occur.
13. Support engine with suitable sling, through lifting
eyes on engine and remove front and rear engine
mounting bolts. Retain hardware.

a
23161

a - Mounting Bolt Locations

Port Front Mount Shown (All Similar)
a

73322 15. Carefully remove engine with transmission.

Installation
c
Engine Installation and Initial
Alignment
1. Follow instructions “a” or “b”:
a. Engine mount(s) or adjustment WAS NOT
DISTURBED during engine service: Pro-
b ceed to following Step 2.
b. Engine mount(s) or adjustment WAS DIS-
TURBED during engine service:
IMPORTANT: Engine mounts must be adjusted,
as explained in the following, to center mount ad-
justment and establish a uniform height on all
mounts.
Ensure that:
(1) All mounts are in the center of their
71706 up-and-down adjustment.
(2) Mounting hole, which is a slot, if so de-
a - Forward Lifting Eye signed, is forward.
b - Rear Lifting Eye
c - Sling
Typical
Index
90-806934 594 MIE (INBOARD) MODELS - 2B-3
 (3) Large diameter of mount trunnion ex-
tended no more than 3/4 in. (19 mm), as
shown.
(4) Each mount base is downward. Tighten
clamping screws and nuts slightly to pre-
vent moving in or out. Mounts must be
free to pivot when installing engine.
Typical Front Mount Shown
b
a that a minimum of 1/4 in. (6mm) up-and-down
23161
Typical Rear Mount Shown
b
a
27035
a - Trunnion Clamping Bolts and Nuts
b - Mount Trunnion MAXIMUM Extension - 3/4 in. (20 mm)
2. Attach a suitable sling to lifting eyes on engine
and adjust so that engine is level when sus-
Index
2B-4 - MIE (INBOARD) MODELS
pended. Refer to “Removal” section for loca-
tion of lifting eyes.
! CAUTION
DO NOT allow lifting sling to hook or compress
engine components or damage will occur.
3. Lift engine into boat and position on engine bed
so that transmission output flange and propeller
shaft coupler are visibly aligned (no gap can be
seen between coupling faces when butted to-
gether). Adjust engine bed height, if necessary,
to obtain proper alignment. DO NOT use mount
adjustments to adjust engine position at this time.
IMPORTANT: Engine bed must position engine so
mount adjustment exists on all four mounts after
performing initial alignment. This is necessary to
allow for final engine alignment.
c
a
b
50609
a - Propeller Shaft
b - Propeller Shaft Coupler
c - Transmission Output Flange
Typical Transmission Shown
4. Check all four mounts to ensure that they are still
positioned properly, then fasten mounts to engine
bed with appropriate bolts or lag screws and hard-
ware. Tighten lag bolts/screws securely.
5. Disconnect and remove sling. Proceed to “Engine
Final Alignment” section following.
90-806934 594
Engine Final Alignment 3. Check that coupling centerlines align, by butting
propeller shaft coupler against transmission out-
put flange. Shoulder on propeller shaft coupler
! CAUTION should engage recess on transmission output
flange face with no resistance.
To avoid vibration, noise and damage to trans-
mission output shaft oil seal and bearings, en-
gine must be properly aligned.

IMPORTANT: Engine alignment MUST BE RE-

CHECKED with boat in the water, fuel tanks filled
and with a normal load on board.
INCORRECT CORRECT

Engine must be aligned so that transmission output

flange and propeller shaft coupler centerlines are
aligned and coupling faces are parallel within .003 in.
(0.07 mm). This applies to installations with solid cou-
plings, as well as flexible couplings. 72597
INCORRECT
1. Check mating surfaces on transmission output
flange and propeller shaft coupler faces to make
sure they are clean and flat. NOTE: Some propeller shaft couplers may not have
a shoulder on mating face. On these installations, use
2. Center propeller shaft in shaft log as follows:
a straight edge to check centerline alignment.
a. Push down and then lift shaft as far as it will
move. Then place shaft in the middle of the
movement. a

b. Move shaft to port and then to starboard as far

as shaft will move. Then place shaft in the b
middle of the movement.
c. With shaft in center of shaft log, as deter-
mined by above procedures “a” and “b,” align
engine to shaft.
c
72598
a
a - Feeler Gauge
b - Transmission Coupling
c - Propeller Shaft
d

b
72595

a - Up
b - Down
c - Port
d - Starboard

Index
90-806934 594 MIE (INBOARD) MODELS - 2B-5
4. Check for angular misalignment, by hand holding
coupling faces tightly together and checking for a
gap between coupling faces with a .003 in.
(0.07mm) feeler gauge at 90° intervals.
Borg-Warner 5000 (All Down Angle Transmission
Similar)
5. If coupling centerlines are not aligned or if cou-
pling faces are more than .003 in. (0.07 mm) out
of parallel, adjust engine mounts as follows:
a. TO ADJUST ENGINE UP OR DOWN: Loos-
en locking nut on mounts requiring adjust-
ment and turn both front mount or rear mount
adjusting nuts equally.

b IMPORTANT: Both front mount (or rear mount)

adjusting nuts must be turned equally to keep en-
a gine level from side to side.
c

d b
23161
50688

Hurth V-Drive a - Locking (Jam) Nut(s)

b - Adjusting Nut(s)
Front Mount Shown (All Similar)
a
c
b

50608

a - Propeller Shaft Coupler

b - Feeler Gauge
c - Transmission Output Flange
d - Check Point Intervals

Index
2B-6 - MIE (INBOARD) MODELS 90-806934 594
 b. TO MOVE ENGINE TO THE LEFT OR
RIGHT: Loosen clamping screw and nut on all
four mount brackets; move engine to the left
or right as necessary to obtain proper align-
ment. Torque clamping screws and nuts to 50
lb. ft. (68 N·m).
NOTE: A small amount of side-to-side adjustment
can also be obtained from the slots on the engine
mount pad (front pads only). Loosen lag screws
(which fasten mounts to engine bed) and move
engine, as required. Tighten lag screws securely.
IMPORTANT: Large diameter of mount trunnion
MUST NOT extend over 3/4 in. (20mm) from
mount brackets on any of the mounts.
Front Mounts
c. After engine has been properly aligned, se-
cure mounts to stringers using appropriate
hardware.
6. Connect propeller shaft coupler to transmission
output flange following instructions “a” or “b”:
IMPORTANT: All coupler bolts must be SAE
Grade 8 (Metric Grade 10.9) or better, with a shoul-
der (grip length) sufficient to pass through the
mating face plane of couplers.
a. All Couplings Without Propeller Shaft Set
Screws: Secure coupling together with bolts,
lockwashers and nuts. Torque to 50 lb.ft. (68
N·m).

b
a
d

a
50687
50687
a - Propeller Shaft Coupler
Rear Mounts b - Bolts (4)
c - Lockwashers and Nuts (4)
b d - Transmission Output Flange
Hurth 8° Down Angle Transmission Shown (All
Similar)

50687

a - Clamping Bolts and Nuts

b - Mount Trunnion Maximum Extension - 3/4 in. (20mm)

Index
90-806934 594 MIE (INBOARD) MODELS - 2B-7
 b. Couplings with Propeller Shaft Set Engine Connections
Screws:
(1) If propeller shaft coupler has set screws,
! CAUTION
remove set screws and mark (dimple) lo-
cations using a transfer punch. It is good practice to ventilate the engine com-
partment prior to servicing any engine compo-
nents to remove any fuel vapors which may cause
difficulty breathing or be an irritant.

IMPORTANT: When routing all wire harnesses

b
and hoses, be sure they are routed and secured
a to avoid coming in contact with hot spots on en-
gine and avoid contact with moving parts.

1. Connect instrument extension harness ends to

engine harness ends– connector collars must be
fully engaged and secure.

50609
c

a - Set Screw Location a

b - Transfer Punch b
Hurth V-Drive Shown (All Similar)
(2) Remove propeller shaft coupler and drill
shallow dimples at locations marked with
punch.
(3) Reinstall propeller shaft coupler and
torque bolts to 50 lb.ft. (68 N·m). Install set
screws and tighten securely. Safety wire 71890
set screws to ensure they do not back out.
a - Extension Harnesses (From Instruments)
b - Engine Harness and Connector Ends
c - Connector Collar(s)

b 2. Connect any ground wires or accessories that

were disconnected from engine.
c
d

50608

a - Propeller Shaft Coupler

b - Bolts (4), with Lockwashers and Nuts (4)
c - Set Screws
d - Safety Wire
e - Transmission Output Flange
Hurth V-Drive Shown (All Similar)
Index
2B-8 - MIE (INBOARD) MODELS 90-806934 594
 ! WARNING b. Connect fuel return line to injection pump re-
turn fitting and secure with hose clamps.
Be careful when working on fuel system compo-
nents; diesel fuel is flammable. Be sure that the
ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled fuel
immediately. DO NOT allow fuel to come into con- c b a
tact with any hot surface which may cause it to
ignite.

! WARNING
Dispose of fuel-soaked rags, paper, etc., in an
appropriate air tight, fire retardant container.
Fuel-soaked items may spontaneously ignite and
result in a fire hazard which could cause serious 23284

bodily injury or death. a - Fuel Line

b - Hose Clamp
c - Return Fitting
! WARNING
FIRE HAZARD: Fuel leakage from any part of the c. Check for leaks. Repair as needed.
fuel system can be a fire hazard which can cause
serious bodily injury or death. 4. After all wires are connected be sure to secure
them with clamps or Sta-Straps which may have
3. Connect fuel lines as follows: been retaining them to engine or hoses prior to re-
moval.
a. Connect flexible fuel line to inlet fitting on fuel
pump and secure with hose clamps. 5. Connect both shift cables to shift plate using
retained locknuts and hardware. Refer to “Shift
Cable Installation and Adjustment” section
outlined later and follow instructions.
d 6. Connect throttle cable using retained hardware.
c Refer to “Throttle Cable Installation and Ad-
justment” section outlined later and follow
instructions.
7. Connect exhaust elbow, riser or water lift muffler,
if so equipped, to exhaust system hose using at
b least two hose clamps at each connection. Tight-
en hose clamps securely.

71710
a - Fuel Line
b - Hose Clamp
c - Inlet Fitting
d - Fuel Pump

Index
90-806934 594 MIE (INBOARD) MODELS - 2B-9
8. Connect seawater inlet hose to seawater pump 10. Connect coolant recovery bottle plastic hose to
fitting. Tighten hose clamp securely. heat exchanger and secure with tubing clamp.

a
73331
b a
71362

a - Seawater Pump Fitting

b - Seawater Inlet Hose 70548

9. If removed previously, connect seawater inlet a - Plastic Tubing

b - Tubing Clamp
hose to seawater strainer and tighten hose
clamps securely.
11. Connect battery cables to engine:
a. Make sure that grounding stud and starter so-
lenoid terminal are free of paint and any other
material that could cause a poor electrical
connection.

b c a b. After battery cables are connected, apply a

thin coat of Liquid Neoprene to the terminals.

71362 c. Be sure to slide rubber boot over the positive

(+) terminal after Liquid Neoprene dries.
a - Seawater Inlet Hose
b - Seawater Strainer 12. Connect battery cables to battery by FIRST con-
c - Hose Clamps (2) necting positive (+) battery cable (usually red) to
positive (+) battery terminal. Tighten clamp se-
curely. Then, connect negative (–) battery cable
(usually black) to negative (–) battery terminal.
Tighten clamp securely.
NOTE: Spray terminals with a battery connection
sealant to help retard corrosion.

Index
2B-10 - MIE (INBOARD) MODELS 90-806934 594
Shift Cable Installation and
Adjustment - Hurth Transmissions
NOTE: On models with other than Quicksilver shift
cables refer to shift cable manufacturer’s instruc-
tions.
IMPORTANT: When installing shift cables, be
sure that cables are routed in such a way as to
avoid sharp bends and/or contact with moving
parts. DO NOT fasten any items to shift cables.
NOTE: Shift cable must be hooked up to remote con-
trol before starting installation and adjustment proce-
dures.
IMPORTANT: These Hurth transmissions are full
reversing transmissions. Direction of output/pro-
peller rotation is determined by hookup of shift
cable at remote control.
Shift cable must be hooked up to remote control
before starting installation and adjustment proce-
dures.
For Left Hand Propeller Rotation – shift cable
hookup at remote control must result in shift cable
end guide moving in direction “B”, when remote
control handle is placed in forward position.
For Right Hand Propeller Rotation – shift cable
hookup at remote control must result in shift cable
end guide moving in direction “A”, when remote
control handle is placed in forward position.
23242
Index
90-806934 594
! WARNING
Avoid serious injury or property damage caused
by improper shifting. Anchor stud for shift cable
must be installed in the correct hole.
1. Be certain anchor stud is installed in the lower,
front hole as shown in the illustration following.
b
b
a a
c c
73588
71020
a - Cable Bracket
b - Shift Cable Anchor Stud Location (For Quicksilver Shift Cables)
Shift Cable Bracket - Anchor Stud Position
Shown for 630A and 630V Transmission
IMPORTANT: Check that shift lever is positioned
approximately 10° aft of vertical when in the neu-
tral detent position and that the distance (“c”)
between studs in the following is set at 7-1/8 in.
(318mm). If necessary, loosen clamping bolt and
position lever so that dimension “c” is as shown
when in the neutral detent position and retighten
bolt.
c
d
73587
a - Shift Lever
b - Lever, in Neutral Detent, Must Be Approximately 10° Aft
of Vertical
c - Dimension Between Studs - 7-1/8 in. (318mm)
d - Clamping Bolt
Typical Hurth Transmission Shown
MIE (INBOARD) MODELS - 2B-11
2. Place remote control shift lever, and transmis-
sion shift lever, in neutral position.
3. Remove nuts and washers from shift cable at-
taching studs.
4. Locate center of remote control and control shift
cable play (backlash), as follows:
a. Check that remote control is in neutral posi-
tion.
b. Push in on control cable end with enough
pressure to remove play, and mark position
“a” on tube.
c. Pull out on control cable end with enough
pressure to remove play, and mark position
“b” on tube.
d. Measure distance between marks “a” and
“b,” and mark position “c,” half-way between
marks “a” and “b.”
b c
a
c
22024
5. Center cable-end play, then adjust cable barrel to
align holes in barrel, and in cable end guide, with
attaching points on transmission.
6. Temporarily install shift cable. Do not secure at
this time.
a b - Lever, in Neutral Detent, Must Be Approximately 10° Aft
73587
Typical
Index
2B-12 - MIE (INBOARD) MODELS
IMPORTANT: Transmission is “fully” in gear
when shift lever comes to a stop, in either direc-
tion.
7. Place remote control shift lever in forward gear
position. Check to ensure transmission is fully in
gear, as follows:
a. Hold shift lever in position.
b. Carefully slide shift cable off of anchor points.
c. Attempt to move shift lever further.
8. Place remote control shift lever in the reverse
gear position. Check that transmission is fully in
gear, following same procedure.
9. If transmission shift lever will position properly in
one gear, but not in the other, recheck shift cable
adjustment. If transmission shift lever will not
position properly in both gears, move transmis-
sion shift lever stud (a), from top hole in shift
lever, to bottom hole, and recheck for proper
positioning. If proper positioning is still not
obtained, remote control does not provide suffi-
cient shift cable travel and must be replaced.
b
c
a
50228
a - Shift Lever Stud (In Bottom Hole, If Required)
of Vertical
c - Shift Lever Top Hole
10. Reattach locknut and washer to cable end guide
stud. Tighten until snug, then back off one-half
turn.
11. Reattach locknut and washer to cable barrel stud.
Tighten until they bottom out. Tighten securely,
but do not overtighten.
90-806934 594
NOTE: To change cable approach direction on SINGLE CABLE - REAR ENTRY
single or dual station installations, only the spacers/
bushings have to be switched to the opposite stud
(the studs are identical).

SINGLE CABLE - FORWARD ENTRY

e

73587

a
CABLE
73589 END GUIDE
STUD
f

CABLE d
BARREL
STUD c
b d

CABLE
BARREL
e STUD
e

c
CABLE
END GUIDE
STUD
b
a 50229
a - Cable End Guide
f b - Locknut and Washer (Tighten Until Bottomed, Then Back
Off One Full Turn)
c - Spacer (Fits over Bushings)
b d - Bushings
71210
e - Cable Barrel Location
a - Cable End Guide f - Spacers (Fit over Stud)
b - Locknut and Washer (Tighten Until Bottomed, Then Back Typical
Off One Full Turn)
c - Spacer (Fits over Bushings)
d - Bushings
e - Cable Barrel Location
f - Spacers (Fit over Stud)
Typical

Index
90-806934 594 MIE (INBOARD) MODELS - 2B-13
DUAL CABLE - FORWARD ENTRY DUAL CABLE - REAR ENTRY

73591
73590

e c

b b

d
a
CABLE
BARREL c CABLE
STUD END GUIDE d
STUD

CABLE
CABLE
END GUIDE
BARREL
STUD
STUD
e
a
50073
b
b 71211
a - Cable End Guides
a - Cable End Guides b - Locknut and Washer (Tighten Until Bottomed, Then Back
b - Locknut and Washer (Tighten Until Bottomed, Then Back Off One Full Turn)
Off One Full Turn) c - Spacer (Fits over Stud)
c - Spacer (Fits over Stud) d - Bushings
d - Bushings e - Cable Barrel Locations
e - Cable Barrel Locations Typical
Typical

Index
2B-14 - MIE (INBOARD) MODELS 90-806934 594
Throttle Cable Installation and
Adjustment
c
NOTE: On models equipped with other than Quick-
f
silver Throttle Cables, attach and adjust throttle b
cables referring to cable manufacturer’s instructions.
a
IMPORTANT: When installing throttle cables, be e
sure that cables are routed in such a way as to
b
avoid sharp bends and/or contact with moving
parts. DO NOT fasten any items to throttle cables. f
On Models Equipped with Quicksilver Throttle d 73348
Cables, connect and adjust throttle cable(s) as out-
lined following: a - Throttle Cable End Guide
b - Locknut and Washer
1. Place remote control lever(s) in neutral/idle posi- c - Spacer (Fit Over Stud)
tion. d - Bushing
e - Cable Barrel Position
2. Lightly push on throttle cable end guide and turn f - Anchor Stud
barrel to align ends with attachment points (This Dual Cable Installations
will place a slight preload on cable to avoid slack
in cable when moving remote control lever.) In-
3. Place remote control lever in full forward
stall cable and secure with hardware as shown.
wide-open-throttle (W.O.T.) position.

! CAUTION
e
The injector pump lever WOT-stop-screw ad-
justs the engine speed governor, and is factory
set and sealed. DO NOT readjust this setting.
f Readjusting the governed speed, and operating
above the specified RPM will cause extensive
engine damage, and/or failure. Removal of the
f a seal, and/or readjustment of the WOT-stop-
screw is considered misuse of engine and re-
sulting damages will not be covered by the lim-
a ited warranty.
71261

f
b f

d
c
b
f
e
73348

a - Throttle Cable End Guide

b - Locknut and Washer
c - Spacer (Fit Over Bushing)
d - Bushing
e - Cable Barrel Position
f - Spacer (Fit Over Stud)
g - Anchor Stud(s)
Single Cable Installation
Index
90-806934 594 MIE (INBOARD) MODELS - 2B-15
4. Check to ensure injector pump lever is contact- 5. Place remote control lever in neutral/idle posi-
ing “W.O.T. Stop Screw,” DO NOT attempt to tion and, if necessary, readjust throttle cable
adjust screw (screw is sealed). Check to ensure barrel.
that remote control and cable are providing
6. Recheck that (when operated) injection pump
proper output.
lever contacts “W.O.T. Stop Screw” as shown
above, and idle screw as shown below.

e a
b

c b
a
23728 a c
d 23728
a - W.O.T. Stop Screw (DO NOT ADJUST - Read “Caution”
preceding)
a - Idle Screw
b - Lever
b - Lever
c - Seal
c - Stop
d - Remote Control Throttle Cable Lever
d - Jam Nut
e - Contact Point - Lever/W.O.T. Stop Screw

Index
2B-16 - MIE (INBOARD) MODELS 90-806934 594
ENGINE
A 1

A 2

3
A
A 4

A 5
ALL MODELS - ENGINE
Note: Refer to the following Service Bulletin regarding this section.

SB 96-10 Piston Ring End Gap A 6

C 7
INDEX
Table of Contents
Page Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19
MerCruiser Diesel Service Tools . . . . . . . . . . . . . . . . 3A-2 Valve Seat Replacement . . . . . . . . . . . . . . . . 3A-19
Kent-Moore Special Tools . . . . . . . . . . . . . . . . . . . . . . 3A-2 Exhaust Valve Seat Specifications . . . . . . . . 3A-19
Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Intake Valve Seat Specifications . . . . . . . . . 3A-20
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 3A-3 Measuring Valve Guide Wear . . . . . . . . . . . . 3A-20
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Valve Guide Replacement . . . . . . . . . . . . . . . 3A-21
Liner I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Valve Seat Reconditioning . . . . . . . . . . . . . . 3A-21
Head Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Valve Refacing . . . . . . . . . . . . . . . . . . . . . . . . 3A-21
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Valve Specifications . . . . . . . . . . . . . . . . . . . . 3A-21
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Valve Spring Specifications . . . . . . . . . . . . . . 3A-22
Valve Specifications . . . . . . . . . . . . . . . . . . . . . 3A-4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22
Valve Seat Specifications . . . . . . . . . . . . . . . . 3A-5 Cylinder Head Studs . . . . . . . . . . . . . . . . . . . 3A-22
Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Determining Head Gasket Thickness . . . . . 3A-23
Valve Guide Specifications . . . . . . . . . . . . . . . 3A-5 Head Gasket Identification . . . . . . . . . . . . . . 3A-24
Valve Spring Specifications . . . . . . . . . . . . . . . 3A-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24
Rocker Arm Specifications . . . . . . . . . . . . . . . 3A-5 Torque Sequence Diagrams . . . . . . . . . . . . . 3A-26
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-29
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-29
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-29
Connecting Rod Bushings / Piston Pins . . . . 3A-6 Adjusting Valve Clearance . . . . . . . . . . . . . . . . . . . . 3A-30
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-31
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-31
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32
D3.6L/180 and D4.2L/220 . . . . . . . . . . . . . . . 3A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32
D3.0L/150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . 3A-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34
Cylinder Head Identification . . . . . . . . . . . . . . . . . 3A-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34
Code Stamping . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9 Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . 3A-35
Glow Plug Arrangement . . . . . . . . . . . . . . . . . 3A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Engine Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Oil Pick-Up Tube Assembly . . . . . . . . . . . . . . . . . . . 3A-36
Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-36
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-36
Piston Rings And Connecting Rods . . . . . . 3A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-36
Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Oil Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-37
Camshaft And Gears . . . . . . . . . . . . . . . . . . . 3A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-37
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Engine Lubrication System – All Models . . . 3A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-39
Engine Lubrication Flow Chart . . . . . . . . . . . 3A-11 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Bearing Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Measuring Lobe Lift . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Scratched By Dirt . . . . . . . . . . . . . . . . . . . . . . 3A-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Lack Of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-41
Improper Seating . . . . . . . . . . . . . . . . . . . . . . 3A-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-42
Radius Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-43
Fatigue Failure . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-43
Tapered Journal . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-43
Compression Testing . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-43
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-13 Valve Lifters (Tappets) . . . . . . . . . . . . . . . . . . . . . . . 3A-44
Front Mount Positions . . . . . . . . . . . . . . . . . . . . . 3A-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-44
MIE (Inboard) Transmission Mounts . . . . . . . . . 3A-13 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 3A-44
Flywheel Related Components . . . . . . . . . . . . . . . . 3A-14 Specifications Chart . . . . . . . . . . . . . . . . . . . . 3A-44
MIE (Inboard) Drive Plate, Adaptor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-44
and Flywheel Housing . . . . . . . . . . . . . . . . . . . . 3A-14 Valve Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-45
MCM (Stern Drive) Engine Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-45
and Flywheel Housing . . . . . . . . . . . . . . . . . . . . 3A-14 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 3A-45
Rocker Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Connecting Rod/Piston Assembly . . . . . . . . . . . . . . 3A-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Measuring Rod Bearing Clearance . . . . . . . . . . 3A-45
Water Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 3A-47
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Connecting Rod And Pin . . . . . . . . . . . . . . . . 3A-47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-47
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Checking Ring End Gap . . . . . . . . . . . . . . . . 3A-49
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-18 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-49
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-50
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-18

3A - ENGINE
90-806934 - ALL MODELS
1194 90-806934
ENGINE - ALL MODELS 1194
- 3A-–1
INDEX
 Page Page
Oil Seal (Rear Main) . . . . . . . . . . . . . . . . . . . . . . . . . 3A-51 Front Main Bearing . . . . . . . . . . . . . . . . . . . . . 3A-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-51 Main Bearing Carriers And Bearings . . . . . . 3A-58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-51 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-58
Crankshaft/Main Bearings . . . . . . . . . . . . . . . . . . . . 3A-52 Rear Main Bearing . . . . . . . . . . . . . . . . . . . . . 3A-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-52 Rear Main Bearing Carrier . . . . . . . . . . . . . . 3A-60
Rear Main Bearing and Carrier . . . . . . . . . . 3A-52 Crankshaft End-play (Axial) Clearance . . . . 3A-62
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-54 Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-62
Front Main Bearing . . . . . . . . . . . . . . . . . . . . . . . 3A-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-62
Timing Gear (Crankshaft) . . . . . . . . . . . . . . . 3A-56 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 3A-63
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . 3A-63
Main Bearings (Measurement) . . . . . . . . . . . 3A-56 Cylinder Liner (Block) Bores . . . . . . . . . . . . . 3A-64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-64

90-806934
3A-0 1194
- ENGINE - ALL MODELS 3A - ENGINE90-806934
- ALL MODELS
1194
INDEX
 Torque Specifications
TORQUE
DESCRIPTION
Lb. In. Lb. Ft. N·m
14mm Dia. Cylinder Head Bolts See NOTE 1
12mm Dia. Cylinder Head Bolts See NOTE 1
Rocker Arm Support 81 110
Connecting Rod 61 82
Flywheel 81 110
Crankshaft Pulley (Loctite 222) 114 155
Oil Drain Plug 59 80
Engine Mount 37 50
Oil Pump 20 27
Rear Main Bearing Housing 20 27
Flywheel Housing 37 50
Main Bearing Carrier 31 42
Rocker Cover 84 10
Oil Pan 96 11
Water Manifold 84 10
Oil Lines (Heat Exchanger to Engine) 18 24
Fuel Injection Pump 23 31
Fuel Injection Pump Gear 66 90
Balancer 37 50
Timing Gear Cover 96 11
Idler Gear 18 25
Main Bearing Carrier Locating Bolts (Banjo) 30 40
Oil Pick-up Tube 96 11
Rocker Arm Lock Nuts 13 18
Drive Plate [MIE (Inboard) Engines] 53 72
Adaptor Plate [MIE (Inboard) D3.0L/150 and D3.6L/180 Engines] 22 30
Coupler [MCM (Stern Drive) Engines] 22 30
Power Steering Pulley (on Crankshaft) 96 11
Alternator Mounts 37 50
Power Steering Pump Mounts 37 50
Camshaft Bolts 20 27
Water Pump 20 27
Water Pump Pulley 96 11

Other fasteners not listed, tighten securely.

NOTE 1: Along with the conventional application of torque, all diesel engines will require cylinder head torque with a suitable
wrench using a Torque Angle Gauge (obtain locally). Refer to Cylinder Head, “Installation” section.

90-806934 1194 ENGINE - ALL MODELS - 3A-1

INDEX
MerCruiser Diesel Kent-Moore Special Tools
Service Tools Can Be Ordered From:
DESCRIPTION PART NUMBER Kent-Moore Tools, Inc.
29784 Little Mack
Cylinder Head Service Tool Kit Roseville, MI 48066
(For Special Cylinder Head 91-806563A1
Screws)
Phone: (313) 574-2332
DESCRIPTION PART NUMBER
Graduated Disc (Timing) 91-801333500
Valve Spring Compressor J-8062
Cylinder Head Guide Pin 91-801333501
Piston Ring Compressor J-8307
Cylinder Liner Puller 91-801333502
Crankshaft Gear Puller 91-801333503 Lubricants/Sealants
Crankshaft Installer 91-801333504
DESCRIPTION PART NUMBER
Injection Pump Gear Puller1 91-801333505
Loctite Master Gasket 92-12564-1
Injection Pump Gear Puller2 91-818371
Loctite 514 92-75505-1
Injection Pump Gear Puller3 91-818372
Quicksilver Needle Bearing
92-42649A1
Flywheel Holder 91-801333506 Assembly Lubricant

91-801763540 Quicksilver 2-4-C Marine

Crankshaft Pulley Puller 92-825407A12
Lubricant
Front Main Bearing and Loctite - 8831 92-823089--1
91-801333508
Camshaft Bearing Puller
Loctite 242 Obtain Locally
Liner Gauge Bar, Metric4 91-814612A1
Loctite 222 Obtain Locally
Liner Gauge Bar, S.A.E.5 91-814812A1 Loctite 620 Obtain Locally
Injection Pump Adaptor Tool, Molykote Obtain Locally
91-801333510
Metric4
Injection Pump Adaptor Tool
91-816997A1
S.A.E.5
Crankshaft Tool (Rotating) 91-814827
Dial Indicator 91-58222A1
Heat Exchanger Core Puller6 91-801761156
Torque Angle Gauge (Degree
TA360
Wheel Torquing)7
Piston Ring Expander 91-24697
Compression Tester Adaptor 91-813810
Compression Gauge7 MT33B
Flywheel Seal Installer 91-801111260
Note 2: For use on D3.0L/150 with VM S/N 70811 and up. Also
for use on D3.6L/180 with VM 5/N 56945 and up.
Note 3: For use on D4.2L/220.
Note 4: For use with millimeter dial gauge.
Note 5: For use with S.A.E. dial gauge.
Note 6: For use on D3.0L/150 and D3.6L/180.
Note 7: SNAP-ON Tool Number

3A-2 - ENGINE - ALL MODELS 90-806934 1194

INDEX
 Engine Specifications

UNIT OF MEASUREMENT
in. (mm)

MODEL D3.0L/150 D3.6L/180 D4.2L/220

Engine Type – In-Line Diesel 5 Cylinder 6 Cylinder 6 Cylinder
Firing Order 1-2-4-5-3 1-5-3-6-2-4 1-5-3-6-2-4
Crankshaft Horsepower (Kilowatts)1 150 (112) 180 (134) 220 (164)
Propeller Shaft Horsepower MCM (Stern Drive Models): 140 (104) 170 (127) 200 (149)
(Kilowatts)2 MIE (Inboard Models)3: 150 (112) 180 (134) 220 (164)
240 lbs. ft. 280 lbs. ft. 387 lbs. ft.
Maximum Torque @ RPM (326 N·m) (380 N·m) (525 N·m)
@ 2750 @ 2750 @ 2400
183 cu. in. 219 cu. in. 254 cu. in.
Displacement
(3.0L) (3.6L) (4.2L)
3.700 in.
Bore 3.622 in. (92mm)
(94mm)
3.937 in.
Stroke 3.543 in. (90mm)
(100mm)
Compression Ratio 22:1 21.5:1
Compression Pressure 348-377 PSI (2400-2600 kPa) @ 300 RPM
Maximum Pressure Difference Between Cylinders 72 PSI (500 kPa)
Recommended Maximum RPM 3800 3600
Idle RPM in Forward Gear 700
Oil Pressure @ RPM 22-36 PSI [ 1.5 - 2.5 bar ( 152-248 kPa ) ],
[Oil Temperature 176_ - 195_ F_ (80_ - 90_ C)] 50-58 PSI [ 3.5 - 4 bar ( 345-400 kPa ) ]
Oil Thermostat (Opening Temperature) 195_ F (90_ C)
Valve Clearance - Intake/Exhaust .012 in. (0.30mm)
2 Continuous effective braked output – per DIN 6271, Part 1, Supplement I.
1 Power rated in accordance with NMMA Procedure – SAE J1228.
3 Engine rated with Hurth 8 degree Down-Angle transmission. Power output with other transmissions will vary.

90-806934 1194 ENGINE - ALL MODELS - 3A-3

INDEX
 HEAD GASKETS
UNIT OF MEASUREMENT
in. (mm) Piston Protrusion
Above Engine Block Gasket Size To
NOTE: Unless listed otherwise, specifications are for 530-TA/636-TA Be Used
all models. D4.2L/220
D183/D219
.019 - .022 .017 - .020
PISTON RINGS .056 (1.42)
(0.48 - 0.57) (0.43 - 0.52)
.023 - .026 .021 - .024
D3.0L/150 and .060 (1.52)
MODELS D4.2L/220 (0.58 - 0.67) (0.53 - 0.62)
D3.6L/180
.027 - .030 .025 - .028
1st .064 (1.62)
.0856 - .0868 .1055 - .1066 (0.68 - 0.77) (0.63 - 0.72)
Compression
(2.175 - 2.205) (2.68 - 2.71) If replacing only one head gasket, use same size as
Tapered
Groove
Width

removed.
2nd .0811 - .0818 .0811 - .0818
Compression (2.06 - 2.08) (2.06 - 2.08) All head gaskets must be the same size on the same
engine.
.1583 - .1591 .1586 - .1594
Oil Control
(4.02 - 4.04) (4.03 - 4.05)
CYLINDER HEAD
1st
.0816 - .0824 .1013 - .1021
Compression
Thickness

(2.075 - 2.095) (2.575 - 2.595) 3.541 - 3.545

Tapered Height
Ring

(89.95 - 90.05)
2nd .0779 - .0783 .0779 - .0783
Height of Cylinder 3.593 - 3.596
Compression (1.978 - 1.990) (1.978 - 1.990)
Head End Spacers (91.26 - 91.34)
.1566 - .1570 .1564 - .1570 Max. Resurface .008 (0.20)
Oil Control
(3.978 - 3.990) (3.975 - 3.990)
1st .0157 - .0255 .0157 - .0255
Compression (0.40 - 0.65) (0.40 - 0.65) CAMSHAFT
Gap
End

2nd .0157 - .0255 .0157 - .0255 .300

Compression (0.40 - 0.65) (0.40 - 0.65) Exhaust
Lobe (7.64)
.0098 - .0228 .0118 - .0236 Lift .283
Oil Control Intake
(0.25 - 0.50) (0.30 - 0.60) (7.20)
Ring to Groove

1st .0024 - .0031 .0033 - .0053 2.1060 - 2.1066

Journal Diameter
Clearance

Compression (0.060 - 0.080) (0.085 - 0.135) (53.495 - 53.510)

2nd .0016 - .0044 .0027 - .0401 Bearing 2.1079 - 2.1098
Compression (0.040 - 0.112) (0.070 - 1.020) Inside Diameter (53.540 - 53.590)
.0016 - .0029 .0016 - .0029 .0019
Oil Control Run-out
(0.040 - 0.075) (0.040 - 0.075) (0.05)

LINER INNER DIAMETER VALVE SPECIFICATIONS

MODELS D3.0L/150 and

D4.2L/220 Exhaust Intake
D3.6L/180
.3118 - .3125 .3126 - .3133
Class 3.6220 - 3.6224 3.7007 - 3.7011 Stem Diameter
(7.922 - 7.940) (7.942 - 7.960)
A (92.000 - 92.010) (94.000 - 94.010)
Standard .096 - .119 .107 - .135
Class 3.6624 - 3.6228 Face Width
——— (2.45 - 3.02) (2.73 - 3.44)
B (92.010 - 92.020)
Max. Out .070 .075
.004 (0.100) Margin (New)
of Round (1.78) (1.90)
Max. Taper .004 (0.100) Margin (After
.051 in. (1.30mm)
Grinding)
Face Angle
45° (30’) 55° (30’)
(New)

3A-4 - ENGINE - ALL MODELS 90-806934 1194

INDEX
VALVE SEAT SPECIFICATIONS ROCKER ARM SPECIFICATIONS

Exhaust Intake .865 - .866

Journal Diameter
(21.979 - 22.000)
Seat Angle 45° 55°
.867 - .868
.055 - .059 .047 - .051 Bushing I.D.
Seat Width (22.020 - 22.041)
(1.40 - 1.50) (1.20 - 1.30)
Max. Clearance .008 (0.200)
1.420 - 1.421 1.656 - 1.657
Seat O. D.
(36.068 - 36.084) (42.070 - 42.086)
.276 - .278 .276 - .278 CRANKSHAFT
Seat Height
(7.00 - 7.05) (7.00 - 7.05)
2.4801 - 2.4807
Front

Main Journal
Counterbore 1.416 - 1.417 1.652 - 1.653 (62.995 - 63.010)

Diameter
Outside
I.D. (35.964 - 35.988) (41.962 - 41.985)
2.4805 - 2.4810
Head Surface .118 .128 Center
(63.005 - 63.020)
To Seat (3.00) (3.25)
2.7553 - 2.7559
Valve .0311 - .0468 .0314 - .0472 Rear
(69.985 - 70.000)
Recession (0.790 - 1.190) (0.800 - 1.200)
.0019 - .0045
Front

Main Bearing
(0.050 - 0.115)

Clearance
VALVE ADJUSTMENT .0011 - .0028
Center
(0.030 - 0.073)
Exhaust Intake
.0015 - .0027
Rear
.012 .012 (0.040 - 0.070)
Clearance
(0.30) (0.30) 2.4827 - 2.4846
Main Bearing Front
(63.060 - 63.110)
VALVE GUIDE SPECIFICATIONS Diameter
Inside
2.4822 - 2.4840
Center
(63.050 - 63.093)
Exhaust Intake 2.7574 - 2.7580
Rear
.002 - .004 .002 - .003 (70.040 - 70.055)
Max. Wear
(0.060 - 0.093) (0.040 - 0.073) Max. Main .008
.315 - .316 Bearing Wear (0.200)
Inside Diameter
(8.000 - 8.015) Connecting Rod 2.1236 - 2.1242
Height Above Journal Outside Diameter (53.940 - 53.955)
.531 - .551
Spring Counter- Connecting Rod .0008 - .0029
(13.50 - 14.00)
bore Bearing Clearance (0.020 - 0.074)
Connecting Rod Bearing 2.1250 - 2.1265
VALVE SPRING SPECIFICATIONS Inside Diameter (53.975 - 54.014)
Max. Rod Bearing .008
Height Pressure Wear (0.200)
1.70 Crankshaft End Play .005 - .013
Free Standing 0
(43.20) (Axial Clearance) (0.121 - 0.323)
1.46 73 - 77 lb. Thrust Washers .091 - .093
Valve Closed
(37) (33 - 35 kg) Standard (2.311 - 2.362)
1.05 194 - 208 lb. .095 - .097
Valve Open 1st Oversized
(26.61) (88 - 95 kg) (2.411 - 2.462)
.099 - .101
2nd Oversized
(2.511 - 2.562)

90-806934 1194 ENGINE - ALL MODELS - 3A-5

INDEX
CONNECTING RODS CONNECTING ROD BUSHINGS / PISTON PINS
(IDENTIFICATION FOR WEIGHT)
1.1807 - 1.1809
Piston Pin O. D.
Color Letter Code Con Rod Weight* (29.990 - 29.996)
Connecting Rod 1.1822 - 1.1828
Sky Blue C 1120 - 1130 gr.
Bushing I.D. (30.030 - 30.045)
White D 1130 - 1140 gr.
.00094 - .00177
Assembly Clearance
Yellow E 1140 - 1150 gr. (0.024 - 0.045)
Red F 1150 - 1160 gr. Maximum Clearance .0039 (0.100)
Green G 1160 - 1170 gr.
Blue H 1170 - 1180 gr. FLYWHEEL
* Max. difference in weight of connecting rods must not exceed Runout — Face .004 (0.10)
10 gr. in one engine.
Runout — Bore .004 (0.10)
PISTONS
OIL PUMP
D3.0L/150 and
MODELS D3.6L/180 D4.2L/220
Rotor
Class 3.6181 - 3.6185 3.6980 - 3.6984 .006 (0.152)
Clearance (Max.)
Diameter A (91.900 - 91.910) (93.930 - 93.940)
Rotor Axial .002 - .003
Standard Class 3.6185 - 3.6188 Clearance (Installed) (0.050 - 0.070)
———
B (91.910 - 91.920)
Max. Weight Diff.
Between Pistons 5 grams
in One Engine
Max. Clearance .0098 (0.25)
Max. Piston Wear .004 (0.1)

3A-6 - ENGINE - ALL MODELS 90-806934 1194

INDEX
 Firing Order

FLYWHEEL

1-5-3-6-2-4
D3.6L/180 and D4.2L/220

FLYWHEEL

50489
1-2-4-5-3
D3.0L/150

90-806934 1194 ENGINE - ALL MODELS - 3A-7

INDEX
General Information Engine Identification
The engine model and serial numbers are located on
Some repairs, that are listed in this section, must be a plate attached to the coolant tank and stamped on
completed with engine removed from boat. Engine the engine block as shown.
removal depends upon type of repair and boat
design. Place engine on repair stand for major
repairs.

NOTE: This section contains disassembly and

assembly procedures of the engine block and
cylinder heads only. Refer to other sections for
disassembly and assembly of various other
components.

IMPORTANT: Do not use any sealers or adhesives

containing silicone. Silicone can cause blockage
in the cooling/heat exchanger systems.
THIS ENGINE
CONFORMS TO INT’L
BODENSEE SHIPPING
COMISSION STDS
CERT NO.
M12 11 3 93 _ _

a c
71675
71675 73321

Mercruiser Serial Number

70427

VM Serial Number
a - MerCruiser Serial Number Plates
b - VM Serial Number (Stamped in Block)
c - Exhaust Gas Emissions Certificate Number (Example)

3A-8 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Cylinder Head Identification Overhead View of Glow Plug Arrangements

CODE STAMPING
Heads are identified by a code stamped on flange as a
shown.

73792

b
70270

a - Head Code Location

GLOW PLUG ARRANGEMENT

Early cylinder heads were designed with a radial

glow plug arrangement in which the glow plug enters
into the center of the combustion chamber, and is
seated at an angle in relation to the center line of the 73792
head. a - Cylinder Head With Radial Glow Plug Arrangement
Later model D3.0L/150 engines beginning with Serial (Glow Plug Enters Side of Head At An Angle)
b – Cylinder Head With Tangential Glow Plug Arrangement
Number 0D725152 and above, D3.6L/180 engines (Glow Plug Enters Perpendicular To Side of Head)
beginning with Serial Number 0D850268 and above,
and D4.2L/220 engines with Serial Number
0D554753 and above, are equipped with cylinder
heads which have a tangential glow plug
arrangement. This design differs from the radial style
in that the glow plug enters the combustion chamber
at the side, that is, on a tangent to the combustion
chamber, but is parallel to the center line of the head.
Cylinder heads with the tangential glow plugs also
have steel inserts between the valve seats.

IMPORTANT: Because of the different glow plug

arrangements there is also a corresponding dif-
ference in the electrical connecting bridges and
pre-chambers, be certain to obtain the correct
parts when ordering.

90-806934 1194 ENGINE - ALL MODELS - 3A-9

INDEX
Engine Rotation
Engine rotation terminology, at times, has caused
confusion. To clarify, engine rotation is determined by
observing flywheel rotation from the rear (transmission or
stern drive end) of the engine looking forward.
Propeller Rotation is not necessarily the same as
Engine Rotation.
The 5 and 6 cylinder diesel engines, stern drive (MCM)
and Inboard (MIE), covered in this manual are left
hand (CCW) rotation, as viewed from flywheel end.
Description
ENGINE BLOCK
The engine block is made of cast iron and is designed
for maximum strength. The crankshaft main bearing
carriers are completely enclosed in the block. The
block has removable cylinder liners which are cooled
by engine coolant. Rubber O-rings on the bottom of
the liners are used to seal off the closed cooling
system from the crankcase.
CRANKSHAFT
The crankshaft is supported in the block by insert type
main bearings, (seven in the six cylinder engine and
six in the five cylinder engine). Each bearing, except
the front main, is held by an aluminum carrier. The
front main bearing is pressed into the block. Long
banjo bolts prevent the bearing carriers from turning
in the block. Crankshaft end play is controlled by
thrust washers in the rear main bearing carrier.
3A-10 - ENGINE - ALL MODELS
INDEX
PISTON RINGS and CONNECTING RODS
The pistons have three rings, two compression and
one oil control. The top compression ring is tapered
and the second compression ring is stepped. The
bottom ring, oil control, has a spring inside to help
press it tight against the cylinder wall.
The pistons use full-floating piston pins retained with
snap rings.
The connecting rods and connecting rod caps have
matching machined grooves for a perfect fit.
Connecting rods are available in six different weights
to help in balancing the engine.
VALVE TRAIN
The valve train consists of lifters, push rods, rocker
arms, rocker arm supports, valves and valve springs.
The lifters and push rods are both solid and are
lubricated by oil running off the rocker arms. The
rocker arms have screws with lock nuts which are
used to adjust valve clearance. Removable bushings
in the rocker arms are lubricated by oil which is piped
thru the rocker arm supports.
There is one heavy duty spring used for each valve.
Valve spring retainers and two-piece keepers hold
the springs in place.
CAMSHAFT and GEARS
The camshaft is supported by bearings which are
pressed in the engine block. It is gear driven at
one-half crankshaft speed and has one lobe to
operate the fuel pump.
CYLINDER HEADS
The cylinder heads are made of aluminum with
replaceable valve seats, and valve guides. A water
manifold supplies each head with coolant.
90-806934 1194
ENGINE LUBRICATION SYSTEM – ALL cooler when it reaches a preset temperature. After
MODELS going through a replaceable filter, oil is piped to the
rocker arm supports and to the turbocharger. Internal
The engine’s oil pump, which is gear driven off the
passages channel oil through banjo bolts to the main
crankshaft, is recessed in the front of the engine
bearing carriers. To help cool the pistons, the main
block. The pressure relief valve is recessed into the
bearing carriers contain jets which spray oil on the
block’s front oil pan flange. A thermostat/valve
underside of the pistons. Another internal passage
assembly in the system directs oil through a
directs oil to the camshaft bearings.
combined engine heat exchanger/coolant tank/oil

ENGINE LUBRICATION FLOW CHART

7
6

4
8 5

3
2
10

11 1

73721

1 - Oil Pan
2 - Oil Pump
3 - Pressure Relief Valve
4 - Oil Thermostat
5 - Oil Filter
6 - Engine Oil Cooler (Lower Portion of Heat Exchanger/Coolant Tank)
7 - Rocker Arms
8 - Camshaft Bearings
9 - Piston Oil Jets
10- Crankshaft Main Bearing Carrier and Bearing
11- Turbocharger
D4.2L/220 Shown (D3.0L/150 and D3.6L/180 Similar)

90-806934 1194 ENGINE - ALL MODELS - 3A-11

INDEX
Bearing Failures

Scratches Overlay Bright (Polished)

Dirt
Wiped Out Sections 70436
Imbedded
SCRATCHED into Bearing LACK OF OIL IMPROPER
BY DIRT Material SEATING

Overlay Gone Radius Ride

from Entire Surface Craters or Pockets 70436

TAPERED RADIUS FATIGUE FAILURE

JOURNAL RIDE

Compression Testing 4. Check that battery is fully charged using a

Periodically check engine compression pressure.
Lowering of pressure causes loss of power, greater
fuel consumption, smoke at the exhaust, low
acceleration, unsteady slow idle, difficulty in starting
and bearing seizure because of engine overheating.
1. Refer to Section 5C – “Fuel Injectors” and
while observing precautions listed in Section
5C, remove fuel injector from head to be tested.
2. Clean injector bore and install Compression
Tester Adaptor Tool 91-813810.
3. Connect gauge to Adaptor Tool and set gauge to
zero reading.
suitable device.
5. Operate starter (engine should be cranking at
approximately 300 RPM) and check compression
gauge reading. Compression should be 348-377
PSI (2400-2600 kPa). Maximum pressure
difference between cylinders should not exceed
72 PSI (500 kPa).
6. Readings lower than specified, or differences
between cylinders greater than specified,
indicate engine problems exist (such as faulty
rings, valves, cylinders and pistons). Refer to
appropriate sections and repair as needed.
7. If readings are within specifications, refer to
Section 5C – “Fuel Injectors” and install injectors
in heads from which removed previously. Bleed
injectors as instructed.

3A-12 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Engine Mounts MIE (Inboard) Transmission Mounts

Front Mount Positions

The front motor mounts can be installed two ways as
shown by the following photos. Be sure and mark the
mounts before removing them from engine block.
Front Mount Standard Position

27035

Hydraulic Transmission Mount Components

50533 Standard Mount Position

Front Mount Alternate Position

50533

a - Mount Bracket Alternate Mount Position

b - Bolts
c - Mount Pad

Reverse mount pad on front mounts by loosening

clamp bolt and turning pad over.

27035

a - Mount Bracket
b - Bolts
23161

a - Mount Pad
b - Clamping Bolts

90-806934 1194 ENGINE - ALL MODELS - 3A-13

INDEX
Flywheel Related Components
MIE (Inboard) Drive Plate, Adaptor and Flywheel Housing

c
a
b

73791

a - Drive Plate Housing

b - Drive Plate
c - Adaptor Plate (D3.0L/150 and D3.6L/180 Engines Only)

MCM (Stern Drive) Engine Coupler And Flywheel Housing

NOTE: Some engines are equipped with a solid (Single Stage) coupler, in place of the “Dual Stage” coupler found
on others.

73791
a - Flywheel Housing
b - Engine Coupler - Solid (Single Stage) Coupler Shown, “Dual Stage” Coupler Similar

3A-14 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Rocker Covers 5. Clean gaskets from rocker covers and cylinder
heads. Do not drop anything into cylinder head
openings.
Removal
1. Remove retaining screw. Remove oil separator Installation
and O-ring seal from rear rocker cover.
1. Install 4 new O-rings on connectors before
a pushing rocker covers together. Push covers
together.
b
c
b

74452

a a
b 70428

a - O-rings (4 - Renew)
b - Connector (2)

2. Install rocker cover gaskets.

NOTE: A small amount of Loctite Master Gasket or
Quicksilver Omnifit can be used to hold gaskets on
rocker covers.
3. Install rocker covers on cylinder heads. Install
70665
long cover plate on top of both rocker covers.
a - Retaining Screw 4. Install new O-rings on retaining nuts. Install nuts,
b - Oil Separator torque to 84 lb. in. (10 N·m).
c - O-Ring Seal
5. Place a new O-ring seal in groove on oil separator
2. Remove rocker cover nuts. Remove long cover and install separator on rear of valve cover. Tight-
plate on top of both rocker covers. en retaining bolt securely.

70271
74452

a - Rocker Cover Nuts

a - Cover Plate
b - Cover Plate
b - Retaining Nut
c - O-Ring
3. Using a rubber hammer, tap against side of rocker
d - Oil Separator
covers to loosen. Remove both covers at the e - O-Ring Seal
same time. f - Retaining Screw
g - Rocker Cover Gasket(s)
4. Pull rocker covers apart. Discard the 4 old O-rings
5 and 6 Cylinder Rocker Cover Components
on the 2 connectors between the rocker covers.

90-806934 1194 ENGINE - ALL MODELS - 3A-15

INDEX
Water Manifold
Removal
1. Follow instructions “a,” “b” and “c”:
a. Loosen hose clamp at rear of water manifold.
b. Remove banjo bolt and vent hoses.
c. Remove retaining screws and washers.
Installation
1. Use a new gasket and install end cover on man-
ifold pieces. Torque screws with washers to 84 lb.
in. (10 N·m).
2. Place new gaskets in position on cylinder heads. A
small amount of Loctite Master Gasket or Quicksilver
Omnifit may be used to hold gaskets in position.
3. Install water manifold. Torque bolts with washers
to 84 lb. in. (10 N⋅m) in a diagonal pattern from
centermost to outer ends.
4. Install banjo bolt and banjo fittings using new
sealing washers. Securely tighten the bolt while
simultaneously positioning the fittings. Install vent
lines if previously removed.
5. Tighten hose clamp on hose at rear of water man-
ifold.
d c
b

e a

70663 f
a - Hose Clamp
i
b - Banjo Bolt and Vent Hose(s) Mounting Location
c - Water Manifold Retaining Screws with Washers
Six Cylinder Shown (Five Cylinder Similar)
2. Using a rubber hammer, tap against side of
manifold to loosen. g h 74453
3. Clean gaskets from flanges and cylinder heads.
Do not drop anything into cylinder head openings. a - Water Manifold (Two Pieces)
b - Screws with Washers
4. Align manifold halves and torque screws to 84 lb. c - Vent Hose (To Turbocharger Fitting)
in. (10 N·m). d - Vent Hose (To Heat Exchanger Fitting)
IMPORTANT: When replacing the gasket between e - Banjo Bolt
f - Sealing Washers
manifold halves, align flanges using a straight
g - End Cover and Gasket
edge as shown. h - Cylinder Head Gaskets
i - Hose and Clamp (To Exhaust Manifold End Cover)
Typical

70660

a - Gasket
b - Straight Edge Device
c - Bolts (4, Two Are Hidden In This View)

3A-16 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Cylinder Heads 3. Take note of shape and location of thick head bolt
washers. Starting at one end of the engine,
remove head bolts.
Removal
IMPORTANT: To avoid distorting cylinder heads,
remove only when engine is cold.
IMPORTANT: Retain fuel Injectors with their
original heads to aid in diagnosis of problems.
Faulty fuel injectors can actually melt the
aluminum cylinder heads.
IMPORTANT: Before removing rocker arm
assemblies and cylinder heads, mark their
position on the engine for reassembly. They must
be reinstalled in their original locations.

1. Mark rocker arm assemblies and cylinder heads

as to position (for reassembly).
2. Follow instructions “a,” “b” and “c”:
a. Remove rocker arm oil feed line banjo bolts
with sealing washers and remove line from
cylinder heads and from rear of engine block. 50528

b. Loosen all valve adjuster lock nuts and back

out adjustment screws. 4. Using a rubber hammer, tap on side of cylinder
heads to loosen and remove.
c. Remove rocker assembly retaining nuts and
remove assemblies.
Identification
If needed, refer to “Cylinder Head Identification” sec-
tion, as previously outlined, for proper identification of
the cylinder heads on the engine before proceeding
with work.

70662

a - Banjo Bolts With Sealing Washers (6 or 7 Depending on

Number of Cylinders)
b - Oil Feed Line
c - Valve Adjuster Lock Nuts
d - Valve Adjustment Screws
e - Rocker Assembly Retaining Nuts (5 or 6 Depending on
Number of Cylinders)

90-806934 1194 ENGINE - ALL MODELS - 3A-17

INDEX
Disassembly
1. Using valve spring compressor, carefully remove
keepers, retainers, and springs. Place valves in
numbered rack according to their position in the
engine.
70272
a - Typical Valve Spring Compressor
3A-18 - ENGINE - ALL MODELS
INDEX
Cleaning
1. Being careful not to damage aluminum heads,
clean carbon deposits and gasket material from
combustion chambers and sealing surfaces.
2. Using wire wheel, remove carbon deposits from
valves.
3. Wash head and components in cleaning solvent.
Dry with compressed air.
4. Clean head bolt holes in engine block.
Inspection
1. Prechamber for cracks or being loose in
counterbore.
2. Glow plug and injector seats for damage.
3. All gasket surfaces for deep grooves or pitting.
4. Valve seats for cracks, excessive wear, or being
loose in counterbore.
5. Valves for cracks, excessive wear, or bent stems.
6. Valve springs for discoloration due to excessive
heat.
7. Valve guides for cracks or chips. Valve guide
bores for seizure marks, carbon deposits, or
scoring. Valve guide height.
8. Rocker arm support journals for scoring.
9. Rocker arm bushings for excessive wear.
10. Valve spring keepers, retainers, and washer for
wear, distortion, or cracks.
11. Any melting of aluminum by faulty fuel injectors.
90-806934 1194
Repair 1. Heat head in oven to 300_ F (150_ C). Remove
old seat. Do not damage counterbore.
NOTE: Heads are identified by a code stamped on
flange as shown. ! CAUTION
To avoid distortion or melting of aluminum heads,
DO NOT use a torch to replace valve seats.
2. Clean dirt from counterbore. Check for nicks and
scratches.
3. Refer to chart for valve seat specifications.

EXHAUST VALVE SEAT SPECIFICATIONS

70270

a - Head Code

VALVE SEAT REPLACEMENT

_
50351

70279 a - 118 in. (3mm)

b - .031 in. to .047 in. (0.790mm to 1.190mm)
a - Replaceable Valve Seats c - 1.416 in. to 1.417 in. (35.964mm to 35.988mm)
d - 1.420 in. to 1.421 in. (36.068mm to 36.084mm)
e - .276 in. to .278 in. (7mm to 7.05mm)
f - .055 in. to .059 in. (1.40mm to 1.50mm)

90-806934 1194 ENGINE - ALL MODELS - 3A-19

INDEX
INTAKE VALVE SEAT SPECIFICATIONS MEASURING VALVE GUIDE WEAR
1. Insert new valve into guide.
2. Using dial gauge as shown, measure amount of
play valve stem has by moving stem back and
forth against gauge. Measure as close to guide as
possible. Refer to diagrams for specifications.

70435

Intake – .002 in. to .003 in. (0.040mm to 0.073mm)

Exhaust – .002 in. to .004 in. (0.060mm to 0.093mm)
_

50351

a - .128 in. (3.25mm)

b - .031 in. to .047 in. (0.800mm to 1.200mm)
c - 1.652 in. to 1.653 in. (41.962mm to 41.985mm)
d - 1.656 in. to 1.657 in. (42.070mm to 42.086mm)
e - .276 in. to .278 in. (7mm to 7.05mm)
f - .047 in. to .051 in. (1.20mm to 1.30mm)

4. Reheat head in oven to 300_ F (150_ C). Cool

new seat in Liquid Nitrogen and install in
counterbore. Seat should fit without using
pressure. Allow to cool.

a - .315 in. to .316 in. (8mm to 8.015mm)

3A-20 - ENGINE - ALL MODELS 90-806934 1194

INDEX
VALVE GUIDE REPLACEMENT
1. Heat head in oven to 185_ F (85_ C). Using a suit-
able drift, drive out old guide from underside of head.
! CAUTION
To avoid distortion or melting of aluminum heads,
DO NOT use a torch to replace valve guides.
2. With head temperature at 185_ F (85_ C), press
new guide in to obtain measurement as shown.
refaced, a knife edge will be ground on part or all of the
valve head, due to amount of metal that must be
removed to completely reface. Knife edges lead to
breakage or burning. After grinding, measure valves and
replace if out of specifications.
Various equipment is available for refacing valves.
Manufacturer’s recommendations should be carefully
followed to attain proper results.
Refer to “Specifications and the following for valve
specifications.

VALVE SPECIFICATIONS

EXHAUST

a - .531 in. to .551 in. (13.50mm to 14mm)

b - Valve Spring Counterbore _

VALVE SEAT RECONDITIONING

Valve seat reconditioning is very important, since a - .312 in. to .313 in. (7.922mm to 7.940mm)
seating of valves must be perfect for engine to deliver b - .096 in. to .119 in. (2.45mm to 3.02mm)
c - .070 in. (1.78mm)
maximum power and performance.
Another important factor is valve head cooling. Good
contact between each valve and its seat in head is
important to insure that heat in valve head will be
INTAKE
properly dispersed.
Several different types of equipment are available for
reconditioning valve seats. Equipment manufacturer’s
recommendations should be followed carefully to attain
proper results.
Regardless of type of equipment, however, it is
essential that valve guide bores be free from carbon
or dirt to insure proper centering of pilot in valve
guide. _
Machine valve seat angles to the following specifications.
Intake - 55_ ;
Exhaust - 45_. a - .313 in. to .313 in. (7.942mm to 7.960mm)
b - .107 in. to .135 in. (2.73mm to 3.44mm)
c - .075 in. (1.90mm)
VALVE REFACING
Pitted valves can be refaced to proper angle on a valve
grinder, thus insuring correct relation between cylinder
head seat and valve mating surface. Replace valves with
excessive wear on stems or valves which are warped
excessively. When an excessively-warped valve head is

90-806934 1194 ENGINE - ALL MODELS - 3A-21

INDEX
VALVE SPRING SPECIFICATIONS
a - Height Measurement: 1.70 [1-45/64] in. (43.20mm)
Free Standing
a - Height Measurement: 1.46 [1-15/32] in. (37mm)
b - Applied Pressure: 73-77 lb. (33-35 kg)
Closed Valve
a - Height Measurement: 1.05 [1-3/84] in. (26.61mm)
b - Applied Pressure: 194-208 lb. (88-95 kg)
Open Valve
3. Check for spring distortion as shown.
a - Measurement: Maximum .079 [5/64] in. (2mm)
3A-22 - ENGINE - ALL MODELS
INDEX
Assembly
1. Lubricate valve guides and valve stems with
S.A.E. 30W Oil.
2. Install each valve in the port from which it was
removed or to which it was fitted.
NOTE: Valve stem seals are not used on intake or
exhaust valves.
NOTE: Grease may be used to hold keepers in place
while releasing compressor tool.
3. Install plate washer, valve spring, and retainer on
valve stem. Using valve spring compressor tool,
carefully compress spring and insert keepers into
valve stem groove.
70275
a - Plate Washer
b - Valve Spring
c - Retainer
d - Keepers
4. Release compressor tool, making sure keepers
seat properly in groove of valve stem.
CYLINDER HEAD STUDS
IMPORTANT: All long cylinder head studs are not
the same length. Some studs are longer than the
rest and are used for attaching accessories.
These studs must be in the correct location
before exhaust manifold is installed.
70273
a - Long Cylinder Head Studs (Lengths Vary)
When replacing cylinder heads, remove studs and
install in new head in same location.
90-806934 1194
 ! CAUTION 3. Set dial indicator to zero at point shown on engine
block.
Head gasket thickness is very important on
Diesel engines. If head gaskets are too thin, the
pistons will hit the valves or heads, causing
severe damage. All head gaskets on one engine
must be the same thickness or exhaust manifold
and water manifold will not fit correctly.

When cylinder heads are removed for service but

pistons and cylinder liners are not disturbed, use the
same thickness gaskets that were removed. Refer to
“Head Gasket Identification.”
70278
Refer to “Determining Head Gasket Thickness”
during a complete engine rebuild or when pistons and a - Dial Indicator Zero Point
liners are being replaced.
4. Move dial indicator to point shown on piston.
Record measurement.
DETERMINING HEAD GASKET THICKNESS

1. Use dial indicator 91-59222A1 and liner gauge bar

91-801333509 to measure piston height above the
engine block with piston at Top Dead Center.
2. Place liner gauge bar with dial indicator attached,
across liner as shown.

70278

a - Measurement Point

5. Measure all piston heights and use largest

reading to determine which gaskets to use for all
cylinders.
6. Refer to Engine Specifications - “Head Gaskets,”
70277
to determine correct head gasket thickness.
a - Liner Gauge Bar
b - Dial Indicator
c - Liner

90-806934 1194 ENGINE - ALL MODELS - 3A-23

INDEX
HEAD GASKET IDENTIFICATION c. Lubricate the threads and underside of bolt
heads on all 14mm cylinder head bolts with
NOTE: All engines use the same cylinder head
Molykote (obtain locally).
gaskets in one of three thickness as previously
determined and shown following. d. Place all parts on a clean surface or lint-free
shop cloth.
The 1.52 and 1.62 head gaskets differ from the 1.42
gasket as follows.
IMPORTANT: Head gaskets must be installed
The 1.52 gasket has two notches while the 1.62
DRY – DO NOT use any sealer on gaskets.
gasket has a smaller hole where indicated, when
compared to the 1.42 and 1.52 gasket.
IMPORTANT: Install head gaskets ONLY as
shown with prechamber seal facing UP.

70280 70280
a - 1.42 Gasket a - Prechamber Seal (Facing UP)
b - 1.52 Gasket, with Two Notches
c - 1.62 Gasket, with Smaller Hole
! CAUTION
Installation The following steps must be carried out properly
to prevent misalignment of cylInder heads or
1. Before installing cylinder heads follow instruc-
head gaskets which could result in failure of the
tions “a” – “c”:
cylinder head gaskets or cylinder heads causing
a. Clean out bolt holes in engine block. Be cer- severe engine damage.
tain no contaminants (dirt, old oil or coolant)
remain in holes.
b. Clean block and heads, on gasket surfaces.
c. Oil cylinder bores with Quicksilver 4 cycle
motor oil.
2. Prepare hardware following instructions “a” – “d”:

IMPORTANT: Cylinder head bolts may be

installed as many as three times, and then must
be replaced with new bolts. Replace if any doubt
exists.
a. Thoroughly clean all cylinder head bolts and
washers, including all formed spacer-
washers (terminal bridges, three types) and
cylinder head spacers (for ends of first and
last cylinder heads).
b. Using clean SAE 30W motor oil, lubricate the
bolt threads and underside of bolt heads of all
12mm cylinder head bolts.

3A-24 - ENGINE - ALL MODELS 90-806934 1194

INDEX
3. Using a screwdriver install two (2) Cylinder Head
Guide Pins 91-801333501, into 12mm bolt holes
in engine block at cylinder Number One location,
as shown.
70278
70437
a - Guide Pin, Bolt Hole Locations (Two at each cylinder)
b - Guide Pins Installed (At Cylinder Number One)
IMPORTANT: Due to the limited space after
installation between the cylinder heads, it is
necessary, IF all heads were removed, to start
with Cylinder Number One and proceed in
numerical order, being certain that when placed
on engine block each head and corresponding
gasket are properly positioned. Align using a
straight edge placed alongside the head and
gasket (Port-to-Starboard) until NO PORTION of
the gasket “FIRE RING” metal is visible, prior to
HAND tightening 12mm Cylinder Head Bolts (as
in the following steps).
90-806934 1194
INDEX
4. Beginning with cylinder Number One, with pre-
chamber seal facing UP (as previously shown)
install new cylinder head gasket and cylinder
head, being certain that NO PORTION of the cyl-
inder head gasket “FIRE RING” metal as shown,
is visible or extends out from under the head. (Re-
fer to “IMPORTANT” precaution above.)
70280
a - Cylinder Head Gasket “FIRE RING” Metal
70724
a - Cylinder Head
b - Cylinder Head Gasket (No “FIRE RING” metal visible)
5. ONE AT A TIME, remove Guide Pins and install
oiled 12mm cylinder head bolts with washers
HAND tight. Do not disturb head placement.
6. Repeat Steps 4 and 5, for each cylinder head and
corresponding cylinder, proceeding in numerical
order from cylinder Number One.
ENGINE - ALL MODELS - 3A-25
TORQUE SEQUENCE DIAGRAMS

D3.0L/150
(5 Cylinder)

50529

D3.6L/180 and D4.2L/220

(6 Cylinder)

3A-26 - ENGINE - ALL MODELS 90-806934 1194

INDEX
7. Install all lubricated 14mm cylinder head bolts, in-
cluding the proper formed spacer-washers (ter-
minal bridges, three types) and cylinder head
spacers, for ends of first and last cylinder heads,
as shown in the following. Lightly HAND tighten
bolts in torque sequence. (Refer to Cylinder Head
Torque Sequence Diagrams.)
50528
a - Spacer(s). First and Last Cylinder Head Ends
b - Formed Spacer-Washers (Terminal Bridges, Three Types)
8. Temporarily install exhaust manifold WITHOUT
GASKETS and FINGER tighten each nut with
locking washer.
9. Slightly loosen 12mm and 14mm bolts as need-
ed, to allow heads to ALIGN as you HAND tighten
exhaust manifold nuts.
10. Hand tighten all 14mm and 12mm cylinder head
bolts in torque sequence.
11. In torque sequence tighten 14mm cylinder head
bolts to 22 lb. ft. (30 N⋅m). Refer to Torque Se-
quence Diagrams. Repeat using the same speci-
fication, to ensure the best preload, before pro-
ceeding.
12. Following the same sequence tighten each
14mm bolt through an angle of 70 Degrees using
a Torque Angle Gauge.
90-806934 1194
INDEX
13. Tighten each 14mm bolt through ANOTHER 70
Degrees following the same sequence.
14. In sequence tighten port and starboard 12mm cyl-
inder head bolts to 22 lb. ft. (30 N⋅m).
15. In sequence tighten only the STARBOARD 12mm
cylinder head bolts through an angle of 85 ± 5 De-
grees using a Torque Angle Gauge.
16. In sequence tighten only the PORT 12mm cylin-
der head bolts through an angle of 85 ± 5 Degrees
using a Torque Angle Gauge.
! CAUTION
Avoid component or engine failure. Cylinder
heads require additional angular torque and con-
ventional torque application after the first 20-30
minute run-in and then, after the first 100 hours or
first operating season whichever occurs first.
17. Remove exhaust manifold.
18. Insert push rods in position. Be certain they seat
in lifters.
19. Make sure lubrication passages on rocker arms
are clean and open. Install rocker arm assemblies
on studs. Position push rod and adjusting screw
together. Tighten retaining nuts to 81 lb. ft. (110
N⋅m).
20. Install rocker arm oil feed line using 2 new sealing
washers at each banjo fitting and bolt.
21. Install manifold strip with new gaskets on cylinder
heads. Torque bolts with washers to 84 lb. in. (10
N⋅m) in a diagonal pattern from centermost to
outer ends.
22. Complete engine assembly. Refer to appropriate
sections of this manual.
ENGINE - ALL MODELS - 3A-27
23. AFTER COMPLETE ENGINE ASSEMBLY AND 24. AFTER 100 HOURS, OR THE FIRST OPERAT-
INSTALLATION, follow these additional cylinder ING SEASON, WHICHEVER OCCURS FIRST,
head angular torque instructions: follow instructions “a” – “e”:
a. Run engine at idle until water temperature a. Remove valve covers. Refer to section,
reaches 158° f. (70° c) and then run engine at Rocker Covers – “Removal.”
2000 rpm for approximately 20-30 minutes at
b. In torque sequence and without loosening,
operating temperatures. Let the engine cool
tighten the 14mm (center) cylinder head bolts
down completely (inoperative overnight, if
through an angle of 15 Degrees.
possible)
c. In sequence and without loosening, torque
b. Remove rocker arm covers. Refer to section,
the 12mm (side) cylinder head bolts through
Rocker Covers – “Removal.” Retorque the
an angle of 15 Degrees.
cylinder head bolts, as follows:
d. Check valve clearance with proper feeler
(1) n torque sequence, and operating on only
gauge and reset clearance if necessary be-
one bolt at a time, loosen each 14 mm
fore valve covers are reinstalled. (Refer to ap-
(center) bolt and then retorque to 22 lb. ft.
propriate section.)
(30 N·m). Continue by tightening the bolt
through an angle of 65 Degrees and then e. Install valve covers. Refer to section, Rocker
through ANOTHER 65 Degrees (130 Covers – “Installation.”
Degrees total).
(2) In sequence and without loosening, check
torque on port and starboard 12 mm (side)
bolts to be 66 lb. ft. (90 N·m)
c. Check valve clearance with proper feeler
gauge and reset clearance if necessary be-
fore valve covers are reinstalled. (Refer to ap-
propriate section.)
d. Install rocker arm covers. Refer to section,
Rocker Covers – “Installation.”

! CAUTION
Avoid component or engine failure. Cylinder
heads require additional angular torque and con-
ventional torque application after the first 100
hours or first operating season, whichever oc-
curs first.

3A-28 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Rocker Arm 2. Lubricate rocker arm bushings and support jour-
nals with S.A.E. 30W Oil.

Repair
1. Using a micrometer, measure outside diameter
(O. D.) of rocker arm support journals.

70274

a - Rocker Arm Bushings

70274 b - Rocker Arm Support Journals
a - O. D. Rocker Arm Support Journal Measurement - 3. Install rocker arms on support. Position as shown.
.865 in. to .866 in. (21.99mm to 22.00mm)

2. Replace rocker arm support if journals are badly

grooved or worn.
3. Using an inside micrometer, measure inside di-
ameter (I.D.) of rocker arm bushing.

70218

a - Rocker Arms (Positioned Correctly)

b - Rocker Arm Support
4. Install strap. Make sure strap is not spread open
70274
or valve cover will not fit.

a - I.D. Rocker Arm Bushing Measurement -

.867 in. to .868 in. (22.02mm to 22.04mm)

4. Replace rocker arm bushing if difference be-

tween bushing I.D. and journal O. D. is greater
than .008 in. (0.2mm).

Assembly
1. Install rocker arm adjustment screw and locknut.
Replace locknut if damaged or if edges are
rounded off.

70217

a - Strap
b - Strap Installed On Rocker Arm Assembly

70274

a - Rocker Arm Adjustment Screw

b - Locknut
c - Rocker Arm

90-806934 1194 ENGINE - ALL MODELS - 3A-29

INDEX
Adjusting Valve Clearance
IMPORTANT: Engine must be cold before setting
valve clearance.
IMPORTANT: Set valves only when the piston of
each cylinder is at top dead center (TDC) of its
compression stroke.
NOTE: Glow plugs may be removed to release com-
pression when turning crankshaft.
! WARNING
Be sure to keep hands, feet, and clothing away
from moving engine parts.
1. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Models: If so
equipped, remove power steering belt and
drive pulley with flange. Remove 3 opposing
balancer (vibration damper) retaining bolts
from crankshaft pulley. Do not remove
balancer.
b. On D4.2L/220 Models: Remove 3 opposing
retaining bolts from the balancer (vibration
damper).
2. Using balancer bolts or suitable, attach crank-
shaft tool 91-814827 to crankshaft pulley.
70485
a - Crankshaft Tool 91-814827
3. Remove oil fill cap from valve cover.
73322
a - Oil Fill Cap
3A-30 - ENGINE - ALL MODELS
INDEX
4. Look through oil fill cap hole into valve cover,
while using a suitable inspection light, and slowly
rotate engine CLOCKWISE watching the first
rocker arm and valve (front-most is Number 1 cyl-
inder’s intake valve). After the valve has opened
(rocker arm moved down) and then CLOSED
(rocker arm up), continue to rotate engine clock-
wise until crankshaft pulley notch aligns with mark
on timing gear cover as shown. Number 1 piston
is at Top Dead Center (TDC) on its compression
stroke at this point.
70281
a - Crankshaft Pulley Notch
b - Timing Cover Mark
NOTE: On D4.2L/220 Engines crankshaft pulley
notch is on smaller power steering pulley edge, be-
hind larger drive pulleys.
5. Using adaptor plate, attach graduated disc
91-801333500 to crankshaft pulley, with zero
positioned as shown.
a
b
c
a - Adaptor Plate, (Retains Graduated Disc to Balancer)
b - Graduated Disc
c - Crankshaft Tool
90-806934 1194
6. Using wire, make a pointer and attach it to a suit-
able location on engine. Align pointer to zero (“0”)
as shown.
70664
a - Wire Pointer
7. Remove rocker arm covers.
8. Loosen locknuts on both rocker arm adjusting
screws of number 1 cylinder.
9. Insert a .012 in. (0.30mm) feeler gauge between
valve stem and rocker arm. Using a screwdriver,
turn adjusting screw to obtain a slight drag while
moving feeler gauge.
c bracket screw from timing gear cover.
a
b water inlet hose to prevent a siphoning action
70666
a - Rocker Arm
b - Valve Stem
c - Feeler Gauge - .012 in. (0.30 mm)
10. While holding screwdriver to maintain clearance,
tighten locknut to 13 lb. ft. (18 N⋅m).
11. Adjust second valve of number 1 cylinder using
the same procedure.
90-806934 1194
INDEX
12. Using crankshaft tool, turn crankshaft clockwise
(6 cylinder – 120 degrees or 5 cylinder – 144
degrees) to bring next cylinder in firing order up to
T.D.C.
Firing Order
5 Cylinder 1-2-4-5-3
6 Cylinder 1-5-3-6-2-4
Valve Clearance
Intake .012 in. (0.30mm)
Exhaust .012 in. (0.30mm)
13. Adjust remaining valves as outlined.
14. Refer to appropriate sections and reassemble
components as instructed.
Timing Gear Cover
Removal
1. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Models: If so
equipped, remove power steering belt. Re-
move three allen-head bolts from vibration
damper (balancer) and remove power steer-
ing drive pulley with flange.
b. On D4.2L/220 Models: If so equipped, loos-
en power steering pump belt.
2. Remove alternator belt(s), and upper alternator
! CAUTION
When removing seawater hoses or seawater
pump, close seacock, if so equipped. If boat is not
equipped with a seacock, remove and plug sea-
that may occur, allowing seawater to flow from
the drain holes or removed hoses and enter boat.
3. Refer to Seawater System section and remove
sea-water pump inlet hose and outlet hose.
Remove seawater pump.
4. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Models: Re-
move six, or the remaining three (if engine is
equipped with power steering), allen-head
bolts and remove crankshaft vibration damp-
er.
b. On D4.2L/220 Models: Remove six allen-
head bolts and remove crankshaft vibration
damper.
5. Install flywheel holding tool 91-801333506.
ENGINE - ALL MODELS - 3A-31
6. Using a suitable socket remove the large crank-
shaft pulley nut.
7. Using Puller 91-801333507, remove crankshaft
pulley.
8. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Models:
Remove lower cover to gain access to a
timing gear cover screw. Remove screw. Note
size and position of fasteners for reassembly.
b. On D4.2L/220 Models: Proceed to Step 9.
70661
a - Lower Cover Location (Cover Removed)
b - Timing Cover Screw
9. Remove fasteners, including one at alternator
bracket, and remove timing cover. Note size and
position of fasteners for reassembly.
Inspection
IMPORTANT: Due to a production change,
engines with VM Serial Numbers 57252 and up
have a different oil pump and timing cover. These
parts cannot be interchanged with those on
engines with VM Serial Numbers 57251 and
below. Be certain to order the proper parts for
your engine should they require replacement.
1. Remove old gasket material from block and
timing cover. Be careful not to gouge or nick
flanges.
2. Clean and check cover for wear or damage.
3. Check oil seal for wear or damage. Using a suit-
able tool remove and replace oil seal if needed.
3A-32 - ENGINE - ALL MODELS
INDEX
NOTE: Bore in timing cover for oil seal must be
3.1496-3.1507 in. (80.000 – 80.030mm). If not,
replace timing cover.
Installation
1. Check to see that crankshaft O-ring seal between
timing gear and pulleys is still in place and in
acceptable condition.
NOTE: While timing cover is removed renew O-ring
if crankshaft and pulleys show signs of oil leakage
from center.
2. Coat new timing gear cover gasket with Loctite
Master Gasket. Install gasket and timing cover
specified for your engine block number. Torque
screws evenly, in a diagonal pattern, to 7 lb. ft. (10
N⋅m).
IMPORTANT: On D3.0L/150 and D3.6L/180 en-
gines do not forget to install and torque timing
cover screw inside lower cover recess.
70661
a - Lower Cover Location
b - Timing Cover Screw [Torque to 7 lb. ft. (10 N⋅m)]
3. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Models:
Install small lower cover with a new gasket
and torque screws to 18 lb. ft. (24 N⋅m).
NOTE: Upper-left screw (10 o’clock position) is an
allen-head screw. Do not substitute with a different
fastener.
b. On D4.2L/220 Models: Proceed to Step 4.
90-806934 1194
4. Install crankshaft pulley. Be certain key remains Removal
in proper position. With flywheel holder tool
91-801333506 in place, torque large pulley nut to 1. Remove timing gear cover.
114 lb. ft. (155 N⋅m). 2. Remove screws securing oil pump.
5. Follow instructions “a” or “b”: NOTE: Oil pump bearing arrangement in this picture
a. On D3.0L/150 and D3.6L/180 Models: may differ slightly from your model. Picture is
Install vibration damper, and if so equipped, representative of all models.
install power steering pulley flange using
damper bolts. Torque allen-head bolts to 37
lb. ft. (50 N⋅m). If power steering pulley was re-
moved from flange, torque bolts to 96 lb. in.
(11 N⋅m).
b. On D4.2L/220 Models: Make certain power
steering pulley belt is in proper position and
then install vibration damper and torque bolts
to 37 lb. ft. (50 N⋅m).
6. Remove flywheel holder tool.
7. Refer to SECTION 6B - “Seawater System”, and
install seawater pump using a new O-ring seal.
Tighten nuts with washers securely.
IMPORTANT: D4.2L/220 seawater pump is NOT in-
terchangeable with seawater pumps on other die-
sel engines. Use only the seawater pump desig-
nated for your engine. 70292
8. Install upper alternator bracket (brace) to timing a - Screws (3)
cover. Torque fastener to 34-37 lb. ft. (45-50 N⋅m). b - Oil Pump
9. Refer to Maintenance Section – “Replace Drive
Belts” and tension alternator belt, power steering 3. Remove oil pump from bore in block.
belt, and vacuum pump belt, if so equipped.
Torque alternator and power steering mounting
and tensioning bolts to specifications.
10. Install seawater pump inlet hose and outlet hose.
Tighten hose clamps securely.
11. Refer to Seawater System Section, and open
seacock if so equipped, or remove plug from
seawater inlet hose and reconnect seawater inlet
hose to inlet of seawater strainer.

Oil Pump
IMPORTANT: Due to a change in production,
engines with VM Serial Numbers 57252 and up 70287
have a different oil pump and timing cover. These a - Oil Pump, Complete Unit
parts cannot be interchanged with those on
engines with VM Serial Numbers 57251 and
below. Be certain to order the proper parts for
your engine should they require replacement.

90-806934 1194 ENGINE - ALL MODELS - 3A-33

INDEX
Inspection
1. Using a feeler gauge, measure clearance
between rotor and housing. Maximum clearance
is .006 in. (0.152mm).
2. If oil pump has ball bearing, lubricate with 2-4-C
Marine Lubricant. (Some models have a sealed
bearing arrangement; no lubrication is possible.)

70282

a - Rotor
b - Housing
70292
c - Clearance Dimension
a - Ball Bearing Arrangement (On some models)
2. End play (axial clearance) of rotor, with pump
installed, is .002 - .003 in. (0.050 - 0.070mm). 3. Refer to “Timing Gear Cover” and install timing
gear cover.
3. If measurements are not within specifications
pump is faulty, and must be replaced as a
complete unit.

Installation
1. Install new O-ring on oil pump. Install pump in
engine block. Tighten screws to 20 lb. ft. (27 N⋅m).

70282

a - O-ring (Renew)

3A-34 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Oil Pressure Relief Valve 4. If spring(s) is/are broken or valve is badly worn or
sticking in bore, replace complete valve
assembly.
Removal NOTE: Bore may need to be heated before removal
from engine block.
1. Remove oil pan. Clean gaskets from engine block
and pan flanges.

! WARNING
Wear safety glasses. There is high spring
pressure against cap. Use caution when
removing or installing snap-ring.

2. Push in cap. Remove snap-ring.

70285

a - Valve Assembly, Complete

Installation
1. When replacing complete valve assembly, apply
Loctite 242 to threads and tighten securely in
70298
engine block.

a - Cap 2. Assemble valve, spring(s) (inner and outer

b - Snap-Ring springs, if dual spring equipped), and cap as
shown.
3. Remove cap, spring(s), and relief valve from
bore.

70284
70283
a - Cap
a - Cap b - Spring (Inner – Present If Dual Spring Equipped)
b - Spring (Inner – Present If Dual Spring Equipped) c - Spring (Referred To As Outer – If Dual Spring Equipped)
c - Spring (Referred To As Outer – If Dual Spring Equipped) d - Relief Valve
d - Relief Valve
NOTE: Some oil pressure relief valves have only one
NOTE: Some oil pressure relief valves have only one spring.
spring.
3. Coat inside of bore with S.A.E. 30W engine oil.
Install assembled valve and spring(s) into bore.
Valve must slide freely.
4. Push cap into bore and install snap-ring.
5. Install oil pan.
90-806934 1194 ENGINE - ALL MODELS - 3A-35
INDEX
Oil Pick-Up Tube Assembly Installation
1. Renew O-rings on oil pick-up tube and elbow.
Removal
1. Remove oil pan. Clean old gasket from engine
block and oil pan flange.
2. Remove screws retaining baffle, oil pick-up
(suction) tube, and oil pick-up (suction) tube
elbow to block.
NOTE: This view is representative of all models. Your
specific pick-up tube inlet (strainer end) may differ
slightly in appearance. 70286

a - O-ring, Oil Pick-up (Suction) Tube

b - O-ring, Oil Pick-up (Suction) Tube Elbow

2. Install elbow on oil pick-up tube and reinstall oil

pick-up tube assembly, with baffle, on engine
block. Torque screws to 8 lb. ft. (11 N⋅m).

70288

a - Baffle
b - Oil Pick-up (Suction) Tube
c - Oil Pick-up (Suction) Tube Elbow
d - Oil Pick-up (Suction) Tube Inlet (Strainer End)

Inspection 70288

1. Remove old O-rings from tube and elbow. a - Baffle

b - Oil Pick-up (Suction) Tube
2. Clean all parts thoroughly and inspect for fatigue c - Oil Pick-up (Suction) Tube Elbow
cracks or damage. Replace parts, if necessary, d - Screws
with those for your specific model.
3. Using a new gasket, reinstall oil pan. Torque oil
pan screws evenly, in a diagonal pattern, to 96 lb.
in. (11 N⋅m).

70286

a - O-rings (Remove and Discard)

b - Clean and Inspect Condition

3A-36 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Oil Thermostat 4. Lift oil filter head and fitting from engine. Remove
fitting with sealing washer.
b
Removal a
1. Using a suitable container to catch oil, remove oil
filter.
2. Disconnect TAN/WHT wire from oil temperature
audio warning switch.

c
71082

a - Oil Filter Head

b - O-Ring Seal
c - Hex Head Fitting
d - Sealing Washer

a 5. Remove hex head retaining cover with sealing

washer, O-ring, spring, and thermostat from filter
head.

b
c 74446

a - Oil Filter a
b - Oil Temperature Switch Connection
c - Oil Filter Head b
Typical MCM Engine Shown (All Similar)
c
3. Completely loosen large hex head fitting retaining
oil filter head to engine block.
d

e
b 74157

a - Thermostat
b - Spring
c - O-ring
d - Sealing Washer
e - Retaining Cover

6. Refer to appropriate sections to continue engine

a 74454
disassembly if rebuilding, or proceed to “Testing”
a - Oil Filter Head and “Installation” if only oil thermostat or filter
b - Hex Head Fitting head and related parts are being serviced.

90-806934 1194 ENGINE - ALL MODELS - 3A-37

INDEX
Testing ! WARNING
! WARNING The following test involves the use of electricity
and intense heat. Failure to follow appropriate
Always wear safety glasses when using com- procedures or warnings can cause burns or
pressed air. shock which can result in severe personal injury
1. Clean parts in solvent. Dry with compressed air. or death. While performing the following test, ob-
serve these general precautions:
2. Thermostat pin should be retracted as shown
when cold. If not, thermostat is faulty and must be D Wear personal protective clothing such as
replaced. rubber gloves, a non-flammable apron, and
eye protection – preferably full face shield or
safety glasses.
D Work area should include the use of rubber
floor mats. Use insulated tools.
D The appropriate heat source should only be
electric. Heat source should be operated by a
qualified person. Be sure to follow all
instructions of the manufacturer of the heat
source. The heat source should be checked
71085 each time it is used to be sure it is functioning
properly.
a - Thermostat
b - Thermostat Pin (Retracted) D The thermometer used in the test should be a
high-temperature thermometer with a
maximum reading of at least 300° F (150° C).
Under no circumstances should the operator
allow temperatures to exceed test
specifications.
D Perform test only in a well ventilated area.
D Use a suitable container to hold the water,
such as metal. Avoid use of glass containers
unless the operator first confirms for
him/herself that the glass container is an
appropriate high-temperature vessel.
D Because the components will reach high
temperatures do not handle materials or
components until COMPLETELY cooled.
3. Observe the preceding precautions and place
thermostat in container of water. Water must
cover thermostat. Suspend a thermometer in the
water. Do not allow thermometer to touch the
bottom of the pan.
4. Heat water and observe thermostat pin.

3A-38 - ENGINE - ALL MODELS 90-806934 1194

INDEX
5. Pin must begin to extend (push up) as shown,
when water temperature reaches 195° F (90° C).
At 212° F (100° C) pin should be extended
approximately 3/16 - 5/16 in. (5-7mm) more than
when it was cold.
NOTE: Thermostat shown removed from test water
for visual clarity. Do not handle until cool.
3. If not already accomplished, remove old O-ring
from groove on oil filter head (on underside of
filter head when mounted). Clean groove and oil
filter head flange using a suitable solvent. Also,
clean engine block flange.
4. Install a new O-ring in groove of filter head flange.
Install large hex head fitting with new sealing
washer through filter head as shown.

71084

a - Thermostat Pin (Extended)

6. If pin does not extend (push out), thermostat is 71086

faulty and must be replaced.
INSTALLATION
1. Coat threads of hex head retaining cover with
Loctite Pipe Sealant with Teflon.
2. Install thermostat, spring, new O-ring, and retain-
ing cover with new sealing washer into oil filter
head. Be certain O-ring is properly seated in
groove of filter head.
a - Oil Filter Head (With Thermostat Assembled)
b - O-ring Groove [On Underside Of Filter Head When
Mounted (Not Visible In This View)]
c - O-ring
d - Hex Head Fitting
e - Sealing Washer
5. Install oil filter head on engine block as shown. Be
certain O-ring seal is positioned properly. Tighten
hex head fitting with sealing washer securely.

a
b
c
c
a 74454

a - Oil Filter Head

b - Fitting
d c - Sealing Washer

e
74157

b - Thermostat
c - Spring
d - O-ring
e - Sealing Washer
f - Hex Head Retaining Cover

90-806934 1194 ENGINE - ALL MODELS - 3A-39

INDEX
6. Coat sealing washer of new oil filter with
Quicksilver 4-Cycle Marine Engine Oil or
15W-40CD engine oil and install. Hand tighten,
do not use a filter wrench. Attach TAN/WHT wire
to oil temperature switch.
a 9. Start engine and closely observe instrumentation
b
8. Pre-lubricate engine and turbocharger. To do this,
move the “STOP” switch toggle lever DOWN and
hold in this position while you turn the key switch
to “START” position. Doing this TOGETHER
turns the engine without starting it. DO NOT
engage starter for more than 15 seconds; allow at
least one minute cool down time before
re-engaging starter for another 15 seconds.
Watch that starter does not overheat.
to make sure that all systems are functioning
correctly. Check for leaks.

Camshaft

Measuring Lobe Lift

1. Remove all rocker arm assemblies.
72706 2. Secure dial indicator 91-58222A1 to head so
indicator plunger rests inside push rod cup.
a - Oil Filter
b - Wiring 3. Turn crankshaft so camshaft lobe is at the bottom
of its travel and zero dial indicator.
7. Remove oil fill cap and fill engine to proper level
4. Turn crankshaft two complete revolutions while
withnew, recommended engine oil.
reading dial indicator. Refer to specifications.
IMPORTANT: Always use dipstick to determine
5. Measure all lobes of camshaft in the same
how much oil is required.
manner.

Camshaft replacement will be necessary if lobe

a dimensions are less than .0019 in. (0.05mm) of
the values indicated in the specification charts.

Removal
1. Turn crankshaft until number one cylinder is at top
dead center (TDC) of its compression stroke.
2. Remove:
a. Timing Gear Cover
b. Fuel Injection Pump
c. Fuel Pump
d. Push Rods
3. Drain engine oil.

73322

a - Oil Fill Cap

3A-40 - ENGINE - ALL MODELS 90-806934 1194

INDEX
IMPORTANT: Engine must be turned upside down Inspection
so lifters will drop away from camshaft.
1. In addition to measuring lobe lift, in the course of
4. Remove camshaft flange mounting screws and general overhaul, inspect the following (refer to
lockwashers. specifications):
a. Camshaft journal dimensions.
b. Camshaft shaft run-out.
IMPORTANT: Camshaft gear is a press-fit on
shaft. If removal is needed, upon reassembly
gear must be heated in an oven to 360°-390° F
(180°-200° C) and pressed on the shaft, after
installing proper thrust plate and positioning key,
until gear is tight against shoulder.
c. Side clearance between thrust plate and
shaft. [Assembly clearance is .0012-.0037 in.
(0.030-0.095mm]. Wear limit is .0078 in.
(0.200mm).] If not within specifications
inspect thrust plate thickness (with gear
removed, pressed-off) at four opposite points.
Replace plate thickness is less than
.1555-.1594 in. (3.95-4.05mm) at any point.
70289

a - Camshaft Flange Mounting Screws with Lockwashers

IMPORTANT: Engine must REMAIN upside down

while camshaft is removed to prevent lifters from
falling out.
5. Carefully remove camshaft.
6. Remove idler gear retaining screws, if complete
engine disassembly is required, or if gear is worn
or damaged.

70357

a - Measure At Four Opposite Points As Shown

b - Thickness Dimension

70292

a - Idler Gear
b - Retaining Screws with Lockwashers

90-806934 1194 ENGINE - ALL MODELS - 3A-41

INDEX
Installation 2. Lubricate camshaft lobes with a mixture of 20%
S.A.E. 30W engine oil and 80% Needle Bearing
BEFORE installation of camshaft, consider the Lubricant 92-42649A1.
following:
3. Lubricate camshaft bearings with S.A.E. 30W
D Inspect camshaft bearings. Replace as needed. engine oil.
(Refer to section.)
4. Carefully insert camshaft.
D Inspect valve lifters (tappets) and push rods.
Replace if needed. (Refer to section.) 5. Align camshaft gear marks with idler gear marks
as shown. Torque screws to 20 lb. ft. (27 N⋅m).
IMPORTANT: Engine must remain upside down
while camshaft is removed to prevent lifters from
falling out.

1. Install idler gear, if previously removed, so marks

align with crankshaft gear as shown. Torque
screws to 18 lb. ft. (25 N⋅m).

! CAUTION
Avoid possible severe engine damage.
Installation of a screw longer than 5/8 in. (16mm)
will partially block oil gallery in engine block
causing lack of lubrication. Be certain retainer
screw “c” as shown, is NOT longer than stated.

70289

a - Camshaft Gear
b - Idler Gear
c - Marks Aligned Properly
d - Camshaft Flange Mounting Screws With Lockwashers

6. Turn engine upright.

7. Complete engine assembly.

70293

a - Idler Gear
b - Retaining Screws with Lockwashers
c - Retaining Screw Must NOT Be Longer Than 5/8 in. (16mm)
d - Marks Aligned Properly

3A-42 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Camshaft Bearings Installation
1. Clean camshaft bearing bores in cylinder block
Inspection with solvent and blow out with compressed air. Be
sure drilled oil passages are clean.
With camshaft removed:
IMPORTANT: Oil feed holes in bearings MUST
1. Visually inspect bearings. Renew if worn or align with drilled oil passages in engine block or
damaged. severe engine damage will result.
2. Measure inner diameter of bearings. (Refer to 2. Using Special Tool 91-801333508 with
specifications.) Renew bearings if not within appropriate hardware, install new bearings.
specifications. Lubricate outer surface of new camshaft bearings
with engine oil to ease installation.
Removal
NOTE: Camshaft bearings can only be removed and
installed with crankshaft removed.
1. Using special tool 91-801333508 with
appropriate hardware remove camshaft bearings
into receiver end of tool (hidden in this view) as
shown.

70354

a - Engine Block
b - Special Tool (91-801333508)
c - Camshaft Bearing
d - Oil Feed Hole (MUST BE aligned with Drilled Passages in
Block)

3. Check position of oil hole in each bearing and

drilling in block, to ensure bearings are positioned
70438 correctly.
a - Engine Block 4. Recheck bearing inner dimensions to verify
b - Special Tool 91-801333508 (In Use) proper installation.
c - Camshaft Bearing Bore
5. Install camshaft. (Refer to previous section.)
6. Complete engine assembly. (Refer to appropriate
sections.)

90-806934 1194 ENGINE - ALL MODELS - 3A-43

INDEX
Valve Lifters (Tappets)
! CAUTION
If the camshaft is replaced, the valve lifters
(tappets) must also be replaced or serious
component failure and engine damage could
result.
Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent and
inspect them carefully. If any parts are damaged or
worn, camshaft and lifters should be replaced. If outer
lifter body wall is scuffed or worn, inspect cylinder
block lifter bore. If bottom of lifter is scuffed or worn
(cupped) inspect camshaft lobe. If push rod seat is
scuffed or worn, inspect push rod (refer to section).

Removal
With the camshaft removed:
! CAUTION
In case camshaft and lifters are reusable, lifters
must be installed on same camshaft lobes where 70668
removed.
a - Lifter Diameter
1. Remove lifters, being certain to keep them in
order. SPECIFICATIONS CHART

Size Dimension (mm)

.5891 – .5899
Lifter Diameter
(14.965 – 14.985)
.5909 – .5919
Dia. of lifter bore
(15.010 – 15.035)
.0010 – .0027
Assembly clearance
(0.025 – 0.070)
Wear limit .0039 (0.100)

Installation

IMPORTANT: Before installIng lifters, coat the

70429 bottom of lifter with engine oil. If new lifters and
new camshaft have been installed, an additive
a - Valve Lifter (Tappet)
containing EP lube should be poured over lifters
and camshaft lobes.

1. In order of removal, install lifters in engine block

bore.
2. Complete engine assembly.

3A-44 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Valve Push Rods
Removal
IMPORTANT: Place rocker arms, rocker arm
components and push rods in a rack or holder for
reinstallation in the same locations.
With valve covers and rocker arm assemblies
removed:
1. Lift push rod from seat in lifter cup.
Cleaning and Inspection
1. Clean all parts with solvent and dry with
compressed air.
2. Inspect all contact surfaces for wear.
3. Check run-out or straightness of each push rod.
4. Replace all damaged or worn parts.
Installation
IMPORTANT: When installing lifters and rocker
arms, coat rocker arm bearing surfaces, rocker
arm and push rod ball and seat with engine oil.
1. Install push rods in order of removal. Be sure push
rods seat in lifter socket.
2. Install rocker arm assemblies. (Refer to section.)
3. Adjust valve clearance. (Refer to section.)
4. Install valve covers. (Refer to section.)
Connecting Rod/Piston
Assembly
Measuring Rod Bearing Clearance
1. Remove oil pan and oil pick-up tube assembly.
NOTE: NOTE: This picture is representative of all
models. Your specific pick-up tube inlet (strainer end)
may differ slightly in appearance.
70288
a - Oil Pick-Up Tube Assembly
90-806934 1194
INDEX
2. Turn crankshaft to gain access to connecting rod
bolts.
3. One cylinder at a time, remove rod caps and
inspect bearings. (Refer to “Bearing Failure”
pictures at front of section.)
4. Measure crank pin with a micrometer for
out-of-round, taper, or excessive wear. If not
within specifications, replace or recondition
crankshaft.
5. Measure new or used bearing clearances with
Plastigage or its equivalent as follows:
a. Clean oil from crank pin.
b. Install bearing in connecting rod.
c. Place a piece of gauging plastic the full width
of crank pin (parallel to crankshaft).
d. Install rod cap with bearing and torque bolts
to 61 lb. ft. (82 N⋅m).
IMPORTANT: Do not turn crankshaft while gaug-
ing plastic is in place.
e. Remove rod cap and, using scale on gauging
plastic envelope, measure gauging plastic
width at widest point.
6. If clearance exceeds specifications, on used
bearings, replace bearings and recheck
clearance. With new bearings, if correct
clearance is not possible, recheck crank pin
(journal) dimensions. If new bearings and
replacement (or reconditioned crankshaft) will not
yield proper measurement, it will be necessary to
remove connecting rod/piston assembly (refer to
following section) to check dimension of
connecting rod crank pin bore.
7. After obtaining the correct clearance, coat crank
pin with S.A.E. 30W engine oil. Coat bearing
surface with oil and install rod cap. Torque to 61
lb. ft. (82 N⋅m).
ENGINE - ALL MODELS - 3A-45
Removal 2. Use Piston Ring Expander 91-24697 to remove 2
top compression rings.
1. Remove cylinder heads.
3. Using same tool, remove lower (oil control) ring
2. Remove oil pan and oil pick-up tube. and spring.
3. Use a reamer to remove the ridge or any deposits
from upper end of cylinder bore.
4. Turn crankshaft to gain access to connecting rod
bolts.
NOTE: Connecting rods are numbered as shown.
Record the numbers and cylinder location for
reassembly.

70291

a - Lower (Oil Control) Ring

b - Spring

4. Remove snap rings retaining piston pin. Push pin

out of connecting rod and piston.

70297

a - Connecting Rod Number Placement

5. Remove connecting rod cap and rod bearings.

6. Push piston and connecting rod out of cylinder.
(Mark or identify each to ensure placement in
original location during reassembly, if to be
reused.)
7. Retain rod cap and bearings with connecting rod/
piston assembly. Do not mix components.

Disassembly
1. Clamp connecting rod in a soft jawed vise as
shown. 70294

a - Snap Ring(s)
b - Piston Pin

70290

3A-46 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Cleaning and Inspection
CONNECTING ROD and PIN:
1. Wash connecting rods in cleaning solvent and dry
with compressed air.
2. Check for twisting of bent rods and inspect for
nicks or cracks. Replace damaged connecting
rods.
3. Measure connecting rod bushing I.D. and piston
pin O. D. Replace bushing if clearance is
excessive. (Refer to specification charts.)
a - Rod Bushing I.D.
b - Piston Pin O. D.
4. Measure connecting rod crank pin bore with a dial
bore gauge or inside micrometer for out-of-round
or excessive wear. Crank pin bore must be
2.2662-2.2670 in. (57.563-57.582mm). Replace
connecting rod if measurement exceeds
allowable dimension by .0008 (0.02mm).
70397
a - Rod Crank Pin Bore
90-806934 1194
INDEX
PISTONS:
! CAUTION
For D3.0L/150 and D3.6L/180 engines, pistons are
provided in two standard sizes and correspond to
the tolerance classes: Class A or Class B. For
D4.2L/220 engines only Class A pistons (and liners)
are provided. Failure to use only the piston Class (A
or B) designated for your engine and cylinder liner
will result in severe engine damage.
IMPORTANT: Determine which Class of piston is
needed by looking on top of piston (as shown
following) or by examining the underside of the
cylinder liner (Refer to Cylinder Liner –
“Identification”) for reference details.
70296
a - Letter “A” or “B” Location for Class A or B Designation
1. Clean varnish from piston skirts and pins with a
cleaning solvent. DO NOT WIRE BRUSH ANY
PART OF PISTON. Clean ring grooves with a
groove cleaner and make sure oil ring holes are
clean.
70229
a - Ring Grooves
b - Oil Ring Holes
ENGINE - ALL MODELS - 3A-47
2. Inspect piston for cracked ring lands, skirts or pin
bosses, wavy worn ring lands, scuffed or damaged
skirts or eroded areas at top of piston. Replace
pistons which are damaged or show signs of
excessive wear. (Refer to Step 6, following.)
3. Inspect grooves for nicks or burrs that might
cause rings to hang up.
4. Except on upper ring groove of pistons (refer to
Step 6, following), insert edge of rings into
respective piston ring groove and roll ring entirely
around the groove to make sure that ring is free.
If binding occurs at any point, determine cause. If
caused by ring groove, remove by dressing with
a fine cut file. Do not remove excess material.
(Verify with feeler gauge and compare to
specifications.) If binding is thought to be a
distorted ring, check with a new ring.
5. Measure piston O. D. about 1/2 in. (13mm) from
bottom of skirt.
70229
a - O. D. Measurement Point - 1/2 in. (13mm)
3A-48 - ENGINE - ALL MODELS
INDEX
6. Proper clearance of piston ring in its piston ring
groove is very important to provide proper ring
action and reduce wear.
Keep in mind that while the second “scraper” com-
pression ring and the oil control ring are typical in na-
ture, the upper (first) compression ring is “trapezoi-
dal” (tapered) in design. That is, it has a 15 degree
taper on both upper and lower surfaces.
Correspondingly, the upper compression ring groove
is tapered 15 degrees on top and bottom.
Note also that the upper ring’s edge (parallel to cylin-
der liner) is not a straight cut. It is rounded, or arced,
in design.
IMPORTANT: Do not mistake these tapered or dif-
ferent design characteristics for unusual wear
patterns.
70441
70440
a - Upper (First) Compression Ring – Trapezoidal (Tapered)
b - Upper (First) Compression Ring Groove – (Tapered)
c - Outer Edge of Upper Compression Ring – (Arced)
As always, when fitting serviceable or new rings,
clearances between all ring and groove surfaces
should be measured. See “Specifications.”
90-806934 1194
 Assembly
1. Coat inside of connecting rod bushing, piston pin
bore, and piston pin with S.A.E. 30W engine oil.
2. Assemble piston to connecting rod with the
combustion chamber recess aligned with rod
numbers.

a - Tapered Compression Ring

b - “Scraper” Compression Ring
c - Oil Control Ring
d - Ring Clearance 70296

a - Combustion Chamber Recess

CHECKING RING END GAP b - Rod Number(s)

1. Select rings comparable in size to piston being 3. Insert piston pin and install snap ring.
used.
4. Clamp in vise as shown.
2. Slip compression ring in cylinder bore, then press
ring down into cylinder bore about 1/4 in. (6mm)
(below ring travel). Be sure that ring is square with
cylinder wall.
3. Measure gap between ends of ring with a feeler
gauge as shown.

70290

70295 NOTE: Always install rings with ring markings facing

Checking Ring End Gap
4. If gap between ends of ring is below
specifications, remove ring and try another for fit.
5. Fit each compression ring to cylinder in which it is
going to be used.
the top of piston.
5. Install spring in lower piston groove.
6. Carefully install oil control ring.
7. Squeeze ring into groove to seat spring and
check for binding.

90-806934 1194 ENGINE - ALL MODELS - 3A-49

INDEX
8. Using Piston Ring Expander 91-24697, install the
“Scraper” compression ring in the center piston
groove. Scraper side of ring must face down.
70299
a - Scraper Side (MUST FACE DOWN)
9. Using piston ring expander, install top
compression ring in upper piston groove.
IMPORTANT: On D4.2L/220 engines the word
“TOP” appears on the upper surface of the first
compression ring, and MUST FACE UP.
Installation
! CAUTION
For D3.0L/150 and D3.6L/180 engines, pistons are
provided in two standard sizes and correspond to
the tolerance classes: Class A or Class B. Failure
to use only the piston Class (A or B) designated
for your engine and cylinder liner will result in se-
vere engine damage.
1. Before installing pistons into cylinders, ring gaps
must be positioned as follows:
a. Top ring gap, 30_ to the right of combustion
chamber recess.
b. Middle ring gap, directly opposite the
combustion chamber recess.
3A-50 - ENGINE - ALL MODELS
INDEX
c. Lower (oil control) ring gap, 30_ to the left of
combustion chamber recess.
a - Top Ring Gap
b - Middle Ring Gap
c - Lower (Oil Control) Ring Gap
2. Lubricate cylinder bore and piston rings with
S.A.E. 30W engine oil.
3. Each piston and connecting rod assembly must
be installed in the cylinder from which it was
removed. The combustion chamber recess and
numbers on connecting rod must face injector
and camshaft side of the engine.
4. Turn crankshaft to position crank pin away from
cylinder so connecting rod will not damage it
during installation.
5. Using ring compressor, install piston by tapping
on piston-top with a suitable device.
70300
a - Ring Compressor
6. Insert bearing shells into connecting rod and
matching rod cap. Lubricate bearings and crank
pin with a mixture of 20% S.A.E. 30W engine oil
and 80% Needle Bearing Lubricant 92-42649A1.
90-806934 1194
7. Align connecting rod with crank pin and tap on 2. CAREFULLY pry out old seal using a suitable
piston top until rod bearing contacts crank pin. Do device.
not scratch or nick crank pin.
8. Install rod cap, lubricate bolt threads with Quick-
silver Needle Bearing Assembly Lubricant
92-825265A1, and torque to 61 lb. ft. (82 N⋅m).
9. Check that corresponding numbers on rod cap
and connecting rod are the same and are on the
same (camshaft) side.
10. Check that connecting rod assembly and crank
pin are not binding and that there is proper side-
to-side movement.
11. Install remaining piston and connecting rod
assemblies.
12. Measure for head gasket thickness as previously
outlined.
13. Refer to appropriate Sections and complete the
engine assembly.
70301

a - Flywheel Housing (Engine Block Portion)

Oil Seal (Rear Main) b - Rear Main Bearing Carrier
c - Oil Seal (Rear Main)
The rear main oil seal rides on both the flywheel and d - Thrust Washers
the crankshaft thrust plate.

Installation
Removal
1. Remove: IMPORTANT: Do not attempt to install rear main
seal using a hammer or mallet. Damage to the
a. Flywheel Housing Assembly (Rear Portion) seal or rear main bearing carrier could result.
b. On MCM: Coupler
On MIE: Drive Plate 1 1. Install new seal in carrier using tool 91-801111260
c. Flywheel which will evenly PRESS the seal into position.
d. Thrust Plate Seal will stop (bottom-out) when seated.
1: It is not necessary to remove the adaptor plate 2. Lubricate sealing surfaces (lips) of seal with clean
(ring) on the D3.0/150 and D3.6L/180 MIE engines. engine oil.

IMPORTANT: Do not damage main bearing carrier

or thrust washers, in the following step.

90-806934 1194 ENGINE - ALL MODELS - 3A-51

INDEX
IMPORTANT: Whenever thrust plate is removed Crankshaft/Main Bearings
renew O-ring.
3. Inspect thrust plate. Be certain there are no
scratches, nicks, cracks, or seizure marks on Removal
plate. Renew plate if any are found. (Only minor
grooves or indentations can be removed.) Install 1. Remove:
new O-ring into groove of thrust plate. a. Pistons
b. Timing Gear Cover
c. Camshaft and Lifters
d. Oil Pump
2. Proceed with removal of the following.

REAR MAIN BEARING AND CARRIER

1. Remove flywheel housing assembly (rear
portion).
2. Follow instructions “a” or “b”:
a. On MIE Models: Remove drive plate from
adaptor plate (D3.0L/150 and D3.6L/180
only) and/or flywheel.
b. On MCM Models: Remove engine coupler
from flywheel.
NOTE: Refer to “Flywheel Related Components”.

70304

a - Thrust Plate
b - O-Ring

4. Install thrust plate with O-ring towards crankshaft.

Tighten thrust plate retaining screw securely.
5. Reinstall flywheel. Lubricate threads of retaining
bolts (6) with clean engine oil and install. Torque
bolts to 81 lb. ft. (110 N⋅m).
6. Follow instructions “a” or “b”:
a. On MIE (Inboard) Models: Reinstall drive
plate. Torque bolts to 30 lb. ft. (40 N⋅m).
b. On MCM (Stern Drive) Models: Reinstall
coupler. Torque bolts to 22 lb. ft. (30 N⋅m).
7. Reinstall flywheel housing assembly (rear
portion). Torque bolts to 37 lb. ft. (50 N⋅m) except
bolt on end of starter pocket (at two o’clock
position) torque to only 25 lb. ft. (34 N⋅m).
8. Complete assembly as required.

3A-52 - ENGINE - ALL MODELS 90-806934 1194

INDEX
3. Remove the six flywheel retaining bolts and the 5. Mark position of rear main bearing carrier in
flywheel. relation to block.

70361

a - Flywheel Retaining Bolts (6)

b - Flywheel

70302
4. Remove 9 bolts and 6 nuts (with respective
washers) retaining flywheel housing. Remove a - Rear Main Bearing Carrier
flywheel housing. b - Engine Block
c - Reference Mark

6. Remove screw locking thrust plate to crankshaft.

70302

70301 a - Locking Screw

b - Thrust Plate
a - Bolts (9), With Washers
b - Nuts (6), With Lockwashers
c - Vacant Holes (Not used)

90-806934 1194 ENGINE - ALL MODELS - 3A-53

INDEX
7. To assist in removing bearing carrier, temporarily
reinstall flywheel housing using only the nuts on
the carrier. By tapping evenly, around the housing
as shown, the carrier and thrust plate will be
pulled from the engine.
Crankshaft
1. Remove main bearing oil feed locating screws
(which hold main bearing carriers in block). Note
position of oil sender in engine block.

70305

a - Engine Block
70303 b - Main Bearing Oil Feed Locating Screws
c - Oil Sender (Note Position, For Proper Reinstallation)
a - Nuts (6)
b - Flywheel Housing 2. Install Crankshaft Installer Tool 91-801333504
c - Tap Evenly, Around the Housing
d - Hold Here
over timing gear as shown, to protect front main
bearing.
8. Remove nuts temporarily holding flywheel
housing to rear bearing carrier, and proceed to
next appropriate section.

70306

a - Tool 91-801333504
b - Timing Gear

3. Turn engine vertical with front facing down.

3A-54 - ENGINE - ALL MODELS 90-806934 1194

INDEX
4. Using a hoist and suitable sling attached to Front Main Bearing
crankshaft, lift crank out of block.
NOTE: If bearings are being inspected prior to re-
placement, refer to “INSPECTION,” in this section,
Main Bearing Carriers and Bearings: before removing front main bearing. If all bearings are
being replaced proceed.
IMPORTANT: Before removing bearing carriers
1. Assemble Bearing Puller 91-801333508 into front
from crankshaft, number or mark them according
main bearing, as shown.
to journal upon which they are fitted. Also mark
both halves for correct reassembly. Do not mix
parts.
1. After marking carriers, remove bolts to split
carrier(s) and remove carrier(s) with bearings
from crankshaft journal(s).

70308

a - Tool 91-801333508
b - Front Main Bearing

70307 2. Remove bearing.

a - Bolts with Washers
b - Bearing Carrier
c - Main Bearings

90-806934 1194 ENGINE - ALL MODELS - 3A-55

INDEX
TIMING GEAR (CRANKSHAFT):
NOTE: Replace gear only if worn or damaged.
1. Install Crankshaft Gear Puller 91-801333503
onto crankshaft and gear, as shown.
MAIN BEARINGS (MEASUREMENT)
1. Inspect bearings. Refer to “Bearing Failures.”
2. To check clearance of center main bearings:
a. Install bearings in original carrier halves, if
removed.
b. Observing marks made earlier, assemble
carriers. Torque bolts with washers to 31 lb. ft.
(42 N⋅m).
c. Measure I.D. of bearing as shown.

70309

a - Tool 91-801333503
b - Timing Gear (Crankshaft)

2. Remove gear.

Inspection

CRANKSHAFT 70310
1. Immerse crankshaft in a solvent bath and clean.
d. Measure O. D. of matching crankshaft journal
2. Clear oil passages with compressed air. as shown.
3. Visually inspect crankshaft for scratches, nicks,
cracks and seizure marks. Replace if needed.

IMPORTANT: No material may be removed, either

by hand or machine grinding, from thrust faces of
crank-shaft.

4. Replace crankshaft if machined surfaces on front

and rear ends or threaded areas of crankshaft
ends are out-of-round, worn or damaged.
5. After a seizure, over-heating or grinding,
crankshaft must be Magnafluxed to verify no
surface cracks are present.
NOTE: It will be necessary to measure I.D. of
bearings in carriers and O. D. of matching crankshaft
journal to determine maximum clearance. [Refer to 70311
following section “Main Bearings (Measurement).”]
e. Calculate difference between measurement
6. Measure journals of crankshaft to determine if taken in step “c” and “d” (clearance) and refer
replacement or regrinding is necessary. Refer to to specifications for maximum clearance of
specifications. bearing being checked.

3A-56 - ENGINE - ALL MODELS 90-806934 1194

INDEX
3. Measure rear main bearing clearance in the same Installation
manner as the center main bearings (no
FRONT MAIN BEARING
assembly of carrier is required).
1. Align oil passage with hole of new bearing.
4. To check clearance of front main bearing:
a. Measure crankshaft front main bearing
journal.
b. Measure I.D. of front main bearing in engine
block as shown.

70313

70312
c. Calculate difference between measurement
taken in step “a” and “b” (clearance) and refer
to specifications for maximum clearance.
a - Oil Passage
b - Bearing Hole
2. Place new bearing on Puller/Installer Tool
91-801333508 as shown. Tool will install bearing
to the correct depth. Oil passage MUST BE
aligned.

70402

a - Tool 91-801333508
b - Bearing (On Tool)

90-806934 1194 ENGINE - ALL MODELS - 3A-57

INDEX
MAIN BEARING CARRIERS AND BEARINGS
1. Install new bearing shells into matching carrier
halves.
2. Lubricate bearings with clean engine oil.
4. Be certain all carriers are positioned so that
piston oil jet faces FRONT of engIne, as
shown, when installing on journal. Install
matching carrier halves (marked earlier) on
crankshaft journals in their original locations.
Lubricate bolts and washers with clean engine oil.
Torque to 31 lb. ft. (42 N⋅m).

FRONT

70307

a - Main Bearing Shells 70404

b - Main Bearing Carrier – Matching Halves
a - Piston Oil Jets (Face Front of Engine)

IMPORTANT: Piston oil jet MUST FACE FRONT CRANKSHAFT

(pulley end) OF ENGINE when installed.
1. Install new timing gear with reference dots facing
3. Identify piston oil jet location on all main bearing FRONT of engine. Install Crankshaft Installation
carriers. Tool 91-801333504 on front gear as shown, to
protect front main bearing.

70382

a - Piston Oil Jet Location

70404

a - Tool 91-801333504

2. Turn engine vertical, flywheel end facing up.

3. Carefully lower crankshaft, with main bearings
attached, into engine block.
4. Turn engine horizontal with bottom facing up.

3A-58 - ENGINE - ALL MODELS 90-806934 1194

INDEX
5. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Models: Turn
all bearing carriers so “arrows” face up as
shown, toward notches in oil pan flange and
piston oil jet faces FRONT of engine.
70405
a - Bearing Carriers With “Arrows” Facing Up (Toward Oil Pan
Flange)
b. On D4.2L/220 Models: Turn all bearing carri-
ers so that “ROUND hole” through casting
faces up as shown, toward oil pan flange and
piston oil jet faces FRONT of engine.
70434
a - Bearing Carriers With “ROUND hole” Facing Up (Toward
Oil Pan Flange)
6. Install new sealing washers on all main bearing oil
feed locating screws and HAND THREAD CARE-
90-806934 1194
INDEX
FULLY (to avoid damaging carrier threads) into
bearing carriers. Where previously noted, install
locating screw for oil sending unit (after removing
sending unit and adaptor nozzle from locating
screw, to allow torquing). Torque all screws to 30
lb. ft. (40 N⋅m).
70386
a - Main Bearing Oil Feed Locating Screw(s)
b - Sealing Washer(s)
7. Reinstall adaptor nozzle and oil sending unit on
proper locating screw. Tighten both securely.
REAR MAIN BEARING
IMPORTANT: Be certain to press bearing so as to
prevent damage to notch arrangement in carrier
where bearing tab aligns.
1. Using a suitable mandrel press bearing out of
carrier.
2. When pressing new bearing into carrier, bearing
tab and notch in carrier MUST BE aligned as
shown.
70382
a - Bearing Tab
b - Notch in Carrier
ENGINE - ALL MODELS - 3A-59
REAR MAIN BEARING CARRIER 3. Install standard size thrust washers into front
(crankshaft) side of carrier. (Use Quicksilver
1. Refer to Oil Seal (Rear Main) – “Installation” and
Needle Bearing Lubricant to help keep washers
install new seal in carrier. Lubricate lips of seal
positioned.)
with clean motor oil.

70408
70406
a - Thrust washers (Standard Size), Front (Crankshaft) Side
a - Rear Main Oil Seal
b - Rear Main Bearing Carrier 4. Install new O-ring into groove around carrier.
(Coat with clean engine oil to assist during
2. Install standard size thrust washers into flywheel installation.)
side of carrier as shown. (Use Quicksilver Needle
Bearing Lubricant to help keep washers
positioned.)

70408

a - O-ring

70407

a - Thrust Washers (Standard Size), Flywheel Side

3A-60 - ENGINE - ALL MODELS 90-806934 1194

INDEX
5. Lubricate crankshaft journal and bearing with 7. Install thrust plate with O-ring towards crankshaft.
clean engine oil. Install rear main bearing carrier Tighten retaining screw securely.
into engine block, align marks previously made.
8. Install new O-ring into groove of flywheel housing
Always be certain lubrication holes on block and
as shown.
carrier align, especially when or if marks are not
present.

70410

a - O-ring

9. Install flywheel housing. Torque bolts with

washers to 37 lb. ft. (50 N⋅m). Then, torque carrier
nuts with washers to 20 lb. ft. (27 N⋅m).

70409 10. Lubricate threads of flywheel bolts with clean

engine oil and install flywheel. Torque bolts to 81
a - Rear Main Bearing Carrier lb. ft. (110 N⋅m).
b - Marks – Align

6. Install new O-ring into groove of thrust plate

(crankshaft side).

70304

a - Thrust Plate
b - O-ring

90-806934 1194 ENGINE - ALL MODELS - 3A-61

INDEX
CRANKSHAFT END-PLAY (AXIAL) CLEARANCE 2. Remove plate from Cylinder Liner Puller
91-801333502.
1. Attach Dial Indicator 91-58222A1 to engine block
to check installed crankshaft end-play (axial)
clearance. Reading can be taken off of counter
weight as shown. Move crankshaft fore and aft in
block to obtain reading. Clearance should be
.005-.013 in. (0.121-0.323mm).

70412

a - Cylinder Liner Puller Tool 91-801333502

b - Plate

IMPORTANT: Mark liners in a suitable fashion as

to the cylinder number (to avoid mismatching to
pistons upon reassembly) and orientation in
block (reference to prechamber bore of head).

3. Install puller tool into cylinder and attach plate to

tool at bottom of liner. Remove liner(s) as shown.
Note location of shim between liner and
crankcase bore relief. Also, note O-rings on liner
70411
lower part.
2. If clearance is incorrect, calculate the necessary
thickness of thrust washers needed (from sizes
listed in parts manual). Install different thickness
thrust washers and recheck. Do this until proper
clearance is reached.

Cylinder Liners
Removal
1. Remove components as needed, including
pistons, as previously outlined.

70413

3A-62 - ENGINE - ALL MODELS 90-806934 1194

INDEX
Identification Cleaning and Inspection

CYLINDER LINERS
! CAUTION
1. Clean liners, especially at areas as shown, and
For D3.0L/150 and D3.6L/180 engines, cylinder where O-rings fit.
liners are provided in two standard sizes and cor-
respond to the tolerance classes: Class A or
Class B. Failure to use only the Class (A or B) liner
designated for your engine, with matching Class
A or B piston, will result in severe engine damage.

1. On D3.0L/150 and D3.6L/180 Engines: As

shown in the following, inspect underside of liner
for tolerance class identification reference mark
(a small radial line). If NO MARK is present the
liner is a standard size “Class A” liner. If MARK
is present the liner is a standard size “Class B”
liner. Refer to specifications – “Liner I.D.” for exact
dimensions.
70414

a - Areas for Special Cleanliness

2. Check liners for abnormal wear or cracks.

Replace as needed with those parts for your
specific model (refer to preceding
“Identification”).
3. Measure liners for out-of-round or taper with a dial
or bore gauge, taking readings at three different
vertical positions and at opposite sides of the liner
bore. Refer to specifications.
4. When cylinder liner wear is within specifications
light honing of the liner bore is allowed. Replace
if liners are not within specifications. Refer to
70416
preceding section Cylinder Liners –
“Identification.”

70439

a - Cylinder Liner
b - Tolerance Size “Class B” Reference Mark

2. On D4.2L/220 Engines: Only Class A tolerance

size liners and pistons are provided. No identifica-
tion steps are needed. (There are no liner refer-
ence marks. However, the piston does have the
letter “A” on its crown.)

90-806934 1194 ENGINE - ALL MODELS - 3A-63

INDEX
CYLINDER LINER (BLOCK) BORES
1. Thoroughly clean the engine block with suitable
solvent and blow dry with compressed air. Inspect
for cracks or flaws.
2. Check cylinder head mating surfaces of block and
area around cylinder liner bores for abnormal
wear or damage.
3. Check block bores for damage and cleanliness,
especially the flanges and counterbores for
cylinder liners as shown.
70415
a - Areas for Special Cleanliness
4. If any checks or inspections reveal unacceptable
conditions replace parts as needed with those for
your specific model.
3A-64 - ENGINE - ALL MODELS
INDEX
Installation
Cylinder liners on all engines are required to protrude
(or rise above the surface of the block) .00004 - .0023
in. (0.01 - 0.06mm). By using one of three shims
available (placed between the liner flange and the
block during installation of liner) it is possible to obtain
the correct protrusion.
1. Make seven cylindrical spacers as shown for use
following.
5/8 in. (16mm)
4 in. (102mm)
50490
2. To determine the correct shim thickness needed
for each liner follow instructions “a” – “e”:
! CAUTION
Be certain cylinder liners are fully seated in block
in the following instructions or incorrect
measurements will occur causing engine
performance problems or severe engine damage.
a. Unless being replaced, install liners in same
cylinder block bore as marked or noted upon
disassembly WITHOUT shims or O-rings.
90-806934 1194
 b. Using a precision depth gauge measure and d. Remove liner and install shim selected and
record the amount of recess (depth below refit liner.
block surface) of each liner as shown.
e. Measure protrusion. Adjust using alternate
shim if required.

70476

a - Liner Recess (Depth of Liner in Block)

b - Cylinder Liner
c - Engine Block 70475
d - Cylinder Head Mounting Surface of Block
a - Cylinder Liner Protrusion (Height Above Block Surface)
b - Cylinder Liner
c. Refer to the following chart to determine and c - Engine Block
select the shim thickness required: d - Shim

Liner Recess
BELOW Shim To Be Liner Protrusion
Block Used ABOVE Block
(Without (Thickness) (With Shim)
Shim)
.0055 - .0035 .0059
(0.14 - 0.09) (0.15)
.0074 - .0055 .0078 .0004 - .0023
(0.19 - 0.14) (0.20) (0.01 - 0.06)
.0086 - .0066 .0090
(0.22 - 0.17) (0.23)

90-806934 1194 ENGINE - ALL MODELS - 3A-65

INDEX
3. Tighten liners, with appropriate shims, to 22 lb. ft. 6. Install O-rings in grooves as shown.
(30 N⋅m) using cylindrical spacers (made in Step
1) and formed spacer-washers as shown.

70417
71207
a - Head Bolts
a - Shim
b - Cylindrical Spacers
b - Upper O-Ring Groove
c - Formed Spacer-Washers
c - Brown or Red (Upper) O-Ring
d - Black O-Rings
4. Recheck-liners for proper amount of protrusion e - Red O-Ring
using liner gauge bar 91-184812A1 (S.A.E.) or
91-801333509 (Metric) and appropriate dial D3.0L/150 and D3.6L/180 Engine Liners with One
gauge as shown. If not as specified, adjust Upper and Three Lower O-Rings
protrusion as previously outlined until each liner
is protruded .0004 - .0023 in. (0.01 - 0.06mm)
above block.

70416

a - Shim
71178 b - Black O-Rings
c - Red O-Ring
5. Remove liners in order, keeping appropriate
shims matched to liners.
D3.0L/150 and D3.6L/180 and D4.2L/220 Engine
Liners with Three Lower O-Rings Only (No Upper
Groove or O-Ring)

3A-66 - ENGINE - ALL MODELS 90-806934 1194

INDEX
7. Lubricate LOWER centering collars in engine 9. Install liners in block, being careful not to damage
block (those areas where lower liner O-rings seal O-rings or distort shim. Hold liners securely in
against the bore) with Needle Bearing Lubricant position with head bolts, cylindrical spacers
92-42649A1 or clean engine oil as shown. (made previously) and head bolt formed,
spacer-washers as shown. Torque bolts to 22 lb.
IMPORTANT: DO NOT lubricate upper bore area
ft. (30 N⋅m). Allow Loctite to dry. (Do not release
even on liners which have an upper brown or red
liners for approximately 1-1/2 to 2 hours.)
O-ring.
NOTE: Liner shown fitted ONLY for visual clarity. DO
NOT install liners in this step.

70417

50491

a - Lubricate This Area Of Engine BLOCK (Lower Centering

Collars)

8. Apply Loctite Master Gasket 92-12564--1 or

Loctite 620 (obtain locally) to liner surfaces AS
SHOWN.
IMPORTANT: DO NOT apply Loctite to shim, shim
contact surfaces, or upper O-ring (if so
equipped).

70418

a - Head Bolts
b - Cylindrical Spacers
c - Formed, Spacer-Washers

10. Once again, verify cylinder liner protrusion and

make corrections if required.
11. Continue engine assembly. Refer to appropriate
sections.

70414

a - Apply Loctite To These Areas ONLY

90-806934 1194 ENGINE - ALL MODELS - 3A-67

INDEX
ELECTRICAL SYSTEM
1
A
2
A
3
A
4
A
5
STARTING SYSTEM
Note: Refer to the following Service Bulletins regarding this section.
A
SB 97-12 Battery and Battery Cable Requirements for MerCruiser
. . . . . . . . . . D-Tronic Diesels
6
SB 91-1 New Battery and Battery Cable Requirements for MerCruiser
. . . . . . . . . . Products
A
A 7
INDEX
Table Of Contents
Page

Starter Identification Number Location . . . . . . . . . . . 4A-1

Starter Motor Specifications . . . . . . . . . . . . . . . . . . . . 4A-1
Sealants – Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
Starting Circuit Description . . . . . . . . . . . . . . . . . . . . 4A-3
Starting System Components . . . . . . . . . . . . . . . . . . 4A-4
Starter – Exploded View . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Starter Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Starter Motor Removal . . . . . . . . . . . . . . . . . . . . . 4A-6
Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-7
Starter Motor Disassembly . . . . . . . . . . . . . . . . . . 4A-8
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4A-9
Armature Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Test For Shorts . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Test For Ground . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Loose Electrical Connections . . . . . . . . . . . . 4A-10
Turning The Commutator . . . . . . . . . . . . . . . 4A-10
Field Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Test For Open Circuit . . . . . . . . . . . . . . . . . . 4A-10
Test For Ground . . . . . . . . . . . . . . . . . . . . . . . 4A-11
Starter Motor Reassembly . . . . . . . . . . . . . . . . . . . . 4A-11
Starter Motor Installation . . . . . . . . . . . . . . . . . . . . . 4A-15

4A -–STARTING
4A-0 STARTINGSYSTEM
SYSTEM 90-806934 1194
INDEX
Starter Identification Number Replacement Parts
Location ! WARNING
Electrical system components on this engine are
not external ignition protected. DO NOT STORE
OR UTILIZE GASOLINE ON BOATS EQUIPPED
WITH THESE ENGINES, UNLESS PROVISIONS
HAVE BEEN MADE TO EXCLUDE GASOLINE
VAPORS FROM ENGINE COMPARTMENT (REF:
70809
33 CFR) Failure to comply could result in fire,
explosion and/or severe personal injury.
a - I.D. Number on Starter

Battery
Starter Motor Specifications IMPORTANT: Boating industry standards (BIA,
DESCRIPTION SPECIFICATION ABYC, etc.) federal standards and Coast Guard
regulations must be adhered to when installing
I.D. Number 0 001 362 3--
or replacing battery or cables. Be sure battery
Engine Rotation Left Hand (Counterclockwise) cable installation meets the pull test
No-Load Test 11.5 Volts requirements and that positive battery terminal
125 Amps is properly insulated in accordance with
7000 RPM regulations.
Commutator New – 1.772 in. (45mm) IMPORTANT: Engine electrical system is
Diameter Min. – 1.673 in. (42.5mm)
negative (–) ground. It is recommended (required
Commutator in some states) that battery be installed in an
Max. – .001 in. (.03mm)
Out-of-Round enclosed case. Refer to regulations for your area.
Minimum
.335 in. (8.5mm) 1. Select a battery that meets all of the following
Brush Length
specifications:
Armature
.004 to .016 in. (.1 to .4mm)
Clearance a. 12-volt marine type.
Torque b. Tapered post connectors or side terminal
Tighten all fasteners securely
Specifications connectors (Do not use a battery with wing
nut connectors).
c. Battery capacity rating of at least:
Sealants – Lubricants
Engine Minimum Required
Quicksilver Liquid Neoprene 92-25111 CID (L)
(cyl./type) Cranking Battery Size
SAE 10W Oil Obtain Locally 5 In-Line 183 (3.0)
6 In-Line 219 (3.6) 750 cca, 950 mca
or 180 Ah
General 6 In-Line 254 (4.2)

The starter motor is designed to operate under great

overload and produce a high horsepower for its size.
It can do this only for a short time, since considerable
heat accumulates and can cause serious damage.
For this reason, the cranking motor must never be
used for more than 15 seconds at any one time.
Cranking should not be repeated without a pause of
at least 2 minutes to permit the heat to escape.

90-806934 1194 STARTING SYSTEM - 4A-1

INDEX
Battery Cables ! CAUTION
1. Select proper size positive (+) and negative (–) To prevent damage to the electrical system be
battery cables, using chart. Battery should be sure to adhere to the following:
located as close to engine as possible.
a. When installing battery, be sure to FIRST
IMPORTANT: Terminals must be soldered to connect the (+) positive battery cable to the
cable ends to ensure good electrical contact. Use (+) positive battery terminal, and THEN
electrical grade (resin flux) solder only. Do not connect the (–) negative battery cable to the
use acid flux solder, as it may cause corrosion (–) negative battery terminal.
and a subsequent failure. b. Never disconnect the battery cables while the
engine is running.
Battery Minimum
Cable Length Cable Gauge c. Check battery condition periodically.
Up to 3-1/2 ft. (0.9m) 2 (35mm2) d. Make sure that battery leads are kept clean
3 - 3-3/4 ft. (0.9 - 1.1m) 1 (50mm2) and tight.
3-3/4 - 4-3/4 ft. (1.1 - 1.4m) 0 (50mm2)
4-3/4 - 6 ft. (1.4 - 1.8m) 00 (70mm2)
6 - 7-1/2 ft. (1.8 - 2.3m) 000 (95mm2) ! WARNING
7-1/2 - 9-1/2 ft. (2.3 - 2.9m) 0000 (120mm2)
n9-1/2 - 12 ft. (2.9 - 3.7m) n 00 (70mm2) Do not use jumper cables and a booster battery
n12 - 15 ft. (3.7 - 4.6m) n 000 (95mm2) to start engine. Damage to various electrical
n15 - 19 ft. (4.6 - 5.8m) n0000 (120mm2) components may occur. Do not recharge a weak
Both positive (+) and negative (–) cables battery in the boat. Remove battery and recharge
in a ventilated area away from fuel vapors,
n Two cables of specified gauge required for positive and two sparks or flames.
required for negative.

Maintenance Testing

Place battery under heavy load (as during engine

! WARNING
Hydrogen gases that escape from the battery
during charging are explosive. Be sure that
battery area is well ventilated and that bilge
blower is in operation when charging. Do not
smoke or allow sources of spark or open flame in
area when charging battery. Do not recharge a
weak battery in the boat.
! WARNING
Battery electrolyte is a corrosive acid and should
be handled with extreme care. If electrolyte is
spilled or splashed on any part of the body,
immediately flush the exposed area with liberal
amounts of water and obtain medical aid as soon
as possible. Safety glasses and rubber gloves
are recommended when handling batteries.
cranking or with a variable resistor tester) and test
cell voltage while under load.
Certain conditions must be met before testing.
a. Battery temperature must be between 60° F
and 100° F (15° C – 38° C).
b. Electrolyte level must be correct in all cells.
c. Battery must be at least half charged.
d. No obvious defects.
1. Check voltage per manufacturer’s specifications.
2. If readings are low, recharge and retest.
3. If readings remain low, battery should be replaced.
! CAUTION
Test battery in well ventilated area as gases
given off by battery are hazardous.

! WARNING
Always disconnect battery cables from battery
before working around electrical system
components to prevent injury to yourself or
damage to electrical system.

4A-2 – STARTING SYSTEM 90-806934 1194

INDEX
Storage
a. Remove battery and clean exterior.
b. Check fluid level and fill if low.
c. Cover terminals and bolts with light coat of
grease.
d. Set battery on wood or in carton, store in cool, dry
place.
e. Check every 20 days for fluid level and slow
charge.
IMPORTANT: A discharged battery can be
damaged by freezing.
Starting Circuit Description
This is a general description of the positive (+12V)
current flow thru the starting circuit.
The starter used on the diesel engine is a high torque
12 volt motor capable of cranking high compression
engines. There are 3 circuit breakers used in the
circuit to prevent overload damage to wires and other
components. A neutral start switch is located in the
circuit to prevent starter operation in forward or
reverse gears. Due to the diesel’s design, the engine
is started and stopped by separate buttons located
on the instrument panel. The ignition switch is used
to control the start button and instrumentation. A
relay is used in the start button circuit to allow higher
amperage to the starter solenoid.

90-806934 1194 STARTING SYSTEM - 4A-3

INDEX
Starting System Components

4
3 5
2 2 6 Note 4
BLK/YEL 1 7
11

3
B
I S Note 3 1
2 8
3 7 YEL/RED

10 4 6 RED/PUR
5

5
6
Note 1
Note 1
4
7
Note 2
Note 2

8
(–)

10
Note 3 (+)

9
73846
1 - Ignition (Start) Switch Note 1 : Wire routing on MIE (Inboard) engine and/or
2 - 20 Ampere Fuse instrument harness.
3 - Engine Stop Switch (See Note 4.)
4 - Remote Control Neutral Safety Switch Note 2 : Wire routing on MCM (Stern Drive) engine
[MCM (Stern Drive) Only] and/or instrument harness.
5 - Start Relay
6 - Circuit Breaker(s) Note 3 : Wires connected together with hex screw
7 - Wire Junction and nut, coated with liquid neoprene and protected
8 - Starter Motor
9 - Ground Stud by a rubber sleeve.
10- Transmission Neutral Safety Switch [MIE (Inboard) Only] Note 4 : Shown for clarification of complete start and
11- Injection Pump Solenoid -For Engine Stop (See Note 4.)
stop circuits.

4A-4 – STARTING SYSTEM 90-806934 1194

INDEX
Starter – Exploded View

50185

a -
Solenoid j - Armature
b -
Drive Gear Housing k - Brush
c -
Shift Lever l - Brush Holder Frame
d -
Snap Ring m- End Frame
e -
Retainer n - Shims
f -
Drive Gear o - C-Clip
Assembly p - Rubber Seal
g - Studs q - Cap
h - Bushing Plate
i - Field Frame

90-806934 1194 STARTING SYSTEM - 4A-5

INDEX
Periodic Inspection Solenoid Switch
Starter motor and solenoid are completely enclosed
REMOVAL
in the drive housing to prevent entrance of moisture
and dirt. However, periodic inspection is required. 1. Remove starter motor as previously outlined.
a. Inspect terminals for corrosion and loose 2. Remove nut as shown, from field coil wire.
connections.
b. Inspect wiring for frayed and worn insulation.
c. Check mounting nuts for tightness.

Starter Motor Repair

Starter Motor Removal

! WARNING
Always disconnect battery cables from battery
before working around electrical system 70811
components to prevent injury to yourself or
damage to electrical system.
a - Nut
1. Disconnect battery cables from battery.
3. Remove 3 screws retaining solenoid.
2. Disconnect wires from solenoid.
3. Remove mounting nuts and lock washers.
4. Pull starter motor away from flywheel and
remove.

70812

a - Retaining Screws (3)

70810

a - Battery Cable
b - Red Wire
c - Solenoid Wire
d - Mounting Nuts with Lockwashers
(2 Total, One Hidden In This View)

4A-6 – STARTING SYSTEM 90-806934 1194

INDEX
4. Slide solenoid plunger off shift fork. 2. Install solenoid to starter with 3 screws. Tighten
securely.

70812

a - Solenoid Retaining Screws (3)

70813 70814 3. Place field coil wire on terminal and secure with
hex nut.
a - Solenoid Plunger
b - Shift Fork

INSTALLATION

1. Slide solenoid plunger on shift fork while holding

drive gear out as shown.

70811

a - Field Coil Wire

b - Hex Nut

70833

a - Solenoid Plunger
b - Shift Fork
c - Drive Gear (Hold “Out”)

90-806934 1194 STARTING SYSTEM - 4A-7

INDEX
Starter Motor Disassembly 4. Remove end frame.

1. Remove solenoid as outlined previously.

2. Remove cap screws and cap.

70816

70814
a - End Frame

a - Cap Screws 5. Remove field frame and brush holder from drive
b - Cap gear housing. Remove studs.
3. Remove rubber seal, C-clip, shims and hex nuts.

70815

a - Rubber Seal
b - C-clip 70817
c - Shims
d - Hex Nuts a - Field Frame and Brush Holder
b - Drive Gear Housing
c - Studs

4A-8 – STARTING SYSTEM 90-806934 1194

INDEX
6. Remove hex nut, wave washer and bolt. Then, lift 8. Pry snap ring out of groove and remove. Slide
armature, drive gear assembly and shift lever retainer, drive assembly and bushing plate from
from drive gear housing. armature.

70821

70819 a - Snap Ring

b - Retainer
a - Hex Nut and Wave Washer c - Drive Assembly
b - Bolt d - Bushing Plate
e - Armature
7. Slide retainer off snap ring.

Cleaning and Inspection

With starting motor completely disassembled,
except for removal of field coils, component parts
should be cleaned and inspected. Defective parts
should be replaced or repaired.
1. Clean all starting motor parts but do not use
dissolving solvents for cleaning over-running
clutch, armature and field coils. Such a solvent
would dissolve grease packed in clutch
mechanism and damage armature and field coil
insulation.
2. Test over-running clutch action. Pinion should
turn freely in over-running direction and must not
70820 slip in cranking direction. Check pinion teeth.
Check spring for tension and drive collar for wear.
a - Retainer
b - Snap Ring
If drive assembly is defective replace starter.
3. Check that brush holders are not damaged or
bent and will hold brushes against commutator.
4. Check brushes. Replace if pitted or worn.
5. Inspect armature commutator. If rough or out-of-
round, turn down and undercut. Inspect points
(where armature conductors join commutator
bars) for good, firm connection. Burned
commutator bar usually is evidence of poor
connection.

90-806934 1194 STARTING SYSTEM - 4A-9

INDEX
Armature Tests
TEST for SHORTS
Check armature for shorts by placing on growler and
holding hack saw blade over armature core while
rotating armature. If saw blade vibrates, armature is
shorted. After cleaning between commutator bars,
recheck. If saw blade still vibrates, replace armature.
LOOSE ELECTRICAL CONNECTIONS
If open soldered connection of armature to
commutator leads is found during inspection, resolder
with rosin flux.
IMPORTANT: NEVER USE ACID FLUX ON
ELECTRICAL CONNECTIONS.
TURNING the COMMUTATOR
When inspection shows commutator roughness,
clean as follows:
1. Turn down commutator in a lathe until thoroughly
cleaned.
2. Recheck armature for shorts as outlined.

Field Coil Tests

TEST for OPEN CIRCUIT
1. With continuity meter, place one lead on each
end of field coils (insulated brush and field con-
nector bar).
2. Continuity should exist. If meter does not move,
field coils are open and starter must be replaced.

01441

TEST for GROUND

1. With continuity meter, place one lead on armature
core or shaft and other lead on commutator.
2. If meter hand moves armature is grounded and
must be replaced.

70822

01440

4A-10 – STARTING SYSTEM 90-806934 1194

INDEX
TEST FOR GROUND Starter Motor Reassembly
IMPORTANT: Be sure that positive brushes and 1. Brush Replacement.
leads do not contact field frame assembly during
test, or false reading will result. a. Make 4 brush fixtures out of stiff wire (wire
coat hanger) as shown.
1. With continuity meter, place one lead on field
connector bar and other lead on ground (field 1 in.
frame). (25.4mm)

2. NO continuity should exist. If meter moves, field

coils are grounded and starter must be replaced. 3/4 in.
(19mm) 1 in.
(25.4mm)

(Actual Size)

b. Cut off worn brush lead at field coil and brush

holder frame.

70824

70823

70825

a - Field Coil
b - Brush Holder Frame
c - Brush Lead

90-806934 1194 STARTING SYSTEM - 4A-11

INDEX
 c. Install new brush leads to holes located in
brush holder frame, and fasten to field coil
with screws and hex nuts provided with new
brushes.
2. Assemble components on armature as follows:
a. Lubricate drive end of shaft with SAE 10W
Oil. DO NOT over-lubricate. Install bushing
plate, drive assembly, retainer and snap ring
as shown.

70826 70821

d. Check to see that brush springs are in place. a - Bushing Plate (Bushing facing windings)
Push brushes into holders and hold in place b - Drive Assembly
c - Retainer
using brush fixtures.
d - Snap Ring
e - Armature
b. Using a deep-well socket and brass hammer,
tap snap ring over shoulder of shaft and into
groove as shown.

70827

a - Brush (Holding) Fixtures

70820

a - Snap Ring
b - Shoulder of Shaft

4A-12 – STARTING SYSTEM 90-806934 1194

INDEX
 c. Install a universal puller plate on drive gear
assembly. Place in arbor press as shown.
Compress snap-ring into groove using a pair
of pliers while lightly pressing down on end of
shaft, until retainer covers snap-ring.
4. Lubricate bushing in drive gear housing with one
drop of SAE 10W oil. DO NOT over-lubricate.
Install armature shaft into drive gear housing,
engaging shift lever into drive gear assembly as
shown.

70829

70828 70830

a - Bushing (In Drive Gear Housing)

3. Insert shift lever into drive gear housing as b - Armature
shown. Do not install bolt at this time. c - Drive Gear Housing
d - Shift Lever
e - Point(s) of Engagement

5. Insert bolt thru housing and shift lever. Fasten

with wave washer and hex nut. Tighten securely.

70829

a - Shift Lever
b - Drive Gear Housing
70831

a - Bolt
b - Wave Washer
c - Hex Nut

90-806934 1194 STARTING SYSTEM - 4A-13

INDEX
6. Install studs into drive gear housing. 8. Remove the 4 brush (holding) fixtures.
9. Lubricate end frame bushing with one drop of
SAE 10W Oil. DO NOT over-lubricate. Install end
frame on armature as shown. Tighten hex nuts
securely.

70817

a - Studs

7. Position field frame over armature, lining up field

coil wire and brush holder frame slots with studs
as shown.

70815

a - Bushing
b - End Frame
c - Hex Nuts

10. Install solenoid as outlined previously.

11. Install shims and C-clip on end of armature using
enough shims to obtain .004 to .016 in. (.1 to
.4mm) clearance between shims and end frame.

70816

a - Field Coil Wire

b - Slots In Brush Holder Frame
c - Studs

70832

4A-14 – STARTING SYSTEM 90-806934 1194

INDEX
12. Install rubber seal and cap. Tighten screws Starter Motor Installation
securely.
1. Install starter motor to bell-housing with lock
washers and hex nuts. Tighten 50 lb. ft. (68 N⋅m).
2. Connect wires to solenoid as shown. Tighten
securely.
3. Coat terminals with Quicksilver Liquid Neoprene.
4. Connect battery cables to battery.

70814

a - Rubber Seal
b - Cap 70810
c - Screws a - Lock Washers and Hex Nuts (2, One Hidden In This View)
b - Red Wire
c - Solenoid Wire (Yellow/Red)
d - Positive (+) Battery Cable

90-806934 1194 STARTING SYSTEM - 4A-15

INDEX
ELECTRICAL SYSTEMS

4
73198
B
GLOW PLUG SYSTEM

Index
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
D3.0L/150 Engines . . . . . . . . . . . . . . . . . . . 4B-1
D3.6L/180 and D4.2L/220 Engines . . . . . 4B-2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4B-2
Tools/Lubricants/Adhesives . . . . . . . . . . . . . . . . . . . 4B-2
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3
Water Temperature Switch . . . . . . . . . . . . . . . . . . . 4B-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Pre-Glow Relay and Power Relay System . . . . . . 4B-5
Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7

Index
4B - GLOW
4B-0 PLUG
- GLOW SYSTEM
PLUG SYSTEM 90-806934 1194
Identification Specifications

General

5 CYLINDER IN-LINE DIESEL ENGINES

NOTE: Glow Plug System will work only when engine
temperature is below 122° F (50° C).

DESCRIPTION SPECIFICATION
Glow Plug Diameter M12 x 1.25
and Thread
Nominal Voltage 11 Volts
Current Draw after 30 7.5 – 9.5 Amps
Seconds of Operation
7 seconds at 12 volts
Preheat Time (18 Seconds more after
engine starts)
70159
Test current at 68° F 69 Amps
In-Line Diesel Engine Glow Plug (20° C)
Resistance, with test 9 – 11 mΩ
current, after 30 se-
conds
Voltage drop, with test .63 – .77 Volt
current, after 30 se-
conds
Contact opening time 7 – 17 seconds
with test current, at 68°
F (20° C)
Contact opens at – 4° F 25 – 40 seconds
(– 20° C) with test cur-
rent of 62 Amps after...

Index
90-806934 1194 GLOW PLUG SYSTEM 4B-1
6 CYLINDER IN-LINE DIESEL ENGINES Glow Plugs
DESCRIPTION SPECIFICATION
Glow Plug Diameter Testing
M12 x 1.25
and Thread
Nominal Voltage 11 Volts ! WARNING
Current Draw after 30 Always disconnect battery cables from battery before
7.5 – 9.5 Amps
Seconds of Operation working around electrical system components to pre-
7 Seconds at 12 volts vent injury to yourself or damage to the electrical sys-
Preheat Time (18 Seconds more after tem.
engine starts) 1. Disconnect battery cables from battery.
Test current at 68° F
79 Amps 2. Remove hex nut and washer from glow plug ter-
(20° C)
minal. Remove voltage supply wire when pres-
Voltage drop, with test ent.
current, after 30 se- .50 – .60 Volt
conds 3. Carefully bend connecting bridge away from glow
plug terminal.
Contact opening time
with test current, at 68° 11 – 26 seconds
F (20° C)
Contact opens at – 4° F
(– 20° C) with test cur- c
35 – 50 seconds
rent of 62 Amps after b
specified time.

Torque Specifications
DESCRIPTION Lb. Ft. N·m a
Glow Plug 17 23
70191

a - Voltage Supply Wire (BLUE/WHITE Wire)

Tools/Lubricants/Adhesives b - Glow Plug Terminal
c - Connecting Bridge
DESCRIPTION PART NUMBER
Volt/Ohm Meter 91-93572 4. Connect ohmmeter between engine ground and
glow plug terminal. Continuity should exist; if no
Liquid Neoprene 92-25711--1 continuity exists, glow plug is faulty.
Quicksilver Perfect Seal 92-34227--1
5. If glow plug is removed, connect ohmmeter be-
tween glow plug terminal (+) and glow plug exter-
nal (–) threads. Continuity should exist; if no conti-
nuity exists, glow plug is faulty. Refer to
“Specifications” for values.
a

73198
b
a - Terminal (+)
b - External Threads (–)

Index
4B-2 - GLOW PLUG SYSTEM 90-806934 1194
Removal
! WARNING
Always disconnect battery cables from battery before
working around electrical system components to pre-
vent injury to yourself or damage to the electrical sys-
tem.
1. Disconnect battery cables from battery.
2. Remove hex nut and washer from glow plug ter-
minal. Remove voltage supply wire when pres-
ent.
3. Carefully bend connecting bridge away from glow
plug terminal.
Installation
1. Clean seat area and install glow plug. Torque to
specifications.
2. Install electrical connections or connectors on
glow plug terminals. (See note.)
NOTE: Be certain contact area of connecting bridge
is clean and free of corrosion or debris before instal-
ling on glow plug terminals. See that wire terminal
connectors are clean and free of corrosion.
c
a

c
b b

70191
a - Contact Areas That MUST BE Clean
b - Voltage Supply Wire Ring Terminal End
a c - Connecting Bridge

! CAUTION
70190
a - Voltage Supply Wire (BLUE/WHITE Wire) Avoid shorting electrical circuits. Some voltage
b - Glow Plug Terminal supply wire ring terminal ends are large and
c - Connecting Bridge could contact the cylinder head which is
grounded (–). Be certain ring terminal is isolated
IMPORTANT: Avoid contaminating cylinders. to the glow plug terminal.
Clean any dirt away from around glow plug before
removal. 3. Attach connecting bridge to glow plug terminal
4. Clean any dirt away from around glow plug and with washer and hex nut. Be certain that the
remove glow plug. BLUE/WHITE voltage supply wire is present,
where previously removed, and not contacting
the cylinder head.
4. Coat all terminal connections with Quicksilver
Liquid Neoprene.
5. Connect battery cables to battery.

Index
90-806934 1194 GLOW PLUG SYSTEM 4B-3
Water Temperature Switch Removal
1. Refer to SECTION 6B and drain coolant from
Testing closed cooling system into a suitable container.
1. Before testing observe the following to obtain 2. Unplug the wiring harness connector.
proper results: 3. Remove the sender and sealing washer.
a. Engine must be cold, less than 122° F (50° C).
b. Fuse at instrument panel is not defective
(blown).
c. Make sure wiring harness connector is at- c
tached to water temperature switch. b
a
2. Turn ignition key to “ON” position.
3. Check for battery voltage at GREEN wire in har-
ness connector. If voltage is present, switch is not
defective.
4. If voltage is not present, check for battery voltage
at PURPLE wire in connector. If voltage is pres-
ent, replace switch. If voltage is not present, PUR-
PLE wire is open. Refer to SECTION 4E - “Wiring
Diagrams”.
74284
c
a - Wiring Harness Connector
b b - Water Temperature Switch
c - Sealing Washer
a Typical

Installation
1. Coat threads of sender with Quicksilver Perfect
Seal.
2. Install sealing washer and thread sender into cyl-
inder head. Tighten securely.
74284
3. Plug in harness connector.
a c 4. Refer to and fill closed cooling system with ap-
b proved coolant.
5. Run engine to operating temperature and check
for leaks.
6. Follow instructions in SECTION 6B. Allow engine
to cool and check coolant level as required.

70192

a - Wiring Harness Connector

b - Water Temperature Switch
c - Last Cylinder Head (Closest to Flywheel)
Locations of Water Temperature Switch

Index
4B-4 - GLOW PLUG SYSTEM 90-806934 1194
Pre-Glow Relay and Power • Closed cooling system is cold, below
approximately 122° F. (50° C).
Relay System • Circuit breakers on electrical box are not
Refer to “Glow Plug Circuit” information for diagrams open (tripped).
and test procedures. • Fuse at instrument panel is not defective
IMPORTANT: Check the following before testing: (blown).
• All wires in circuit are connected.
• Plug-in connectors are fully engaged.
• Battery is fully charged.
• All connections are tight and corrosion
free.

Index
90-806934 1194 GLOW PLUG SYSTEM 4B-5
Glow Plug Circuit When the coolant is cold, below approximately 122°
F. (50° C), the switch is closed, allowing current to
flow to the pre-glow relay and pre-heat light. The relay
is timed to prevent the glow plugs from staying on too
Description long and overheating. When the coolant is hot, above
The glow plug circuit is controlled by the water tem- approximately 122° F. (50° C) the glow plugs are not
perature located in the closed cooling system. needed to start the engine.

Diagram

See Note.
3 4

d c

10 9

2 b
h J
11

g k f

e
8 1 7 10 5
6
5 6
1 7
2 9

11 8
l m
73876

a- Glow Plug NOTE: Not present on 5 cylinder engines.

b- Water Temperature Sender
c- Preheat Indicator Lamp 1 Represents a Numbered Test Point Location (Refer to
d- Ignition Switch “TESTING” outlined on following page.)
e- Battery
f - Pre Glow Relay
g- Start Relay
h- Circuit Breaker (60 Amp)
i - Circuit Breaker (60 Amp)
j - Power Relay
k- Slave Relay
l - Power Relay Connector
m- Pre-Glow Relay Connector
D3.0L/150, D3.6L/180 and D4.2L/220 Engines
Index
4B-6 - GLOW PLUG SYSTEM 90-806934 1194
Testing
NOTE: Location of Test Points are given on the pre-
vious page.

STEP 1
Using an ohmmeter (R x1 Scale), check for con-
tinuity between : Test Point 1 and Ground Point
2 to Ground

No Continuity:
BLACK Ground
Wire is open.
open

Continuity

STEP 2
Use a voltmeter for the following tests. Turn
ignition switch to the “ON” position. NOTE:
Pre-glow relay will stay on for approximately
7 seconds. Turn ignition switch to “OFF”
position to reset relay. Check for battery volt-
age at points 3-4-5-7-8-9-10-11 in relay con-
nectors. Voltage at the Test Point 6 will be
less than battery voltage.

No Voltage
Present At Test Problem
Point Number:
BLU/WHT wire is open between
3
glow plugs and pre-glow relay.
BLU/WHT wire is open between
4
glow plugs and power relay.
RED/PUR wire is open between
5
circuit breaker and pre-glow relay.
GRN wire is open between water
Battery voltage present at all Test Points:
6 temperature sender and pre-glow
Relays are good.
relay.
PUR wire is open between igni-
7
tion switch and pre-glow relay
8 Pre-glow relay is faulty.
BLU/WHT wire between relays is
9
open
RED/PUR wire is open between
10
power relay and circuit breaker.
11 Power relay is faulty.

Index
90-806934 1194 GLOW PLUG SYSTEM 4B-7
ELECTRICAL SYSTEMS

4
72078
C
CHARGING SYSTEM

Index
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Mando 65 Amp Alternator
Replacement Parts Warning . . . . . . . . . . . . . . . . . . . . 4C-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Tools/Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-3
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-3
Alternator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4
Battery Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5
Dual Battery Charging Systems
Using a Battery Isolator . . . . . . . . . . . . . . . . . . . . . 4C-5
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5
Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . 4C-6
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-6
Troubleshooting Tests (Alternator on Engine) . . . . . 4C-6
Circuitry Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-6
Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-6
Excitation Circuit . . . . . . . . . . . . . . . . . . . . . . . . 4C-7
Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-7
Current Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 4C-8
Voltage Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 4C-8
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-9
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-11
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4C-14
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 4C-14
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-14
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-15
Rectifier and Diode Assembly . . . . . . . . . . . . 4C-16
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-20
Index
4C - -CHARGING
4C-0 CHARGINGSYSTEM
SYSTEM
Page
Prestolite 65 Amp
Replacement Parts Warning . . . . . . . . . . . . . . . . . . . 4C-21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-21
Tools/Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-21
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4C-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-21
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-22
System Components . . . . . . . . . . . . . . . . . . . . . . . . . 4C-22
Alternator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-23
Battery Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-24
Dual Battery Charging Systems
Using a Battery Isolator . . . . . . . . . . . . . . . . . . . . 4C-24
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4C-24
Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . 4C-25
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-25
Troubleshooting Tests (Alternator on Engine) . . . . 4C-25
Circuitry Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-25
Alternator Output Test . . . . . . . . . . . . . . . . . . . 4C-25
Harness Voltage Test . . . . . . . . . . . . . . . . . . . 4C-26
Open Diode-Trio Test . . . . . . . . . . . . . . . . . . . 4C-26
current output test . . . . . . . . . . . . . . . . . . . . . . 4C-27
Open Regulator test . . . . . . . . . . . . . . . . . . . . 4C-28
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-28
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-30
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4C-31
Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-32
Slip Rings/Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . 4C-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-33
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-34
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-34
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-35
Positive/Negative Rectifier
and Diode-Trio Assembly . . . . . . . . . . . . . . . . . . 4C-35
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-35
Negative (–) Rectifier . . . . . . . . . . . . . . . . . . . 4C-35
Positive (+) Rectifier and Diode-Trio . . . . . . . 4C-36
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-37
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-39
NOTICE
For information and procedures on troubleshoot-
ing, refer to SECTION 1C.
90-8069341194
90-806934 1194
Identification Mando 65 Amp Alternator

Replacement Parts Warning

c ! WARNING
Electrical, ignition and fuel system components
on your MerCruiser are designed and manufac-
tured to comply with U.S. Coast Guard Rules and
Regulations to minimize risks of fire and explo-
sion.
Use of replacement electrical, ignition or fuel sys-
tem components, which do not comply with these
b rules and regulations, could result in a fire or ex-
plosion hazard and should be avoided.

a 72078

a - Excitation Wire - PURPLE Specifications

b - Sensing Wire - RED/PURPLE
c - Mando Part Number (Hidden in This View) DESCRIPTION SPECIFICATION
Mando 65 Amp Alternator Excitation Circuit 1.3-2.5 Volts
Current Output 65 Ampere
Voltage Output 13.9-14.7 Volts
Condenser Capacity .5 MFD
Minimum Brush Length 1/4 in. (6 mm)
a

Special Tools/Sealants
DESCRIPTION PART NUMBER
b Magneto Analyzer 91-76032
Bearing Removal and 91-31229A5
c Installation Kit
Universal Puller Plate 91-37241
Multi-Meter/DVA Tester 91-99750
73078 Quicksilver Liquid 92-25711--1
Neoprene
a - Excitation Wire - PURPLE
b - Sensing Wire - RED/PURPLE
Ammeter (0-70 Volts) Obtain Locally
c - Prestolite Part Number

Prestolite 65 Amp Alternator

Index
90-806934 1194 CHARGING SYSTEM - 4C-1
Torque Specifications A 3-phase stator is mounted directly over the rotor
pole pieces and between two end frames. It consists
TORQUE of three windings wound 120 degrees electrically out-
DESCRIPTION of-phase on the inside of a laminated core. The wind-
Lb. In. Lb. ft. N⋅m ings are all connected together on one end, while the
End Frame Screws 55 5.6 other ends are connected to a full-wave rectifier
Brush Setscrews 18 1.5 bridge.

Regulator Mounting The rectifier bridge contains six diodes which are ar-
43 4.5 ranged so that current flows from ground, through the
Screws
stator and to the output terminal, but not in the oppo-
Ground Terminal Nuts 25 2.5 site direction.
Regulator Leads 25 2.5
When current is supplied to the rotor field winding,
Pulley Nut 33 58 and the rotor is turned, the movement of the magnetic
Alternator Brace to Al- fields created induces an alternating current into the
192 28 stator windings. The rectifier bridge then changes this
ternator
alternating current to direct current which appears at
Alternator Brace to En-
30 41 the output terminal. A diode trio also is connected to
gine Block
the stator windings to supply current to the regulator
Alternator to Mounting and the rotor field during operation.
35 48
Bracket
Voltage output of the alternator is controlled by regu-
Alternator Mounting
lating the current supplied to the rotor field. This is ac-
Bracket to Engine 30 41
complished by a transistorized voltage regulator that
Block
senses the voltage at the battery and regulates the
1/2 In. (13 mm) field current to maintain alternator voltage within pre-
V-Belt Tension
See Note 1. scribed limits for properly charging the battery. Cur-
rent output of the alternator does not require regula-
Note 1. : Depress belt with thumb at midway point
tion, as maximum current output is self-limited by the
between circulating pump pulley and alternator.
design of the alternator. As long as the voltage is reg-
ulated within the prescribed limits, the alternator can-
not produce excessive current. A cut-out relay in the
Description voltage regulator also is not required, as the rectifier
diodes (which allow current to flow in one direction
The alternator has a rotor, which is supported in two only) prevent the battery from discharging back
end frames by ball bearings, and is driven by a pulley through the stator.
at approximately twice engine speed. The rotor con-
tains a field winding that is enclosed between two Due to the lack of residual magnetism in the rotor pole
multiple-finger pole pieces. The ends of the field pieces, a small amount of current must be supplied to
winding are connected to two brushes (mounted in the rotor field to initially start the alternator charging.
the rear end frame) which make continuous sliding (or This is accomplished by means of an excitation circuit
slipping) contact with the slip rings. The current (flow- in the regulator which is connected to the ignition
ing through the field winding) creates a magnetic field switch. Once the alternator begins to produce output,
that causes the adjacent fingers of the pole pieces to field current is supplied solely by the diode trio, as ex-
become alternate north and south magnetic poles. plained, preceding.
The alternator also is equipped with a fan (mounted
on the rotor shaft) which induces air flow through the
alternator to remove the heat created by the rectifiers
and stator. A capacitor protects the rectifier system
from high voltages and suppresses radio noise.

Index
4C-2 - CHARGING SYSTEM 90-806934 1194
Precautions System Components
The following precautions MUST BE observed when The alternator system consists of the alternator, bat-
working on the alternator system. Failure to observe tery, the ignition switch and the wiring which connects
these precautions may result in serious damage to these components.
the alternator or alternator system.
Battery
1. DO NOT attempt to polarize the alternator. Meter
Ignition
2. DO NOT short across or ground any of the termi- Switch
nals on the alternator, except as specifically
instructed in the “Troubleshooting Tests.” Harness
Plug
3. NEVER disconnect the alternator output lead or
battery cables when the alternator is being driven
by the engine. Alternator
4. NEVER disconnect regulator lead from alternator
regulator terminal when the alternator is being
driven by the engine.
5. ALWAYS remove negative (–) battery cable from
battery before working on alternator system. Circuit
6. When installing battery, BE SURE to connect the Breaker
positive (+) battery cable to the positive (+) bat-
Starter
tery terminal and the negative (–) (grounded) bat- Motor
tery cable to negative (–) battery terminal.
7. If a charger or booster battery is to be used, BE
SURE to connect it in parallel with existing battery
(positive to positive; negative to negative).
Ground
Stud

Battery

72933

Index
90-806934 1194 CHARGING SYSTEM - 4C-3
Alternator Circuits - Typical

STARTER

8 GA. MIN.

AUXILIARY
BATTERY

MAIN
BATTERY

74146

Index
4C-4 - CHARGING SYSTEM 90-806934 1194
Battery Isolators
Dual Battery Charging Systems
Using a Battery Isolator
Battery isolators allow the addition of an auxiliary (se-
cond) battery to the MerCruiser electrical system.
The auxiliary battery is primarily used as a power
source for various accessories installed on the boat.
The battery isolator will allow the alternator to charge
both the cranking and auxiliary batteries at the same
time while preventing accessories, connected to the
auxiliary battery, from drawing power from the crank-
ing battery.
Mercury Marine does not manufacture any battery
isolator systems. Battery isolators must be bought
from an outside manufacturer. Mercury Marine sug-
gests following the manufacturer’s instructions care-
fully.
IMPORTANT: Alternators used on MerCruiser en-
gines ARE NOT equipped with an isolation diode.
! CAUTION
Follow battery isolator manufacturer’s instruc-
tions for wire gauge. Battery isolator installation
must conform to BIA Low Voltage Wiring Stan-
dard No. 125-79.
NOTE: MerCruiser engines equipped with a 3-wire,
belt driven alternator, can use a battery isolator.
Periodic Maintenance
The following maintenance check should be per-
formed every 50 hours or 60 days (whichever comes
first) in fresh water areas or every 25 hours or 30 days
in salt water areas.
! CAUTION
Remove all battery cables from battery (before
conducting the following check) to prevent acci-
dentally shorting out electrical system.
1. Inspect entire alternator system for corroded or
loose connectors.
2. Check wiring for frayed or worn insulation.
3. Check alternator drive belt for excessive wear,
cracks, fraying and glazed surfaces. Also, check
drive belt tension and adjust, if necessary, as ex-
plained under “Drive Belt Tension Adjustment.”
4. Check alternator mounting bolts for adequate
tightness.
5. Inspect slip ring end frame flame arrestor screen
for debris and clean, if necessary, using com-
pressed air or a cloth. Screen MUST BE clean, or
alternator may overheat.

WIRING COLOR CODE ABBREVIATIONS

BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR or PPL = PURPLE
RED = RED
TAN = TAN 72078
WHT = WHITE
YEL = YELLOW
LIT or LT = LIGHT
DRK = DARK

Index
90-806934 1194 CHARGING SYSTEM - 4C-5
Drive Belt Tension
Adjustment
Alternator
1. Install drive belt on pulleys and adjust tension as
follows:
a. Pivot alternator away from engine, as re-
quired, until correct tension is obtained as
shown. Belt should depress 1/2 in. (13 mm).
a not been caused by running engine at too low a
Troubleshooting Tests
(Alternator on Engine)
Use the following tests in conjunction with the “Trou-
bleshooting” in Section 1. Before proceeding with the
tests, however, perform the following checks to elimi-
nate possible problem areas. Also observe “Precau-
tions,” preceding, to prevent damage to alternator
system.
1. If problem is an undercharged battery, check to
ensure that undercharged condition has not been
caused by excessive accessory current draw or
by accessories which have accidentally been left
on. Also, check that undercharged condition has
speed for extended periods of time.
2. Check physical condition and state of charge of
battery, as outlined in “Battery - Storage” in Sec-
tion 4A. Battery MUST BE at least 75% (1.230
specific gravity) of fully charged to obtain valid re-
sults in the following tests. If not, charge battery
before testing system.
3. Inspect entire alternator system wiring for de-
fects. Check all connections for tightness and
cleanliness, particularly battery cable clamps and
battery terminals.

72669
4. Check alternator drive belt for excessive wear,
cracks, fraying and glazed surfaces and replace
a - Check Point if necessary. Also, check drive belt tension and
adjust if necessary, as outlined under “Drive Belt
Typical Tension Adjustment.”

b. After obtaining correct tension, securely re-

tighten alternator brace attaching bolts and
alternator mounting bolts.
2. If a new drive belt has been installed, recheck belt
tension after running for five minutes.
Circuitry Test
Perform the following tests, using a 0-20 volt DC volt-
meter, to check that all of the circuits between the al-
ternator and the other components within the alterna-
tor system are in good condition.

OUTPUT CIRCUIT
1. Connect positive (+) voltmeter lead to alternator
output terminal and negative (–) lead to a ground
terminal on alternator.

Index
4C-6 - CHARGING SYSTEM 90-806934 1194
2. Wiggle engine wiring harness while observing
voltmeter. Meter should indicate approximate
battery voltage and should not vary. If no reading
is obtained, or if reading varies, check alternator
output circuit for loose or dirty connections or
damaged wiring.
5. If reading is between 6.0 and 7.0 volts, rotor field
circuit probably is open. Remove regulator and in-
spect for worn brushes or dirty slip rings. Replace
brushes if less than 1/4 in. (6 mm) long. If brushes
and slip rings are in good condition, disassemble
and perform rotor test as outlined under “Compo-
nent Testing - Rotor” following.

TEST 1 TEST 2
d
d

e
e
b
c c

b 72784 a 72785
a - Output Wire - ORANGE a - Excitation Wire - PURPLE
b - Excitation Wire - PURPLE b - Sensing Wire - RED/PURPLE
c - Sensing Wire - RED/PURPLE c - Tie Strap/Terminal
d - Voltmeter (0-20 Volts) d - Voltmeter (0-20 Volts)
e - Ground e - Ground

EXCITATION CIRCUIT
SENSING CIRCUIT
1. Connect positive (+) voltmeter lead to tie strap/
terminal on alternator and negative (–) lead to a 1. Unplug red/purple lead from voltage regulator.
ground terminal on alternator (Test 1).
2. Connect positive (+) voltmeter lead to RED/PUR-
2. Turn ignition switch to “RUN” position and note PLE lead and negative (–) voltmeter lead to
voltmeter reading. Reading should be 1.3 to 2.5 ground terminal.
volts.
3. If no reading is obtained, an opening exists in al-
ternator excitation lead or in excitation circuit of
regulator. Unplug PURPLE lead from regulator.
Connect positive voltmeter lead to purple lead
and negative voltmeter leads to ground (Test 2).
If voltmeter now indicates approximate battery
voltage, voltage regulator is defective and must
be replaced. If no voltage is indicated, check ex-
citation circuit for loose or dirty connections or
damaged wiring.
4. If reading is between .75 and 1.1 volts, rotor field
circuit probably is shorted or grounded. Disas-
semble alternator and test rotor as outlined under
“Alternator Repair,” following.

Index
90-806934 1194 CHARGING SYSTEM - 4C-7
3. Voltmeter should indicate battery voltage. If bat-
tery voltage is not present, check sensing circuit
(RED/PURPLE lead) for loose or dirty connection
or damaged wiring.
d ing, to determine if fault is in regulator or alterna-
a perform “Voltage Output Test,” following, to deter-
e
c
b
72786
a - Output Wire - ORANGE
b - Excitation Wire - PURPLE
c - Sensing Wire - RED/PURPLE
d - Voltmeter (0-20 Volts)
e - Ground
Current Output Test
Perform this test to check if alternator is capable of
producing rated current output, using a 0-80 amp DC
ammeter.
! WARNING
Be sure that engine compartment is well-venti-
lated and that there are no gasoline vapors pres-
ent (during the test) to prevent the possibility of
an explosion and/or a fire, should a spark occur.
1. Disconnect negative (–) battery cable from bat-
tery.
2. Disconnect ORANGE lead from alternator output
terminal and connect ammeter in series between
lead and output terminal. Connect positive (+)
side of ammeter toward output terminal.
3. Reconnect negative battery cable.
4. Turn on all accessories and turn ignition switch to
“RUN” position, and allow glow plug system to op-
erate through one cycle. Turn switch to “OFF”
position. Turn off accessories.
5. Start engine and adjust engine speed to
1500-2000 RPM. Quickly observe ammeter.
Reading should be at least 30 amps.
Index
4C-8 - CHARGING SYSTEM
6. If reading is low, stop engine and connect a jump-
er wire between alternator output terminal and
regulator terminal. Repeat Steps 4 and 5.
7. If reading is now within specifications, diodes are
faulty. Disassemble alternator and replace rectifi-
er as explained under “Alternator Repair,” follow-
tor.
8. If reading is still low with jumper wire connected,
mine if fault is in regulator or alternator.
b
e
d c
72787
a - Output Wire - ORANGE
b - Ammeter (0-80 Amps)
c - Jumper Lead
d - Regulator Terminal
e - Ground
Voltage Output Test
Perform this test to determine if voltage regulator is
operating correctly, using a 0-20 volt DC voltmeter.
IMPORTANT: Battery MUST BE fully charged
(1.260 or above specific gravity) to obtain proper
voltage reading in this test. If necessary, charge
battery with a battery charger or allow engine to
run a sufficient length of time to fully charge bat-
tery before taking reading.
1. Connect positive (+) voltmeter lead to positive
battery terminal and negative (–) voltmeter lead to
negative terminal.
2. Start engine and run at fast idle until engine
reaches normal operating temperature. Adjust
engine speed to 1500-2000 RPM and observe
voltmeter for highest reading. Reading should be
between 13.9 and 14.7 volts.
90-806934 1194
3. If reading is high, check for a loose or dirty regula-
tor ground lead connection. If connection is good
(and sensing circuit checked out good in “Circuit-
ry Test”), voltage regulator is faulty and must be
replaced. Be sure to disconnect battery cables
before attempting to remove regulator.
5. If a voltmeter reading of 14.5 volts or above is now
obtained, voltage regulator is faulty and must be
replaced. If voltmeter reading is below 14.5 volts,
inspect brushes and slip rings for wear, dirt or
damage. If brushes and slip rings are good, alter-
nator is faulty internally. Disassemble alternator
and test components, as outlined under “Alterna-
tor Repair,” following.

a
d
e
c

b c
72788 72971

a - Output Wire - ORANGE a - Ground

b - Excitation Wire - PURPLE b - Brush/Regulator Assembly
c - Sensing Wire - RED/PURPLE c - Brush Terminal
d - Voltmeter (0-20 Volts) d - Jumper Wire (Solder Connection to Ground)
e - Ground

! WARNING
Be sure that engine compartment is well-venti-
Alternator Repair
lated and that there are no gasoline vapors pres-
ent (during the next steps) to prevent the possi-
Removal
bility of an explosion and/or fire, should a spark
occur. 1. Disconnect negative (–) battery cable from bat-
tery.
! CAUTION
2. Disconnect wiring harness from alternator.
DO NOT allow tie jumper wire to contact alterna-
3. Loosen alternator support bracket screw.
tor end frame (in next step), as rectifier and diode
assembly may be damaged. 4. Loosen alternator brace-to-alternator and alter-
nator brace-to-engine attaching screws. Loosen
4. Remove four nuts holding excitation and sensing
alternator mounting bolt, then pivot alternator in-
wires and Phillips screw. Remove regulator cover
ward and remove alternator drive belt.
and install wires and nuts for testing. Connect a
jumper wire from the ground stud to the brush ter- 5. Remove alternator brace-to-alternator attaching
minal on the lower right- hand side of the brush bolt and washer.
assembly. Restart engine and gradually increase 6. Remove alternator mounting bolt, washers, and
engine speed to 1500 RPM while observing volt- nut. Remove alternator.
meter. DO NOT allow voltage to exceed 16 volts.

Index
90-806934 1194 CHARGING SYSTEM - 4C-9
Exploded View

19
20
22
21

25
24

27 26
3 1
28 6 2 4
29
23 2

3 5
8
10
9
12 2
10 13 2

16 1
15 3 13
17
2
14
18
7
10

11

72276
1 - Screw (3) 15- Rectifier Assembly
2 - Nut (9) 16- Flat Washer
3 - Flat Washer (4) 17- Screw
4 - Sensing Wire (RED/PURPLE) 18- Stator
5 - Excitation Wire (PURPLE) 19- Rotor and Slip Rings
6 - Cover 20- Retaining Plate
7 - Tie Strap 21- Front Bearing
8 - Rubber Gasket 22- End Frame (Front)
9 - Condenser 23- Screw (3)
10- Insulator (3) 24- Fan Spacer
11- Bolt (4) 25- Fan
12- End Frame (Rear) 26- Pulley Spacer
13- Cap (2) 27- Pulley
14- Brush/Regulator Assembly 28- Lockwasher
29- Nut
Mando 65 Amp Alternator

Index
4C-10 - CHARGING SYSTEM 90-806934 1194
Disassembly 4. Remove two brush/regulator attaching screws
and remove brush/regulator assembly.
IMPORTANT: The following instructions are for
complete disassembly and overhaul of the alter-
nator. In many cases, however, complete disas-
sembly of alternator is not required and, in those
cases, it is necessary only to perform the opera-
tions required to repair or replace the faulty part.
1. Mount alternator in a vise so that rear end frame
is facing you.
2. Disconnect regulator leads from terminals on rear b
end frame. Remove four nuts, Phillips head screw
and two regulator leads. Then pull regulator cover c
away from rear end frame.
d
a
72823
a - Screws
b - Brush/Regulator Assembly
c - Stud Cover Insulator
d - Tie Strap
d
c b
5. Scribe a mark on rear end frame, stator and front
end frame to ensure proper reassembly later.
6. Remove four screws which secure end frames
a and stator together.
72963 IMPORTANT: DO NOT insert screwdriver blades
a - Regulator Leads
b - Nuts (4) more than 1/16 in. (1.5 mm) into openings (in next
c - Phillips Head Screw step), as stator windings may be damaged.
d - Regulator Cover

3. Remove stud cover insulator, two nuts and tie

strap from brush/regulator assembly.

Index
90-806934 1194 CHARGING SYSTEM - 4C-11
7. Separate rear end frame and stator assembly 9. Turn end frame over (stator upward) and remove
from front end frame and rotor assembly using one Phillips head screw which secures rectifiers
two thin blade screwdrivers (positioned 180 de- to end frame.
grees apart from one another) at the locations
shown. Use the two slots shown to initially sepa-
rate units.

a
b

c
e
a a
b
d

72826

a - Rectifier Assembly
72824 b - Phillips Head Screw
a - DO NOT Insert Screwdriver Blades More than
1/16 In. (1.5 mm) into Slots 10. Separate stator and rectifier assembly from rear
b - Rear End Frame
c - Stator end frame using screwdriver slots.
d - Front End Frame 11. Unsolder the three stator leads from the rectifier
e - Scribe Marks
heat sink. Place a needle nose pliers on diode ter-
minal between solder joint and diode body to help
prevent heat damage to diodes. Unsolder joints
as quickly as possible and allow diode terminal to
cool before removing pliers.

72825

8. Place rear end frame and stator assembly on the

bench with stator downward. Be sure that bench
is clean and free of metal chips. Remove nuts, b
washers, insulators and condenser from output
72827
and ground studs.
a - Heat Sink
b - Stator Leads (3)

Index
4C-12 - CHARGING SYSTEM 90-806934 1194
IMPORTANT: With alternator disassembled to 13. Remove the three Phillips head screws and lock-
this point, stator, rectifier, diodes, and rotor may washers which secure the front bearing retaining
be tested, as explained under “Component Test- plate.
ing,” following.

IMPORTANT: DO NOT clamp vise on rotor pole

pieces when removing pulley nut (in next step), a
as pole pieces may be distorted.

12. Remove pulley retaining nut by clamping pulley in

a vise (using an oversize V-belt or protective jaws
to protect pulley) and turning nut counterclock-
wise with a 7/8 in. wrench. Remove lockwasher
and slide pulley and fan from shaft. If pulley is diffi-
cult to remove, it may be necessary to use a uni-
versal puller. b

72829

a - Phillips Head Screws and Lockwashers

b - Front Bearing Retaining Plate

b
14. Remove front bearing from front end frame using
a an arbor press and a suitable size mandrel. (Dis-
card bearing.)

72828
a - 7/8 In. Wrench
b - Over-Sized V-Belt to Protect Pulley

72830

Removing Front Bearing from Front End Frame

15. If rotor slip rings or rear bearing requires replace-

ment, entire rotor must be replaced. Parts cannot
be purchased separately.

Index
90-806934 1194 CHARGING SYSTEM - 4C-13
Cleaning and Inspection Component Testing
1. Clean all parts with a clean, soft cloth. DO NOT
use solvent, or electrical components may be ROTOR
damaged. 1. Test rotor field circuit for opens, shorts or high re-
2. Inspect the following parts for wear and damage: sistance (Test 1), using an ohmmeter (set on R x1
scale), as follows:
a. Brush/regulator assembly - inspect for
cracked casing, damaged brush leads, poor TEST 1 TEST 2
brush lead solder connections, weak or bro-
ken brush springs or worn brushes. Replace
brush set if brushes are less than 1/4 in. (6
mm) long.
b. Rotor - inspect for stripped threads, scuffed
pole piece fingers or damaged bearing sur-
faces (because of bearing turning on shaft).
c. Rotor-slip rings - clean slip rings with 400
grain (or finer) polishing cloth while spinning
rotor in a lathe. Blow off dust with compressed
air. Inspect slip rings for grooves, pits, flat
spots or out-of-round [.002 in. (0.051 mm)
maximum] and replace rotor, if present. 72831
d. Rotor shaft and front end bearings - in- Testing Rotor Field Circuit
spect for damaged seals, lack of lubrication,
discoloration (from overheating) and exces-
sive side or end play. Bearing should turn a. Connect one ohmmeter lead to each slip ring.
freely without binding or evidence of rough b. Ohmmeter reading should be 4.2 to 5.5 ohms
spots. with rotor at room temperature 70-80°F
e. Stator - inspect for damaged insulation or (21-26°C).
wires; also inspect insulating enamel for heat c. If reading is high or infinite (no meter move-
discoloration, as this is usually a sign of a ment), high resistance or an open exists in the
shorted or grounded winding or a shorted field circuit. Check for poor connections be-
diode. tween field winding leads and slip ring termi-
f. Front and rear end frames - inspect for nals. If cause for open or high resistance can-
cracks, distortion, stripped threads or wear in not be found, connect ohmmeter directly to
bearing bore (from bearing outer race spin- slip ring terminals. If correct reading is now
ning in bore). End frame(s) MUST BE re- obtained, or if reading is still high or infinite, re-
placed, if bearing has spun. Also, inspect place complete rotor assembly.
bearing retainer recess in front end frame for
damage.
g. Fan - inspect for cracked or bent fins, broken
welds (bi-rotational fan only) or worn mount-
ing hole (from fan spinning on shaft).
h. Pulley - inspect pulley mounting bore end for
wear. Inspect drive surface of pulley sheaves
for trueness, excessive wear, grooves, pits,
nicks and corrosion. Repair damaged sur-
faces, if possible, with a fine file and a wire
brush or replace pulley, if beyond repair. Drive
surfaces MUST BE perfectly true and smooth
or drive belt wear will be greatly accelerated.

Index
4C-14 - CHARGING SYSTEM 90-806934 1194
 d. If reading is low, a short exists in the field cir-
cuit. Inspect slip rings to be sure that they are
not bent and touching outer slip ring. Also, be
sure that excess solder is not shorting termi-
nals to aft slip ring. If cause for short cannot
be found, unsolder field winding leads from
slip ring terminals and connect ohmmeter di-
rectly to leads. If correct reading is now ob-
tained, or if reading is still low, slip rings and
rotor field windings are shorted, and complete
rotor assembly must be replaced.
d b. Continuity should be present in all three cases
b
a. Connect one lead of ohmmeter to one of the
stator leads and the other lead to stator frame.
Be sure that lead makes good contact with
frame.
b. Meter should indicate no continuity (meter
should not move). If continuity does exist, sta-
tor is grounded and must be replaced.
2. Test for opens in stator (Test 2), using an ohmme-
ter (set on R x1 scale) as follows:
a. Connect ohmmeter between each pair of sta-
tor windings (three different ways).
(meter should move). If it does not, one or
more of the windings are open and stator
must be replaced.

TEST 1 TEST 2 TEST 2 TEST 2

c

a
73112
a - Field Winding Leads
b - Slip Rings
c - Rotor Shaft
d - Pole Pieces

2. Test rotor field circuit for grounds (Test 2), using

an ohmmeter (set on R x1 scale) as follows:
a. Connect one lead of ohmmeter to either slip
ring and the other lead to rotor shaft or pole
pieces.
b. Meter should indicate no continuity (meter
should not move).
c. If continuity does exist, complete rotor assem-
bly must be replaced.
IMPORTANT: If alternator has output at low
speeds, but no output at high speeds, rotor field
winding may be shorting or grounding out, due to
centrifugal force. Replace rotor if all other electri-
cal components test good.
72833
Testing Stator
3. A short in the stator is difficult to detect without
special equipment, because of the low windings
resistance. If all other electrical components test
out good, and alternator fails to produce rated
output, stator probably is shorted and should be
replaced. Also, examine stator for heat discolor-
ation, as this usually is a sure sign of a short.

STATOR
IMPORTANT: Stator leads MUST BE discon-
nected from rectifier for this test.
1. Test stator for grounds (Test 1), using an ohmme-
ter (set on R x1 scale) as follows:

Index
90-806934 1194 CHARGING SYSTEM - 4C-15
RECTIFIER AND DIODE ASSEMBLY ! CAUTION
NOTE: Failure of any component in tests following
DO NOT use a test instrument with more than a 12
will require replacement of entire rectifier assembly.
volt source (in the following test), as rectifier may
be damaged.
Negative (–) Rectifier
1. Connect one lead of an ohmmeter (set on R x1
IMPORTANT: Rectifier MUST BE disconnected scale) to 1/4 in. stud on positive (+) rectifier heat
from stator for this test. sink and the other lead to one of the rectifier termi-
nals. Note the meter reading.
! CAUTION
2. Reverse leads and again note reading.
DO NOT use a test instrument with more than a 12
3. Meter should indicate a high or infinite resistance
volt source (in the following test), as rectifier may
(no meter movement) when connected one way
be damaged.
and a low reading when connected the other. If
1. Connect one lead of an ohmmeter (set on R x1 both readings are high or infinite, rectifier is open.
scale) to negative (–) rectifier heat sink and the If both readings are low, rectifier is shorted.
other lead to one of the rectifier terminals. Note
4. Repeat Steps 1 through 3 for two other rectifiers
the reading.
in heat sink.
2. Reverse leads and again note reading.
3. Meter should indicate a high or infinite resistance
(no meter movement) when connected one way
and a low reading when connected the other. If
both readings are high or infinite, rectifier is open.
If both readings are low, rectifier is shorted.
b
4. Repeat Steps 1 through 3 for two other rectifiers
in heat sink.
5. Replace assembly if any of the rectifiers is
shorted or open. c

b a 72834

a - Stud
b - Rectifier Terminal
c - Repeat Test between These Terminals and Stud
c
5. Replace assembly if any one of the rectifiers is
shorted or open.

a
72147

a - Heat Sink
b - Rectifier Terminal
c - Test These Two Rectifiers in Same Manner

Positive (+) Rectifier and Diodes

Index
4C-16 - CHARGING SYSTEM 90-806934 1194
6. Connect one lead of an ohmmeter (set on R x1)
to the common side of the diode and the other
lead to the other side, of one of the three diodes.
Reassembly
1. Install new front bearing into front end frame bear-
ing bore using an arbor press. If necessary, use
a bearing driver that contacts outer race only.

b
a

72835

72148 Installing Front Bearing into Front End Frame

a - Common Side of Diode Circuit Board 2. Install front bearing retaining plate using three
b - Repeat Test for These Two Diodes Phillips head screws and lockwashers.

7. Reverse leads and again note reading.

8. Meter should indicate a high or infinite resistance a
(no meter movement) when connected one way
and a low reading when connected the other. If
both readings are high or infinite, diode is open.
If both readings are low, diode is shorted.
9. Repeat Steps 6 through 8 for the other two
diodes.
10. Replace rectifier assembly if any one of the
diodes is shorted or open.
b
CONDENSER 72829
1. Using magneto analyzer and accompanying a - Phillips Head Screws and Lockwashers
instructions, perform the following condenser b - Front Bearing Retaining Plate
tests:
a. Condenser Capacity Test (must be .5 mfd).
3. Slide front end frame over rotor.
b. Condenser Short or Leakage Test.
IMPORTANT: DO NOT clamp vise on rotor pole
c. Condenser Series Resistance Test.
pieces when tightening pulley nut (in next step),
2. Replace condenser if test results are not within or pole pieces may be distorted.
specifications.
4. Slide fan spacer onto rotor shaft. Install fan,
pulley, lockwasher and nut on shaft. Clamp pulley
in a vise, using protective jaws or an old oversize
V-belt to protect pulley, and torque nut to specifi-
cations. Tighten vise only enough to allow tighten-
ing of nut, as excessive tightening may distort
pulley.

Index
90-806934 1194 CHARGING SYSTEM - 4C-17
5. Assemble stator to rectifier by soldering the three
leads to the three rectifier terminals.
8. Position rear end frame and stator assembly over
front end frame and rotor assembly and align
scribe marks on each (scribed during disassem-
bly). Hand-press end frames together, then install
four screws. Tighten screws securely.

a e

d
72826

a - Stator Lead Connections

c
NOTE: Be sure to connect leads to their original posi-
b 72561
tions.
6. Install assembled stator and rectifier assembly a - Rear End Frame
into rear end frame, aligning scribe marks on b - Stator
each (scribed during disassembly), and install c - Front End Frame
d - Scribe Marks
Phillips head screw and washer to retain. e - Insert Screws (4) (Two Hidden)
IMPORTANT: The insulating washers MUST BE
installed as shown or damage to the alternator
will result. 9. Depress brushes flush with top of brush holder
and insert a #54 drill bit or smaller (.050 in.) into
7. Position stator down with rear end frame up and hole in brush holder to hold brushes compressed
reinstall insulators, nuts and condenser. during reassembly.

b c
b

72561

a - Insulators (3)
b - Nuts (5) - ONE REMOVED a
c - Condenser

72836
a - Drill Bit
NOTE: Rubber gasket shown removed for clarity.

Index
4C-18 - CHARGING SYSTEM 90-806934 1194
10. Install brush/regulator assembly in rear end 12. Install cover with one Phillips head screw and two
frame cavity and secure with two mounting nuts. Install two leads with nuts.
screws, as shown. Tighten screws securely. Re-
move drill bit to release brushes against slip rings.

a
a
b

c
72963
a - Phillips Head Screw
72837
b - Nuts (4)
c - Leads
a - Brush/Regulator Assembly
b - Mounting Screws
13. Install insulator caps.
11. Install tie strap to rectifier stud and stud on brush/
rectifier assembly. Tighten nuts securely.

b
72078
a - Insulator Caps

a
72823

a - Studs
b - Tie Strap

Index
90-806934 1194 CHARGING SYSTEM - 4C-19
Installation 6. Connect negative battery cable to battery.

IMPORTANT: If the mounting bracket has been re-

moved, refer to the diagram at the bottom of this
page. Be certain that the mounting spacer and
proper length brace spacer are in position for the d
appropriate engines as indicated.
1. Install alternator in mounting bracket. DO NOT
tighten fastener at this time. c

2. Fasten alternator brace to alternator. DO NOT b

tighten screw at this time.
3. Position alternator drive belt on pulleys and adjust e
a
tension as explained under “Drive Belt Tension
Adjustment.” 72838
a - Excitation Lead - PURPLE
4. Torque fasteners to specifications. Securely b - Sensing Lead - RED/PURPLE
tighten all other fasteners. c - Ground Lead - BLACK
d - Output Lead - ORANGE
5. Reconnect wiring harness to alternator. Coat ter- e - Charge Indicator Lamp (System Monitor Panel) - BROWN
minals with Quicksilver Liquid Neoprene. f - Alternator Driven Tachometer Lead - GRAY (Not Shown)
Used Only When Required
1 - Key
2 - Alternator
3 - Mounting Spacer(s) 8
4 -
5 -
Mounting Bracket
Mounting Stud, Lockwasher and Nut
b 10
6 - Mounting Screw With Lockwasher
7 - Alternator Mounting Bolt With Hardware a 11
8 - Alternator Brace
9 - Alternator Brace Spacer
10- Brace Bolt, Washers and Nut
11- Tensioning Screw, Lockwasher and Flat Washers 1
12- Pulley, Lockwasher and Nut 9 A
13- Alternator V-Belt

3
4
c 5

c 6
7 a
12
Lubricant/Sealant Application Points
A Quicksilver Liquid Neoprene - 92-25711
Torque Specifications
a 192 lb. in. (28 N·m) 13
b 30 lb. ft. (41 N·m)
c 35 lb. ft. (48 N·m) 74467

Index
4C-20 - CHARGING SYSTEM 90-806934 1194
Prestolite 65 Amp Alternator Torque Specifications
Lb. Ft. Lb. In.
Fastener Location (N•m) (N•m)
Replacement Parts Warning
Housing Screws 50-60
(5.6-6.7)
! WARNING
Pulley Nut 35-50
Electrical, ignition and fuel system components (48-68)
on your MerCruiser are designed and manufac-
Front Bearing Screws 25-35
tured to comply with U.S. Coast Guard Rules and (2.8-3.9)
Regulations to minimize risks of fire and explo-
sion. Alternator to Mounting Bracket 35
(48)
Use of replacement electrical, ignition or fuel sys-
tem components, which do not comply with these Adjustment Brace to Alternator 192
rules and regulations, could result in a fire or ex- (28)
plosion hazard and should be avoided.
Alternator Brace to Block 30
(41)

Specifications Alternator Mounting Bracket 30

(41)
Description Specification
Alternator Support Bracket Tighten Securely
Excitation Circuit 1.5 to 3.0 Volts
V-Belt Tension (Note) Depress 3/16 In.
Current Output 60 Amp. Min. (5 mm)

Voltage Output 13.8 to 14.8 Volts NOTE: Depress belt with thumb at midway point
between circulating pump pulley and alternator.
Condenser Capacity .5 MFD

Minimum Brush Length 3/16 in. (5 mm)

Description
The alternator has a rotor, which is supported in two
end frames by ball bearings, and is driven by a pulley
Tools/Sealants at approximately twice engine speed. The rotor con-
Part Number Description tains a field winding that is enclosed between two
multiple-finger pole pieces. The ends of the field
91-76032 Magneto Analyzer
winding are connected to two brushes (mounted in
91-37241 Universal Puller Plate the rear end frame) which make continuous sliding (or
slipping) contact with the slip rings. The current (flow-
91-99750 Multi-Meter/DVA Tester ing through the field winding) creates a magnetic field
that causes the adjacent fingers of the pole pieces to
92-25711--2 Quicksilver Liquid Neoprene become alternate north and south magnetic poles.
Obtain A 3-phase stator is mounted directly over the rotor
Locally Ammeter (0-50 Amps) pole pieces and between two end frames. It consists
of three windings wound 120 degrees electrically out-
of-phase on the inside of a laminated core. The wind-
ings are all connected together on one end, while the
other ends are connected to a full-wave rectifier
bridge.
The rectifier bridge contains six rectifiers which are
arranged so that current flows from ground, through
the stator and to the output terminal, but not in the op-
posite direction.
Index
90-806934 1194 CHARGING SYSTEM - 4C-21
When current is supplied to the rotor field winding, 4. NEVER disconnect regulator lead from alternator
and the rotor is turned, the movement of the magnetic regulator terminal when the alternator is being
fields created induces an alternating current into the driven by the engine.
stator windings. The rectifier bridge then changes this
5. ALWAYS remove negative (–) battery cable from
alternating current to direct current which appears at
battery before working on alternator system.
the output terminal. A diode trio also is connected to
the stator windings to supply current to the regulator 6. When installing battery, BE SURE to connect the
and the rotor field during operation. positive (+) battery cable to the positive (+) bat-
tery terminal and the negative (–) (grounded) bat-
Voltage output of the alternator is controlled by regu-
tery cable to negative (–) battery terminal.
lating the current supplied to the rotor field. This is ac-
complished by a transistorized voltage regulator that 7. If a charger or booster battery is to be used, BE
senses the voltage at the battery and regulates the SURE to connect it in parallel with existing battery
field current to maintain alternator voltage within pre- (positive to positive; negative to negative).
scribed limits for properly charging the battery. Cur-
rent output of the alternator does not require regula-
tion, as maximum current output is self-limited by the
design of the alternator. As long as the voltage is reg-
System Components
ulated within the prescribed limits, the alternator can- The alternator system consists of the alternator, bat-
not produce excessive current. A cut-out relay in the tery, the ignition switch and the wiring which connects
voltage regulator also is not required, as the rectifier these components.
diodes (which allow current to flow in one direction
only) prevent the battery from discharging back
through the stator. Battery
Meter
Due to the lack of residual magnetism in the rotor pole Ignition
pieces, a small amount of current must be supplied to Switch
the rotor field to initially start the alternator charging. Harness
This is accomplished by means of an excitation circuit Plug
in the regulator which is connected to the ignition
switch. Once the alternator begins to produce output,
field current is supplied solely by the diode trio, as ex-
plained, preceding. Alternator
The alternator also is equipped with a fan (mounted
on the rotor shaft) which induces air flow through the
alternator to remove the heat created by the rectifiers
and stator. A capacitor protects the rectifier system
from high voltages and suppresses radio noise.
Circuit
Breaker
Precautions Starter
Motor
The following precautions MUST BE observed when
working on the alternator system. Failure to observe
these precautions may result in serious damage to
the alternator or alternator system.
Ground
1. DO NOT attempt to polarize the alternator. Stud
2. DO NOT short across or ground any of the termi-
nals on the alternator, except as specifically
instructed in the “Troubleshooting Tests.” Battery
3. NEVER disconnect the alternator output lead or
73079
battery cables when the alternator is being driven
by the engine.

Index
4C-22 - CHARGING SYSTEM 90-806934 1194
Alternator Circuits -Typical

STARTER

8 GA. MIN.

AUXILIARY
BATTERY

MAIN
BATTERY

74147

Index
90-806934 1194 CHARGING SYSTEM - 4C-23
Battery Isolators
Dual Battery Charging Systems
Using a Battery Isolator
Battery isolators allow the addition of an auxiliary (se-
cond) battery to the MerCruiser electrical system.
The auxiliary battery is primarily used as a power
source for various accessories installed on the boat.
The battery isolator will allow the alternator to charge
both the cranking and auxiliary batteries at the same
time while preventing accessories, connected to the
auxiliary battery, from drawing power from the crank-
ing battery.
Mercury Marine does not manufacture any battery
isolator systems. Battery isolators must be bought
from an outside manufacturer. Mercury Marine sug-
gests following the manufacturer’s instructions care-
fully.
IMPORTANT: Alternators used on MerCruiser en-
gines ARE NOT equipped with an isolation diode.
! CAUTION
Follow battery isolator manufacturer’s instruc-
tions for wire gauge. Battery isolator installation
must conform to BIA Low Voltage Wiring Stan-
dard No. 125-79.
NOTE: MerCruiser engines equipped with a 3-wire,
belt driven alternator, can use a battery isolator.
Periodic Maintenance
The following maintenance check should be per-
formed every 50 hours or 60 days (whichever comes
first) in fresh water areas or every 25 hours or 30 days
in salt water areas.
! CAUTION
Remove all battery cables from battery (before
conducting the following check) to prevent acci-
dentally shorting out electrical system.
1. Inspect entire alternator system for corroded or
loose connectors.
2. Check wiring for frayed or worn insulation.
3. Check alternator drive belt for excessive wear,
cracks, fraying and glazed surfaces. Also, check
drive belt tension and adjust, if necessary, as ex-
plained under “Drive Belt Tension Adjustment.”
4. Check alternator mounting bolts for adequate
tightness.
5. Inspect slip ring end frame flame arrestor screen
for debris and clean, if necessary, using com-
pressed air or a cloth. Screen MUST BE clean, or
alternator may overheat.

WIRING COLOR CODE ABBREVIATIONS

BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
73078
ORN = ORANGE
PNK = PINK
PUR or PPL = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LIT or LT = LIGHT
DRK = DARK

Index
4C-24 - CHARGING SYSTEM 90-806934 1194
Drive Belt Tension
Adjustment
Alternator
1. Install drive belt on pulleys and adjust tension as
follows:
a. Pivot alternator away from engine, as re-
quired, until correct tension is obtained as
shown. Belt should depress 1/2 in. (13 mm).
a not been caused by running engine at too low a
Troubleshooting Tests
(Alternator on Engine)
Use the following tests in conjunction with the “Trou-
bleshooting” in Section 1. Before proceeding with the
tests, however, perform the following checks to elimi-
nate possible problem areas. Also observe “Precau-
tions,” preceding, to prevent damage to alternator
system.
1. If problem is an undercharged battery, check to
ensure that undercharged condition has not been
caused by excessive accessory current draw or
by accessories which have accidentally been left
on. Also, check that undercharged condition has
speed for extended periods of time.
2. Check physical condition and state of charge of
battery, as outlined in “Battery - Storage” in Sec-
tion 4A. Battery MUST BE at least 75% (1.230
specific gravity) of fully charged to obtain valid re-
sults in the following tests. If not, charge battery
before testing system.
3. Inspect entire alternator system wiring for de-
fects. Check all connections for tightness and
cleanliness, particularly battery cable clamps and
battery terminals.

72669
a - Check Point
Typical
b. After obtaining correct tension, securely re-
tighten alternator brace attaching bolts and
alternator mounting bolts.
2. If a new drive belt has been installed, recheck belt
tension after running for five minutes.
4. Check alternator drive belt for excessive wear,
cracks, fraying and glazed surfaces and replace
if necessary. Also, check drive belt tension and
adjust if necessary, as outlined under “Drive Belt
Tension Adjustment.”
Circuitry Test
Perform the following tests, using a 0-20 volt DC volt-
meter, to check that all of the circuits between the al-
ternator and the other components within the alterna-
tor system are in good condition.
! WARNING
Be sure that engine compartment is well-venti-
lated and that there are no gasoline vapors pres-
ent (during the test) to prevent the possibility of
an explosion and/or a fire, should a spark occur.

ALTERNATOR OUTPUT TEST

1. Connect positive (+) voltmeter lead to alternator
output terminal (ORANGE wire) and negative (–)
lead to a ground terminal on alternator. With en-
gine running about 1500 RPM and all accessories
turned on, voltage should be between 13.8-14.8.
Index
90-806934 1194 CHARGING SYSTEM - 4C-25
2. If voltage output does not fall within specifica- OPEN DIODE-TRIO TEST
tions, alternator should be tested for probable
1. With ignition on and engine not running, check for
cause and disassembled for repair.
battery voltage at alternator output terminal (Test
1) and 1.5 to 3.0 volts at regulator terminal (Test
b 2).

c
a d
e
a
b c
73081
a - Output Wire - ORANGE d
b - Excitation Wire - PURPLE
73083
c - Sensing Wire - RED/PURPLE
d - Voltmeter (0-20 Volts)
e - Ground a - Regulator Terminal
b - Output Terminal
c - Ground
HARNESS VOLTAGE TEST d - Voltmeter (0-20 Volts)

With ignition off, unplug RED/PURPLE wire and
check for battery voltage at harness wire. No voltage
at harness wire indicates wiring harness is “open” and
should be repaired or replaced.
a
2. Connect a jumper wire between regulator and
output terminal. Start engine and run at idle. If
charging voltage (13.8-14.8 volts) is present at
output terminal, the diode-trio is probably defec-
tive and alternator should be removed for repair.

d
d
c e
b
c
73082
73084
a - Excitation Wire - Purple
b - Sensing Wire - Red/Purple a - Regulator Terminal
c - Voltmeter (0-20 Volts) b - Output Terminal
d - Ground c - Jumper Lead
d - Ground
e - Voltmeter (0-20 Volts)

Index
4C-26 - CHARGING SYSTEM 90-806934 1194
CURRENT OUTPUT TEST 7. If reading is now within specifications, diodes are
faulty. Disassemble alternator and replace recti-
Perform this test to check if alternator is capable of
fier as explained under “Alternator Repair,”
producing rated current output, using a 0-50 amp DC
following, to determine if fault is in regulator or
ammeter.
alternator.
! WARNING 8. If reading is still low with jumper wire connected,
perform “Voltage Output Test,” following, to deter-
Be sure that engine compartment is well-venti-
mine if fault is in regulator or alternator.
lated and that there are no gasoline vapors pres-
ent (during the test) to prevent the possibility of
an explosion and/or a fire, should a spark occur.
1. Disconnect negative (–) battery cable from bat-
tery. d
2. Disconnect ORANGE lead from alternator output
terminal and connect ammeter in series between c
lead and output terminal. Connect positive (+)
side of ammeter toward output terminal.
3. Reconnect negative battery cable. b
4. Turn on all accessories. Turn ignition switch to e
“RUN” position, and allow glow plug system to op-
erate through one cycle. Turn switch to “OFF” a
73109
position. Turn off accessories.
a - Output Wire - ORANGE
5. Start engine and adjust engine speed to b - Ammeter (0-80 Amps)
1500-2000 RPM. Quickly observe ammeter. c - Jumper Lead
Reading should be at least 30 amps. d - Regulator Terminal
e - Ground
6. If reading is low, stop engine and connect a jump-
er wire between alternator output terminal and
regulator terminal. Repeat Steps 4 and 5.

Index
90-806934 1194 CHARGING SYSTEM - 4C-27
OPEN REGULATOR TEST

IMPORTANT: This test requires removal of regu- a

lator.
d
! CAUTION
To prevent electrical system damage and/or b
sparks, disconnect battery cables at battery.
c
1. Remove insulator cap from regulator terminal.
73086
2. With ignition switch in the “RUN” position and en-
a - Field Terminal (Green Wire)
gine not running, check for battery voltage at al- b - Regulator Terminal
ternator output terminal (Test 1) and regulator ter- c - Ground
minal (Test 2). d - Voltmeter (0-20 Volts)

NOTE: Felt gasket is shown removed for visual clar-

ity.

Alternator Repair
! WARNING

a Be sure that engine compartment is well-venti-

lated and that there are no gasoline vapors pres-
b c ent to prevent the possibility of an explosion and/
d or a fire, should a spark occur.
73083

a - Regulator Terminal Removal

b - Output Terminal
c - Ground
d - Voltmeter (0-20 Volts)
3. Remove the four screws which secure the regula-
tor to the alternator.
4. Connect a jumper wire between field terminal
(green wire) and ground/ If 1.5 to 3.0 volts are
present at regulator terminal, regulator is defec-
tive. If voltage is not present at regulator terminal,
there is an open field circuit (brushes slip rings,
etc.). Remove alternator for repair.
! CAUTION
To prevent electrical system damage and/or
sparks, disconnect battery cables at battery.
1. Disconnect battery cables from battery.
2. Disconnect wiring harness from alternator.
3. Loosen alternator support bracket screw.
4. Loosen alternator brace-to-alternator and alter-
nator brace-to-engine attaching screws. Loosen
alternator mounting bolt, then pivot alternator in-
ward and remove alternator drive belt.
5. Remove alternator brace-to-alternator attaching
bolt and washer.
6. Remove alternator mounting bolt, washers, and
nut. Remove alternator.

Index
4C-28 - CHARGING SYSTEM 90-806934 1194
Exploded View

25

26
28 27

31 29
30

32
33
1
34 RED
PURPLE 2
BLACK
GREEN
13 10
4
5
12 11

14 5
BROWN

7 3
4 4

22 15 17 5

24
6 8
9
16 8
9
19 21
18 20

23

73106

1 - Regulator and Leads 18- Nut

2 - Screws (4) 19- Washer
3 - Insulator Cap 20- Insulating Washer
4 - Nuts (6) 21- Insulator
5 - Washers (3) 22- Negative Rectifier
6 - Condenser 23- Positive Rectifier/Diode-Trio
7 - Insulating Washer 24- Stator
8 - Nuts (2) 25- Rotor and Slip Rings
9 - Insulating Washers (2) 26- Snap Ring
10- Felt Gasket 27- Bearing
11- Screws (2) 28- Front End Frame
12- Brush Assembly 29- Fan Bushing
13- Screws (4) 30- Woodruff Key
14- Rear End Frame 31- Fan
15- Star Washers (2) 32- Pulley
16- Insulator 33- Lockwasher
17- Insulating Washers (2) 34- Nut

Prestolite 65 Amp Alternator

Index
90-806934 1194 CHARGING SYSTEM - 4C-29
Disassembly
1. Using an oversized V-belt to protect the pulley,
clamp alternator in vise as shown. Remove pulley
nut and lockwasher.
3. Disconnect regulator leads from terminals on rear
end frame. Remove four regulator attaching
screws, then pull regulator away from rear end
frame and disconnect field lead.
c
b

b
a

a a

72828 73088

a - Regulator Leads (2)

a - 7/8 In. Wrench b - Screws (4)
b - Oversized V-Belt to Protect Pulley c - Regulator

2. Remove pulley, fan, woodruff key and spacer. 4. Remove brush holder.

g a

e b
f

b d

73087
c

a - Nut
b - Lockwasher
c - Pulley 73090
d - Woodruff Key
e - Fan a - Attaching Screws
f - Spacer b - Brush Holder
g - Alternator
5. Note location of remaining insulating washers
and nuts and remove.
6. Scribe a mark on rear end frame, stator and front
end frame to ensure proper reassembly later.
7. Remove the four screws which secure end
frames and stator together.
Index
4C-30 - CHARGING SYSTEM 90-806934 1194
 ! CAUTION Cleaning and Inspection
Do not insert screwdriver blades deeper than 1/16 1. Clean all parts with a clean, soft cloth. Do not use
in. (1.5 mm) to avoid damaging stator windings. solvent, or electrical components may be dam-
aged.
8. Using a suitable holding fixture, separate front 2. Inspect the following:
end frame and stator assembly from rear end a. Brush Set - Inspect for cracked porcelain
frame using two thin blade screwdrivers (posi- casing, damaged brush leads, poor brush
tioned 180 degrees apart from each other) at the springs or worn brushes. Replace brush set if
locations shown. brushes are less than 3/16 in (5 mm) long.
b. Rotor - Inspect for stripped threads, scuffed
pole piece fingers or damaged bearing sur-
a faces (because of bearing turning on shaft).
c. Rotor Slip Rings - Clean slip rings with 400
b
d grain (or finer) polishing cloth. Blow off dust
with compressed air. Inspect slip rings for
grooves, pits, flat spots or out-of-round [.002
in. (.05 mm) maximum]. Replace if defective.
d. Rotor Shaft Bearings - Inspect for damaged
seals, lack of lubrication, discoloration (from
c overheating) or excessive side or end play.
73091
Hold inner race of bearings while turning outer
a - Front End Frame race. Bearing should turn freely without bind-
b - Stator ing or evidence of rough spots.
c - Rear End Frame
d - Scribe Marks e. Stator - Inspect for damaged insulation or
wires; also inspect insulating enamel for heat
9. While supporting front housing, use an arbor discoloration, as this is usually a sign of a
press to remove rotor from front end frame. shorted or grounded winding or a shorted
diode.
f. Regulator - Inspect leads for damaged in-
sulation.
b g. Front and Rear Housings - Inspect for
c
cracks, distortion, stripped threads or wear in
bearing bore (from bearing outer race spin-
ning in bore). Replace if defective.
h. Fan - Inspect for cracked or bent fins, broken
welds or worn mounting hole (from fan spin-
a
ning on shaft).
i. Pulley - Inspect pulley mounting bore and for
wear. Inspect drive surface of pulley sheaves
for trueness, excessive wear, or corrosion.
Repair damaged surfaces, if possible, with a
fine file and a wire brush, or replace pulley.
73092
Drive surfaces must be true and smooth, or
a - Front Housing drive belt wear will be greatly accelerated.
b - Rotor Shaft
c - Bearing Driver j. Alternator - If alternator has output at low
speeds, but no output at high speeds, rotor
field winding may be shorting or grounding out
because of centrifugal force. Replace rotor, if
all other electrical components test good.

Index
90-806934 1194 CHARGING SYSTEM - 4C-31
Front Bearing Slip Rings/Rear Bearing

Removal Removal
1. Remove snap ring. 1. Unsolder wires and carefully unwind them from
slip ring terminals.
2. Use an arbor press to remove bearing from hous-
ing. IMPORTANT: Do not damage rotor wires when re-
moving slip rings or bearing.
2. Install a universal puller plate between bearing
and slip rings. Insert a 10 x 1 in. cap screw into
opening of slip ring assembly.
b

c b

a
c
73093

a - Front Housing
b - Bearing Driver
c - Bearing
73095

a - Universal Plate Puller

Installation
1. Using an arbor press, press on outer race of new
bearing until fully seated in housing.
b - Cap Screw
c - Slip Rings
3. Using an arbor press, push against cap screw to
remove slip rings.
4. Install a universal puller plate under bearing.
5. Using an arbor press, remove bearing.

73094

2. Install snap ring to retain bearing.

Index
4C-32 - CHARGING SYSTEM 90-806934 1194
Installation
1. Press new rear bearing all the way onto rotor shaft
(until inner race contacts shoulder) with an arbor
press and a bearing driver that contacts inner
bearing race only, as shown. Use extreme care to
prevent damage to field winding leads.
IMPORTANT: Be sure to support rotor on end of
shaft and not on pole pieces, as pole pieces are
only press-fit onto shaft.
IMPORTANT: Press on the center of slip rings
only. Do not bend terminals or pinch wires.
3. Using an arbor press, install slip rings. Press on
center of slip rings until they contact shoulder of
rotor.
4. Carefully wrap WHITE wire around outer slip ring
terminal, and BLUE wire around inner slip ring ter-
minal. Solder wires in place.

b c

a
b

73098

a - WHITE Wire
73096 b - BLUE Wire

a - Arbor Press
b - Bearing Driver
c - Bearing
d - Rotor

2. Insert wires through hole in slip rings as shown.

73097

Index
90-806934 1194 CHARGING SYSTEM - 4C-33
Component Testing
Rotor
1. Test rotor field circuit for grounds, using an ohm-
meter (set on R x1 scale) as follows:
a. Connect one lead of ohmmeter to either slip
ring and the other lead to rotor shaft or pole
pieces.
b. Meter should indicate no continuity (meter
should not move).
c. If continuity does exist, rotor field circuit is
grounded. Inspect slip ring terminals to be
sure that they are not bent and touching rotor
shaft. Also be sure that excess solder is not
grounding terminals to rotor shaft. If cause for
ground cannot be found, unsolder field wind-
ing leads from slip ring terminals and connect
ohmmeter between one of the leads and rotor
shaft or pole pieces. If continuity still exists,
replace rotor assembly. If continuity is elimi-
nated, replace slip rings.
b
a
c
73099
a - Slip Rings
b - Ohmmeter with Leads
c - Pole Pieces
2. Test rotor field circuit for opens, shorts or high re-
sistance, using an ohmmeter (set on R x1 scale)
as follows:
a. Connect one ohmmeter lead to each slip ring.
b. Ohmmeter reading should be 4.1 to 4.7 ohms
with rotor at room temperature [70-80°F
(21-26°C)].
Index
4C-34 - CHARGING SYSTEM
c. If reading is high or infinite (no meter move-
ment), high resistance or an open exists in the
field circuit. Check for poor connections be-
tween field winding leads and slip ring termi-
nals. If cause for open or high resistance can-
not be found, connect ohmmeter directly to
slip ring terminals. If correct reading is now
obtained, replace slip rings. If reading is still
high or infinite, replace complete rotor assem-
bly.
d. If reading is low, a short exists in the field cir-
cuit. Inspect slip rings to be sure that they are
not bent and touching outer slip ring. Also be
sure that excess solder is not shorting termi-
nals to aft slip ring. If cause for short cannot
be found, unsolder field winding leads from
slip ring terminals and connect ohmmeter di-
rectly to leads. If correct reading is now ob-
tained, slip rings are shorted and must be re-
placed. If reading is still low, rotor field
windings are shorted, and complete rotor as-
sembly must be replaced.
d
b
a
73112
a - Field Winding Leads
b - Slip Rings
c - Rotor Shaft
d - Pole Pieces
90-806934 1194
Stator
IMPORTANT: Stator leads MUST BE discon-
nected from rectifiers and diode-trio for this test.
! CAUTION
Excessive heat from de-soldering may cause
damage to rectifiers or diode-trio assembly when
disconnecting leads.
1. Test stator for grounds, using an ohmmeter (set
on R x1 scale) as follows:
a. Connect one lead of ohmmeter or test lamp to
one of the stator leads and the other lead to
stator frame. Be sure that lead makes good
contact with frame.
b. Meter should indicate no continuity (meter
should not move). If continuity does exist, sta-
tor is grounded and must be replaced.
73101
NOTE: It is necessary to test only three of the six
leads on EITHER side of the stator as the leads are
interconnected in the windings.
2. Test for opens in stator, using an ohmmeter (set
on R x1 scale) as follows:
a. Connect ohmmeter or test lamp between
each pair of stator windings (3 different ways).
b. Continuity should be present in all three cases
(meter should move). If it does not, one or
more of the windings are open and stator
must be replaced.
Index
90-806934 1194
3. A short in the stator is difficult to detect without
special equipment, because of the low windings
resistance. If all other electrical components test
out good, and alternator fails to produce rated
output, stator probably is shorted and should be
replaced. Also, examine stator for heat discolor-
ation, as this usually is a sign of a short.
Positive/Negative Rectifier and
Diode-Trio Assembly
IDENTIFICATION
73100
NEGATIVE (–) RECTIFIER
! CAUTION
Do not use a test instrument with more than a
12-volt source in the following test, as rectifier
may be damaged.
IMPORTANT: Rectifier MUST BE disconnected
from stator for this test.
! CAUTION
Excessive heat from de-soldering may cause
damage to rectifier when disconnecting leads.
1. Identify the leads prior to removal so they can be
reassembled to their original positions.
CHARGING SYSTEM - 4C-35
2. Using an ohmmeter (set on R x1 scale), check for 4. Replace assembly if any of the rectifiers is
continuity between rectifier terminal and heat shorted or open.
sink. Reverse ohmmeter leads and recheck. Con-
tinuity should be observed in one direction (polar-
ity) only.
3. Check other two rectifiers in same manner.
4. Replace assembly if any of the rectifiers is
shorted or open.

73103

5. Using an ohmmeter (set on R x1 scale), check for

continuity between the common side of the
diodes and one of the terminals on other side of
the diode. Reverse ohmmeter leads and recheck.
73102
Continuity should be observed in one direction
(polarity) only.
6. Check other two diodes in same manner.
POSITIVE (+) RECTIFIER AND DIODE-TRIO 7. Replace diode-trio if any of the diodes is shorted
! CAUTION or open.

Do not use a test instrument with more than a

12-volt source in the following test, as rectifier
may be damaged.

IMPORTANT: Rectifier MUST BE disconnected

from stator for this test.

! CAUTION
Excessive heat from de-soldering may cause
damage to rectifier or diode-trio assembly when
disconnecting leads.
1. Identify the leads prior to removal so they can be
reassembled to their original positions.
2. Using an ohmmeter (set on R x1 scale), check for
continuity between rectifier terminal and heat 73104
sink. Reverse ohmmeter leads and recheck. Con-
tinuity should be observed in one direction (polar-
ity) only.
3. Check other two rectifiers in same manner.

Index
4C-36 - CHARGING SYSTEM 90-806934 1194
Condenser 3. Position rear end frame and stator assembly with
insulators over front end frame and rotor assem-
1. Using Magneto Analyzer (P/N 91-76032) and ac- bly. Align scribe marks on each (scribed during
companying instructions, perform the following disassembly). Hand press end frames together,
condenser tests: then install four screws. Torque screws to 50-60
a. Condenser Capacity Test (must be .5 mfd) lb. in. (5.6-6.7 N•m).
b. Condenser Short or Leakage Test
c. Condenser Series Resistance Test
2. Replace condenser if test results are not within
a
specifications.
b
d
Reassembly
c
1. Solder positive/negative rectifier and diode-trio
assembly to stator. Connect leads to original loca-
tion as identified during disassembly.

73105
a - Front End Frame
b - Stator
c - Rear End Frame
d - Scribe Marks

4. Install brush holder into rear end frame and slide

forward to depress brushes against slip ring. In-
sert two screws and tighten securely.

a
73100

2. Install rotor to front end frame. b

IMPORTANT: The insulators MUST BE installed

as shown or damage to the alternator will result.

73090
a b
d 73085 a - Attaching Screws
b - Brush Holder
a - Insulating Washers
b - Insulators
c - Negative Rectifier
d - Positive Rectifier/Diode-Trio

Index
90-806934 1194 CHARGING SYSTEM - 4C-37
5. Attach field lead to brush assembly. Install regula- 7. Install spacer, woodruff key, fan, pulley, lock-
tor and felt gasket to rear end frame. Install four washer and nut.
screws and tighten securely. Reconnect regulator
terminal leads to appropriate stud on rear end g
frame.

e
f
c a
d d
b

73087
c
b d a - Nut
b - Lockwasher
c - Pulley
d - Woodruff Key
e - Fan
f - Spacer
73107 g - Alternator

a - Regulator
b - Felt Gasket 8. Using an oversized belt to protect the pulley,
c - Screws (4) clamp alternator in vise as shown. Tighten pulley
d - Regulator Leads nut to 35-50 lb. ft. (48-68 N•m).

6. Place condenser on ground terminal and lead on

output terminal. Install insulator cap on regulator
a
terminal.

73108
a b
c a - Oversized Belt
73088
b - Pulley
a - Output Terminal
b - Ground Terminal
c - Condenser

Index
4C-38 - CHARGING SYSTEM 90-806934 1194
Installation 5. Reconnect wiring harness to alternator. Coat ter-
minals with Quicksilver Liquid Neoprene.
NOTE: Some early engines with Prestolite alterna-
tors have a cast mounting bracket and related com- 6. Connect negative battery cable to battery.
ponents. Refer to page 4C-20 for assembly views,
only substitute the Prestolite alternator and connec-
tions, if so equipped. b
IMPORTANT: On engines with a stamped steel a
mounting bracket, if the mounting bracket has
been removed, refer to the diagram at the bottom
of this page. Be certain that the mounting spacer
and proper length brace spacer are in position for
the appropriate engines as indicated.
1. Install alternator in mounting bracket. DO NOT
tighten fastener at this time. c
2. Fasten alternator brace to alternator. DO NOT e
d
tighten screw at this time.
a - Excitation Wire - PURPLE 73078
3. Position alternator drive belt on pulleys and adjust b - Sensing Wire - RED/PURPLE
tension as explained under “Drive Belt Tension c - Ground Lead - BLACK (Not Visible in This View)
Adjustment.” d - Output Lead - ORANGE
e - Charge Indicator Lamp (System Monitor Panel) -BROWN
4. Torque fasteners to specifications. Securely f - Alternator Driven Tachometer Lead - GRAY (Not Shown -
tighten all other fasteners. Connects to “AC” Terminal, When Required)

9
7
b 8

1 10 a A

1 - Alternator V-Belt
2 - Alternator
3 - Mounting Spacer (ONLY on D3.0L/150 and
D3.6L/180 Engines)
4 - Mounting Bracket
5 - Mounting Bolt, and Self-Locking Nut
6 - Mounting Screws With Lockwashers
7 - Alternator Brace 2
8 - Brace Bolt, Washer and Nut
9 - Brace Spacer - Two Lengths : 3
- .873 in. (22.5 mm) Long on D3.0L/150 and D3.6L/180 Engines
- .440 in. (11 mm) Long on D4.2L/220 Engines
10- Tensioning Screw, Lockwasher and Flat Washers

Lubricant/Sealant Application Points

A Quicksilver Liquid Neoprene - 92-25711 c 6

Torque Specifications
a 192 lb. in. (28 N·m)
b 30 lb. ft. (41 N·m) 4
c 35 lb. ft. (48 N·m) 5 a 74457

Index
90-806934 1194 CHARGING SYSTEM - 4C-39
ELECTRICAL SYSTEMS

4
73288
D
INSTRUMENTATION

Index
Table of Contents
Page
Wiring Colors for MerCruiser Diesels . . . . . . . . . . . . 4D-1
Wire Color Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 4D-1
Identification - Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Tachometer Special Information . . . . . . . . . . . . . . . . . 4D-2
Gauge Special Information . . . . . . . . . . . . . . . . . . . . . 4D-3
Lighting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3
QSI Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3
Oil Pressure and Water Temperature . . . . . . . . . . 4D-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3
Volt Meter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4
Cruiselog (Engine Hour Meter) . . . . . . . . . . . . . . . 4D-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6
Water Temperature - Primary Station . . . . . . . . . . 4D-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-8
Water Temperature - Second Station . . . . . . . . . . 4D-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-10
Primary Station Switches . . . . . . . . . . . . . . . . . . . . . . 4D-10
Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . 4D-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-10
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11
Index
4D-0 - INSTRUMENTATION
4D - INSTRUMENTATION
Page
Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Audio Warning Test and Panel Light Switch . . . 4D-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Secondary Station Switches . . . . . . . . . . . . . . . . . . . 4D-13
Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-13
Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-14
Audio Warning System . . . . . . . . . . . . . . . . . . . . . . . . 4D-14
Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Water Temperature Switch . . . . . . . . . . . . . . . . . . 4D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-16
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-17
Transmission Fluid Temperature Switch . . . . . . 4D-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-18
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-19
NOTICE
For information and procedures on troubleshoot-
ing, refer to Section 1C.
90-806934 1194
Wiring Colors for MerCruiser Diesels
Where Used
Color Code
Primary Usage Secondary Usage
Black All Grounds
Black/Yellow Engine Stop
Blue Instrument Lighting
Blue/Black Glow Plug Wait Switch
Blue/Tan Oil / Water Alarms
Blue/White Glow Plugs Glow Plug Wait Lamp
Brown Reference Electrode-MerCathode Alternator Charge Lamp
Brown/White Trim Sender to Trim Gauge
Gray Tachometer Signal
Green/White Trim -”Down” Switch Spare
Lt. Blue Oil Pressure Sender to Gauge
Lt. Blue/White Trim- ”Up” Switch
Orange Alternator DC Output Anode Electrode-MerCathode
Pink Fuel Gauge Sender to Gauge
Purple Ignition Switch (+12 V)
Purple/White Trim-”Trailer” Switch Water In Fuel Module and Instruments
Red Unprotected Wires from Battery
Red/Purple Protected (Fused) Wires from Battery Protected (+ 12V) to Trim Panel
Red/White Water In Fuel Sender (Probe)
Tan Water Temperature Sender to Gauge
Tan/Black Water Temperature Switch Transmission Fluid Temperature Switch
Tan/Blue OIl / Water Alarms
Tan/White Oil Pressure Switch Drive Oil Level Switch
White/Green Spare
Yellow Timing Advance Sender
Yellow/Black Transmission Neutral Safety Switch
Yellow/Red Starter Switch to Starter Solenoid to
Neutral Start Switch

Wire Color Abbreviations

BLK Black PUR or PPL Purple
BLU Blue RED Red
BRN Brown TAN Tan
GRY Gray WHT White
GRN Green YEL Yellow
ORN Orange LIT or LT Light
PNK Pink DRK Dark

Index
90-806934 1194 INSTRUMENTATION - 4D-1
Identification - Gauges If all instruments appear suspect, check the main
harness or electrical connector to ensure good
contact.

Before testing individual instruments, check the

following:
• All wires in circuit are connected.
• Plug in connectors are fully engaged.
• Battery is fully charged.
• All connections are tight and corrosion free.

! CAUTION
Avoid short circuits. It may be necessary to re-
move instrument panel or Engine System Moni-
tor panel from dashboard to gain access to
instruments and switches. Do not allow wires to
come in contact with metal or other wires.

72965
Typical QSI Series Gauge
General
! WARNING
Always disconnect battery cables from battery
before working around electrical system compo-
nents to prevent injury to yourself or damage to
electrical system.
IMPORTANT: If all instruments appear suspect,
an electrical overload may have occurred. A fuse
may be defective or a circuit breaker may be
tripped open. The cause must be found and cor-
rected before replacing fuse or resetting circuit
breaker.
Tachometer Special
Information
If using a tachometer, from another manufacturer,
that must be connected to the alternator for driving
the tachometer, do not use the magnetic tachometer
pickup mounted on the flywheel housing. The GRAY
wire in the wiring harness to the alternator will be
used. Refer to wiring schematics and proceed as fol-
lows:
1. Disconnect both the GRAY and BLACK wire ter-
minal ends from the existing magnetic tachome-
ter pickup. Tape each wire terminal end with at
least two layers of electrical tape.
2. Connect the loose GRAY wire terminal end, near
the alternator, to the terminal marked “P” on the
Mando alternator and “AC” on the Prestolite alter-
nator. The markings should appear on the back
of the alternator near the respective terminal.
Tighten fastener securely. Coat the connection
with Quicksilver Liquid Neoprene (92-25711-1).
3. Follow the specific installation manual proce-
dures, or the manufacturer’s instructions, for the
remaining connections at tachometer.

Index
4D-2 - INSTRUMENTATION 90-806934 1194
Gauge Special Information

Lighting Options

QSI SERIES
These gauges are equipped with optional illumination
lighting. Light bulb socket can be removed and con-
tacts can be aligned to be used with ignition switch
lighting circuit +12 V or separate instrumentation a
lighting circuit LT. Standard position on diesel prod-
ucts is for use with the separate Panel Lights/Audio
Test switch. 72968

IMPORTANT: Light socket must be removed from a - +12 V Power Supply from Ignition Switch (PURPLE Wire)
gauge and turned when adjusting lighting option
to desired setting. Turning socket while still in- Ignition Switch Lighting Circuit Position
(Optional Position)
stalled in gauge could result in damage to gauge
or socket.
NOTE: For different lighting effects, colored sleeves
are available through the Quicksilver Accessories
and can be assembled to the bulb. Gauges
IMPORTANT: If testing proves a gauge to be de-
fective, it must be replaced as there is no repair
b available.

Oil Pressure and Water Temperature

TESTING
a 1. Turn ignition switch to OFF.
2. Remove signal wire from terminal S (SEND).

72969

a - +12 V Power Supply from Ignition Switch

b - +12 V Power Supply from Panel Lights/Audio Test Switch
(BLUE Wire)
Separate Instrumentation Lighting Circuit Position
(Standard Position)

a
72819

a - “S” - Sender Wire Lead

Index
90-806934 1194 INSTRUMENTATION - 4D-3
3. Turn ignition switch to RUN. Gauge being tested Volt Meter Gauge
must be at position A.
TESTING
1. Remove cables from battery and fully charge bat-
tery. Remove wires from back of gauge.
2. Connect negative (–) jumper lead from battery to
gauge terminal G (GND).
a
a 3. Connect positive (+) jumper lead from a 12 Volt
power source, or battery, to gauge terminal I or
73288
+12 V.

a - Needle at Position A
Typical
4. Turn ignition switch to OFF.
5. Connect jumper wire from terminal G (GND) to b
terminal S (SEND).

a
72750

a - Volt Meter
b - 12 Volt Power Source
4. Check gauge reading; if not indicating battery
voltage, as shown, replace gauge.

a 72748

a - Jumper Wire
6. Turn ignition switch to RUN.
7. Indicator needle of gauge being tested must read a
at position B.

73290

a a - Needle Indicating Battery Voltage

a
Typical

73289
a - Needle at Position B
Typical

Index
4D-4 - INSTRUMENTATION 90-806934 1194
Cruiselog (Engine Hour Meter)
TESTING
1. Remove cables from battery and fully charge bat-
tery. Remove wires from back of gauge.
2. Connect positive (+) jumper lead from battery to
gauge terminal + (12 V).
3. Connect negative (–) jumper lead from battery to
gauge terminal GND (ground).
72750 72815
4. Observe gauge run indicator on face of gauge. If
indicator is turning, the gauge is operable. If not
replace gauge.
Tachometer
TESTING
1. If gauge is not accurate, be certain the switch on
the back of the tachometer is set properly. On In-
Line Diesel engines using magnetic tachometer
pickup for source, the setting is as follows:
Tachometer
Type Allowable Range
5000 RPM + 100 RPM
Gauge Replacement
1. Disconnect battery cables from battery.
2. Remove wires from back of gauge.
3. Disconnect light socket wiring if separate.
4. Remove holding strap and remove gauge.
5. Position gauge assembly in appropriate mount-
ing hole.
6. Install holding strap and nuts. Tighten nuts evenly
and securely.
IMPORTANT: Do not distort case or bracket by
over-tightening.
7. Connect ground (BLACK) wire to ground termi-
nal, if gauge is not mounted in metal panel.
8. Connect other wires to gauge as shown in SEC-
TION 4E - “Wiring Diagrams”.
9. Install gauge light socket.
10. Coat all terminals with Quicksilver Liquid Neo-
prene.
11. Reconnect battery cables to battery.

Tachometer Switch Setting

Engine Pulses Switch
Model
Per Revolution Position
D3.0L/150,
D3.6L/180 and 103 1
D4.2L/220

NOTE: Refer to “Tachometer Special Information” as

discussed earlier, if using an alternator driven
tachometer.

2. If properly set and still inaccurate, connect a die-

sel timing tool or suitable service tachometer to
engine and compare readings.
3. Replace if not within specifications.

Index
90-806934 1194 INSTRUMENTATION - 4D-5
Senders NOTE: Sender shown removed for visual clarity only.

Oil Pressure

REMOVAL
1. Remove LIGHT BLUE wire from sender.
2. Using a suitable wrench to hold the adaptor fitting
(to prevent loosening of main bearing locating
screw), unscrew the sender.
70686 72936

b a
c
c

74281

a - Oil Pressure Sender

d
b - Adaptor Fitting
c - Install Manual Pressure Gauge Here on a“T”-Fitting
74281

a - LIGHT BLUE Wire 4. Refer to chart. Check the resistance values of the
b - Oil Pressure Sender appropriate sender at pressures as shown and
c - Adaptor Fitting
d - Main Bearing Locating Screw verified on manual gauge with engine running.
Replace sender if values are not correct.

SINGLE STATION SENDER - 805267

TESTING
OIL PRESSURE OHMS
PSI (kPa) READING
IMPORTANT: Use following test procedure for
checking accuracy of oil pressure sender only. If 0 (0) 240
15 Ω
oil pressure gauge indicates zero oil pressure, re- 60 (413.7) 103
15 Ω
fer to Section 1C - “Troubleshooting.”
DUAL STATION SENDER - 805268
1. Remove LIGHT BLUE wire from sender. Insulate
Oil Pressure Ohms
to avoid possible short circuit.
PSI (kPa) Reading
2. Install a manual pressure gauge graduated in at 0 (0) 120
7 Ω
least 10 PSI (100 kPa or 1 bars) increments, using
a suitable “T”-fitting arrangement with the existing 60 (413.7) 52
7 Ω
sender and adaptor or fitting.
3. Connect an ohmmeter between sender terminal 5. When replacing sender, coat threads with Loctite
and sender case. Pipe Sealant with Teflon and install. Tighten se-
curely.
Index
4D-6 - INSTRUMENTATION 90-806934 1194
Water Temperature - Primary Station
REMOVAL
1. Drain coolant from closed cooling system into a
suitable container, as outlined in SECTION 6B.
2. Remove harness wiring block from temperature
switch located as shown.
TESTING
IMPORTANT: Use the following test to determine
the accuracy of the Water Temperature Sender
gauge circuit. If gauge indicates NO temperature
when running engine refer to the “TROUBLE-
SHOOTING” section.
1. Connect an ohmmeter between sender terminal
“G and switch hex (case) for “ground” (–) as
shown.

a c
b

70192

Engines With Sender Mounted On Manifold End Cover

70686

c b
a

74284
Engines With Sender Mounted On Cylinder Head
a - Harness Wiring Block
b - Water Temperature Sender
c - Sealing Washer

3. Remove sender and sealing washer.

Index
90-806934 1194 INSTRUMENTATION - 4D-7
 ! WARNING d. Turn heat source “OFF”. Allow sand and com-
ponents to cool.
The following test involves the use of intense
heat. Failure to follow appropriate procedures or NOTE: While sand cools you may recheck ohmmeter
warnings can cause burns which can result in se- readings.
vere personal injury. While performing the follow-
ing test, observe these general precautions:
• Wear personal protective clothing such as
rubber gloves, a non-flammable apron, and
eye protection - preferably full face shield or
safety glasses.
• The appropriate heat source should only be d
electric. Heat source should be operated by a e b
qualified person. Be sure to follow all instruc-
tions of the manufacturer of the heat source.
The heat source should be checked each time 70688
it is used to be sure it is functioning properly.
• The thermometer used in the test should be a
high- temperature thermometer with a maxi-
mum reading of at least 300°F (150°C). Under
no circumstances should the operator allow
temperatures to exceed test specifications.
• Perform test only in a well ventilated area. a
• Use a suitable container, such as metal, to
hold the sand. Avoid use of glass containers c
unless the operator first confirms for himself/
herself that the glass container is an appropri-
ate high-temperature vessel.
• Because the components will reach high tem-
peratures DO NOT handle materials or com- a - Suitable Container
ponents until COMPLETELY cooled. b - Thermometer
c - Heat Source
d - Water Temperature Sender
e - Ohmmeter Leads
! WARNING
Use only clean, dry sand such as used for general TEST TEMPERATURE OHMS READING
sandblasting purposes. Use of sand containing 140° F (60° C) 121 - 147
contaminants could result in hazards such as
194° F (90° C) 47 - 55
fire, short circuiting, hot-spots, or other hazards.
212° F (100° C) 36 - 41
2. Follow these instructions:
INSTALLATION
a. With an ohmmeter connected as outlined and
using suitable container, thermometer and 1. Coat threads of sender with Quicksilver Perfect
heat source, suspend sender with tip in sand. Seal and install sender with new sealing washer.
Maximum torque is 18 lb. ft. (25 N·m). DO NOT
b. Heat sand and observe temperature on
OVER-TORQUE.
thermometer.
2. Connect harness wiring block.
c. As temperature rises, ohmmeter readings
must be within the ranges specified for each 3. Refill closed cooling system with approved cool-
temperature (see chart). ant as outlined in SECTION 6B.

Index
4D-8 - INSTRUMENTATION 90-806934 1194
Water Temperature - Second Station
REMOVAL
1. Drain coolant from closed cooling system into a
suitable container, as outlined in SECTION 6B.
NOTE: On engines with engine mounted Gear Lube
Monitor it may be necessary to temporarily place the
gear lube bottle aside, in an upright position.
2. Remove TAN harness wire from temperature
sender located as shown.
3. Stabilize the adaptor with a suitable wrench and
remove the sender.
b
a
c •
74234
a - TAN Wire
b - Second Station Water Temperature Sender
c - Adaptor Fitting
Sender Mounted On Cylinder Head
TESTING
IMPORTANT: Use the following test to determine
the accuracy of the Second Station Water Tem-
perature Sender gauge circuit. If gauge indicates
NO temperature when running engine refer to the
“TROUBLESHOOTING” section.
Index
90-806934 1194
! WARNING
The following test involves the use of intense
heat. Failure to follow appropriate procedures or
warnings can cause burns which can result in se-
vere personal injury. While performing the follow-
ing test, observe these general precautions:
• Wear personal protective clothing such as
rubber gloves, a non-flammable apron, and
eye protection - preferably full face shield or
safety glasses.
• The appropriate heat source should only be
electric. Heat source should be operated by a
qualified person. Be sure to follow all instruc-
tions of the manufacturer of the heat source.
The heat source should be checked each time
it is used to be sure it is functioning properly.
• The thermometer used in the test should be a
high- temperature thermometer with a maxi-
mum reading of at least 300°F (150°C). Under
no circumstances should the operator allow
temperatures to exceed test specifications.
• Perform test only in a well ventilated area.
• Use a suitable container, such as metal, to
hold the sand. Avoid use of glass containers
unless the operator first confirms for himself/
herself that the glass container is an appropri-
ate high-temperature vessel.
Because the components will reach high tem-
peratures DO NOT handle materials or com-
ponents until COMPLETELY cooled.
! WARNING
Use only clean, dry sand such as used for general
sandblasting purposes. Use of sand containing
contaminants could result in hazards such as
fire, short circuiting, hot-spots, or other hazards.
INSTRUMENTATION - 4D-9
1. Follow these instructions: INSTALLATION
1. Apply Loctite Pipe Sealant with Teflon to threads
a. With an ohmmeter connected as shown fol- of sender and install. Tighten securely.
lowing and using a suitable container, ther-
2. Refill closed cooling system with approved cool-
mometer and heat source, suspend sender
ant as outlined in SECTION 6B.
with tip in sand.
b. Heat sand and observe temperature on ther-
mometer.
Primary Station Switches
IMPORTANT: Disconnect battery cables from bat-
tery before testing switches with wires still con-
nected to switches.

IMPORTANT: The decal, or decals, on the side of

– + the toggle switches, with the arrow and the word
“UP”, refer to the position of the switch when
installed on the panel.

Ignition Key Switch

REMOVAL
1. Remove nut retaining switch to Engine System
Monitor Panel.
70688
c
c. As the temperature rises ohmmeter readings
must be within the ranges specified for each
temperature. Refer to the chart below for
specifications.
b
SECOND STATION SENDER - 49734
Ohms a
Test Temperature 73546
Reading
100° F (38° C) 203 - 247 Ω a - Engine System Monitor Panel
160° F (71° C) 59 - 70 Ω b - Ignition Key Switch
c - Retainer
220° F (71° C) 22 - 25 Ω
2. Remove wires from back of switch.

d. Turn heat source “OFF”. Allow sand and com-

ponent to cool.

NOTE: While sand cools you may recheck ohmmeter

readings.
2. Replace sender if ohmmeter readings are other
than as shown, for each temperature.

Index
4D-10 - INSTRUMENTATION 90-806934 1194
TESTING Stop Switch
The “STOP” switch is a single-pole, momentarily
1. Before testing key switch, check all fuses and/or
“closed” switch, provided for stopping the engine.
circuit breakers in electrical circuit which could
This is done by electrically shutting off the fuel deliv-
prevent operation of starter. ery system.
IMPORTANT: Disconnect battery cables from bat-
NOTE: The ignition key switch must be in the “RUN”
tery before testing ignition key switch with wires position for the stop switch to function properly when
still connected to switch.
installed and connected.
2. Disconnect battery cables from battery, if pro-
ceeding to test switch with wires still connected. REMOVAL
With key switch in OFF position, there should be
1. Remove hex nut retaining switch to Engine Sys-
no continuity between switch terminals.
tem Monitor Panel.
3. With key switch in RUN position, continuity will ex-
ist between switch terminals “B” to “I”. There b c
should be no continuity between terminal “S” and
any other terminals.
4. With key switch in START, continuity will exist be-
tween terminals “B” to “I” and “B” to “S”.
5. Terminals are to make contact at angles shown
and to stay in contact condition as switch is ro-
tated toward START. a
73546
6. If ignition key switch tests bad, unscrew or un-
solder wire connections and remove switch. Test a - Engine System Monitor Panel
switch again, as in Steps 2-5, preceding. If switch b - Toggle “STOP” Switch
c - Hex Nut Retainer
tests good, wiring in harness is bad. There should
be no continuity between any switch harness 2. Remove wires from back of switch.
wires with key switch removed.
TESTING
f 1. With switch removed, or accessible, attach an
e ohmmeter to terminal numbers 1 and 2 as indi-
d cated by the decal.
c 2. With switch lever toggled “DOWN” to its spring
loaded “ position continuity should exist between
terminal numbers 1 and 2. If no continuity exists,
a b replace switch.
c
S
B

É
I
2
87-805676

É
É
UP

Key View Back View 74103

1

a - Key

É
b - Off
c - Continuity B to I Terminals
d - Run d
e - Continuity, B to S Terminals b
f - Start
a
a - Stop Switch
b - Toggle Lever Spring Loaded Position
(Direction of Movement DOWN When Installed)
c - Terminal Number 2
d - Terminal Number 1

Index
90-806934 1194 INSTRUMENTATION - 4D-11
INSTALLATION
1. Using screws provided, install wires to appropri-
ate switch terminals as shown in chart.
2. Make sure that all connections are secure. Seal
terminals with Liquid Neoprene (92-25711--1).
3. Install switch in Engine System Monitor panel.
Tighten hex nut securely to prevent switch from
ÉÉ
turning in its mounting hole. DO NOT overtighten.
Audio Warning Test and Panel Light
Switch
The switch provided for the audio warning test and
panel (dash) lights is a three-position toggle switch.
It must be wired and installed correctly to provide
proper operation of the systems.
REMOVAL

ÉÉ
1. Remove hex nut retaining switch to Engine Sys-

ÉÉ
tem Monitor Panel.
h c

ÉÉ
e 2. Remove wires from back of switch.
f

ÉÉ É TESTING

ÉÉ É
2
87-805676

ÉÉ É
1. With switch lever toggled “DOWN” to its spring
UP

loaded AUDIO TEST position continuity should

É
1

ÉÉ exist between terminal numbers 1 and 2 (as

ÉÉ indicated by decals). If no continuity exists,

ÉÉ
d replace switch.

ÉÉ
b 2. With switch lever toggled “UP” to the panel light

ÉÉ g
a “ON” position, continuity should exist between

ÉÉ
terminal numbers 4 and 5 (as indicated by de-
73369
cals). If no continuity exists, replace switch.
a - Stop Switch d a

É
b - Toggle Lever Spring Loaded Position
(Direction of Movement DOWN When Installed)

1
É
87-805675
c - Terminal Number 2

É
d - Terminal Number 1

UP
e - Jamb Nut 2
f - Locking Washer
3
g - Panel
h - Hex Nut Retainer b
c
Harness Wire Terminal
Connect To:
(Color Code) Number 6 1
BLK/YELLOW
2 5 2
UP

(BLK/YEL) 4 3
PURPLE (PPL)
1 73369

a - Audio Test/Panel Light Switch

b - Spring-Loaded Audio Test Portion
(Direction of Movement DOWN When Installed)
c - Terminal Number(s)
d - Terminal(s)

INSTALLATION
1. Using screws provided, connect the listed color
coded wires to numbered switch terminals as
shown.
2. Make sure that all connections are secure. Seal
terminals with Liquid Neoprene (92-25711).

Index
4D-12 - INSTRUMENTATION 90-806934 1194
3. Install switch in Engine System Monitor panel. TESTING
Tighten hex nut securely to prevent switch from
1. Toggle switch lever to its spring loaded START
turning in its mounting hole. DO NOT overtigh-

ÉÉ
position.
ten.
a
ÉÉ 2. Continuity should exist between terminal num-

ÉÉ
d h bers 1 and 2 (as indicated by decals). If no conti-
e

É ÉÉ
nuity exists, replace switch.

1
87-805675
É ÉÉ INSTALLATION

UP É ÉÉ
a
2

ÉÉ
1. Using screws provided, connect the listed color
3

coded wires to numbered switch terminals as

c f
ÉÉb g shown in chart.

ÉÉ
73369
2. Make sure that all connections are secure. Seal
b terminals with Liquid Neoprene (92-25711).
6 1
71886 3. Install jamb nut, and then locking washer, on
5 2
UP

switch threaded portion. Secure to panel using

4 3 hex nut. Tighten securely, to prevent switch from
turning in hole. DO NOT overtighten.
a - Audio Test/Panel Light Switch
b - Spring-Loaded Audio Test Portion b
(Direction of Movement DOWN When Installed)
c - Terminal Number(s)
d - Terminal(s)
e - Jamb Nut
f - Locking Washer

É
74057
g - Engine System Monitor Panel

É
h - Hex Nut
h e

É É
f c
Harness Wire Terminal

É É
Connect To:

87-805676
1 2
(Color Code) Number
BLACK (BLK)
2
É É
UP
TAN/BLACK
1
É É
É
(TAN/BLK) b d

É
g a
BLUE (BLU)
5 73369

PURPLE (PPL)
4 a - Start Switch

b - Toggle Lever Spring Loaded Position
(Direction of Movement DOWN When Installed)
c - Terminal Number(s)
d - Terminal(s)
Secondary Station Switches e - Jamb Nut
f - Locking Washer
Start Switch
Harness Wire Terminal
Connect To:
The “START” switch, provided for starting the engine (Color Code) Number
at this second station, is a single-pole, momentarily PURPLE (PPL)
1
“closed” switch.
YELLOW/RED
2
(YEL/RED)
REMOVAL
1. Remove hex nut retaining switch to Engine Sys-
tem Monitor Panel.
2. Remove wires from back of switch.

Index
90-806934 1194 INSTRUMENTATION - 4D-13
Stop Switch H a r nC eo sn
Terminal Number
sn e Wc it r
and/or Connection
The “STOP” switch, provided for stopping the engine ( C o l To:
o r C o d e
Location
at this second station, is a single-pole, momentarily
“closed” switch. PURPLE (PPL)
1
BLACK/YEL-
REMOVAL LOW
2
(BLK/YEL)
1. Remove hex nut retaining switch to Engine Sys-
tem Monitor Panel. Note 1.: Wire is sta-strapped to instrument harness
2. Remove wires from back of switch. near connector collar.

INSTALLATION
1. Using screws provided, connect the listed color Audio Warning System
coded wires to numbered switch terminals as The Audio Warning System is divided into two sepa-
shown in chart. rate circuits. Both circuits have an individual audio
2. Make sure that all connections are secure. Seal warning buzzer that does NOT include any time
terminals with Liquid Neoprene (92-25711). delay.
3. Install jamb nut, and then locking washer, on One circuit consists of the engine water temperature
switch threaded portion. Secure to panel using switch and related wiring. If this switch is activated
hex nut. Tighten securely, to prevent switch from (“closed”) during the operation of the engine, the
turning in hole. DO NOT overtighten. alarm buzzer will sound and the Engine System Moni-

ÉÉ tor panel light will be illuminated until the problem is

ÉÉ e corrected or the electrical system is shut off (key

h c

ÉÉ
f switched “OFF”).

ÉÉ É
The other circuit consists of the engine oil pressure
2
87-805676

ÉÉ É
switch, the transmission temperature switch [MIE (In-
UP

board) models] or the gear lube monitor bottle switch

ÉÉ É
1

[MCM (Stern Drive) models) and related wiring.

ÉÉ d These switches are connected to the audio warning

ÉÉ buzzer through a control relay which is activated

ÉÉ
g b when the glow plug control system has completed the
a 73369 “preheat cycle”. Likewise, the Engine System Moni-
tor panel light is illuminated whenever the respective
switch is activated (“closed”) until the problem is cor-
rected or the electrical system is shut off (key
switched “OFF”)..
The function of an audio warning buzzer can be
tested by holding the toggle lever of the Audio Test
b switch (on the Engine System Monitor panel) DOWN
momentarily, with the key switch in the “RUN” posi-
74057
tion. If the buzzer sounds the buzzer is operable.
a - S t o p S w i t c h
b - T o g g l e L e v e r S p r i n g L o a d e
( D i r e c t i o n o f M o v e m e n t D O W
c - T e r m i n a l N u m b e r ( s )
d - T e r m i n a l ( s )
e - J a m b N u t
f - L o c k i n g W a s h e r

Index
4D-14 - INSTRUMENTATION 90-806934 1194
Buzzer NOTE: Sender shown removed for visual clarity only.

! WARNING c

The following test involves the use of electricity.

Failure to follow appropriate procedures can
cause burns or shock which can result in severe
personal injury or death.

TESTING
1. If buzzer does not sound:
a. Disconnect bullet connectors from suspect
buzzer. Connect a 12 volt positive (+) jumper 70686
wire to where the PURPLE wire (depending
on which buzzer is being tested) was con-
nected. Connect the remaining wire (where a
the TAN/BLACK or TAN/BLUE was con-
nected) to a clean, unpainted ground or nega-
tive (–) connection using a jumper wire.
b. If buzzer does not sound, replace it. b
74446
2. If the buzzer worked in Step 1, reconnect wires
and: a - Oil Pressure Audio Warning Switch
b - TAN/WHITE Wire
a. Remove wires at the switches involved and c - Continuity Meter and Connection Points
briefly jumper the wire ends together. With
Typical
the key switch in the “RUN” position, the buzz-
er should sound.
OIL PRESSURE SWITCH
b. If buzzer sounds, the problem is in the PSI (kPa) CONDITION
switch(es). Refer to individual switches - 0 (0) Closed
“Testing”, as follows, and test suspect switch.
Replace as instructed. 4.5 - 7.5 (31 - 52) Open

3. If the buzzer did not sound in Step 2: Refer to wir-

ing diagrams and check wires or connectors to 3. When replacing switch, coat threads with Loctite
the individual switches. Repair as needed. Pipe Sealant with Teflon and install. Tighten se-
curely.

Oil Pressure Switch

TESTING
When the engine is OFF the switch is normally
closed.
1. Remove TAN/WHITE wire from switch. Insulate
to avoid possible short circuit.
2. Connect continuity meter between switch
terminal and switch case [negative (–)]. With
engine NOT running, meter should indicate full
continuity.

Index
90-806934 1194 INSTRUMENTATION - 4D-15
Water Temperature Switch/Sender TESTING

When engine is COLD audio warning circuit is nor- 1. With engine COLD, remove wiring block from
mally open. switch/sender terminals. Note position on switch/
sender for terminal referred to as “W”
REMOVAL
1. Drain coolant from closed cooling system into a
suitable container, as outlined in SECTION 6B. b
2. Remove harness wiring block from temperature
switch/sender located as shown.

a c
b
a
70683

a - Water Temperature Switch/Sender

b - Terminal “W” - Audio Warning Switch Circuit

2. Refer to the proceeding and connect a continuity

meter between switch terminal “W” and sender
hex (case).
a. No continuity should exist.
70192
b. If continuity exists, replace sender.
Engines With Switch/Sender Mounted On Manifold
End Cover
3. To test switch circuit for closing (sound buzzer),
as if coolant temperature rises above operating
specifications, follow instructions “a ”- “f”:
a. Refer to ”Removal” as previously outlined and
remove the switch/sender.
b. Refer to top view of switch/sender in Step 1,
c b and using suitable jumper leads connect
a buzzer terminal “–” to switch terminal “W”.
Then, using suitable jumpers and being care-
ful to avoid short circuits, connect the nega-
tive (–) of a 12 volt power source to sender
case and the positive (+) to the “+” on the
buzzer, as shown following.

74284
Engines With Switch/Sender Mounted On Cylinder
Head
a - Harness Wiring Block
b - Water Temperature Switch/Sender
c - Sealing Washer

3. Remove switch/sender and sealing washer.

Index
4D-16 - INSTRUMENTATION 90-806934 1194
 ! WARNING c. Using suitable container, thermometer and
heat source, suspend switch with tip in sand.
The following test involves the use of intense
heat. Failure to follow appropriate procedures or d. Heat sand and observe temperature on
warnings can cause burns which can result in se- thermometer.
vere personal injury. While performing the follow- e. Replace switch/sender if it does not close
ing test, observe these general precautions: (sound buzzer) within the range of tempera-
• Wear personal protective clothing such as tures indicated in chart.
rubber gloves, a non-flammable apron, and f. Turn heat source “OFF”. Allow sand and com-
eye protection - preferably full face shield or ponents to cool.
safety glasses.
71772
• The appropriate heat source should only be
electric. Heat source should be operated by a
qualified person. Be sure to follow all instruc- e
tions of the manufacturer of the heat source.
The heat source should be checked each time d
it is used to be sure it is functioning properly.
• The thermometer used in the test should be a b
high- temperature thermometer with a maxi-
mum reading of at least 300°F (150°C). Under
no circumstances should the operator allow
temperatures to exceed test specifications.
• Perform test only in a well ventilated area.
a
• Use a suitable container, such as metal, to
hold the sand. Avoid use of glass containers
unless the operator first confirms for himself/ c
herself that the glass container is an appropri-
ate high-temperature vessel.
• Because the components will reach high tem- 70758
peratures DO NOT handle materials or com-
ponents until COMPLETELY cooled. a - Suitable Container
b - Thermometer
c - Heat Source
! WARNING d - Water Temperature Switch/Sender
e - 12 Volt Power Source and Jumper Leads
Use only clean, dry sand such as used for general f - Audio Warning Buzzer With Jumper Lead
sandblasting purposes. Use of sand containing
contaminants could result in hazards such as SWITCH
TEST TEMPERATURE
fire, short circuiting, hot-spots, or other hazards. CONDITION
215 - 220° F (102 - 106° C) Closed

INSTALLATION
1. Coat threads of switch/sender with Quicksilver
Perfect Seal and install with new sealing washer.
Maximum torque is 18 lb. ft. (25 N·m). DO NOT
OVER-TORQUE.
2. Connect harness wiring block.
3. Refill closed cooling system with approved cool-
ant as outlined in SECTION 6B.

Index
90-806934 1194 INSTRUMENTATION - 4D-17
Transmission Fluid Temperature
Switch
When transmission is COLD or at a temperature less
than as shown (See “Test Temperature Chart”follow-
ing.), the switch is open.
REMOVAL
1. Disconnect harness wires at switch.
2. Remove switch and sealing washer.
TESTING
1. With transmission COLD, connect one lead of an
ohmmeter to one terminal of transmission switch.
Connect the other lead of ohmmeter to other ter-
minal.
NOTE: Shown removed for visual clarity only.

a b

72771
a - Ohmmeter Leads
b - Transmission Fluid Temperature Switch
72770
a - Transmission Fluid Temperature Switch with Sealing
Washer
b - Harness Wires 2. Switch should read no continuity. Replace switch,
if continuity exists.
Hurth Transmissions (630A and 630V)

Index
4D-18 - INSTRUMENTATION 90-806934 1194
 ! WARNING c. As temperature rises, switch will close and
ohmmeter will indicate continuity. Refer to
The following test involves the use of intense chart below for specifications.
heat. Failure to follow appropriate procedures or
warnings can cause burns which can result in se-
vere personal injury. While performing the follow-
ing test, observe these general precautions:
• Wear personal protective clothing such as
rubber gloves, a non-flammable apron, and e
eye protection - preferably full face shield or
safety glasses.
b
• The appropriate heat source should only be
electric. Heat source should be operated by a
qualified person. Be sure to follow all instruc-
tions of the manufacturer of the heat source.
The heat source should be checked each time
it is used to be sure it is functioning properly. a
• The thermometer used in the test should be a d
high- temperature thermometer with a maxi- c
mum reading of at least 300°F (150°C). Under
no circumstances should the operator allow
temperatures to exceed test specifications.
72772
• Perform test only in a well ventilated area.
a - Suitable Container
• Use a suitable container, such as metal, to b - Thermometer
hold the sand. Avoid use of glass containers c - Heat Source
d - Transmission Fluid Temperature Switch
unless the operator first confirms for himself/
e - Ohmmeter Leads
herself that the glass container is an appropri-
ate high-temperature vessel.
• Because the components will reach high tem-
peratures DO NOT handle materials or com- SWITCH
TEST TEMPERATURE
ponents until COMPLETELY cooled. CONDITION
258 - 282° F (126 - 138° C) Closed
! WARNING 218 - 242° F (103 - 117° C) Open

Use only clean, dry sand such as used for general

sandblasting purposes. Use of sand containing
contaminants could result in hazards such as
fire, short circuiting, hot-spots, or other hazards.
3. Follow these instructions:
a. With an ohmmeter connected as outlined and
using suitable container, thermometer and
heat source, suspend sender with tip in sand.
b. Heat sand and observe thermometer.
4. Turn heat source off. Allow sand to cool. Note
thermometer reading to ensure switch opens at
specified temperature while cooling.
5. Replace switch if switch fails to either open or
close within the specified temperature.
INSTALLATION
1. Apply Quicksilver Perfect Seal to threads of trans-
mission fluid temperature switch.
2. Install switch with sealing washer in transmission
and tighten securely.
3. Reconnect harness wires and coat with Quicksil-
ver Liquid Neoprene.
4. Check transmission fluid level.

Index
90-806934 1194 INSTRUMENTATION - 4D-19
ELECTRICAL SYSTEMS

4
E
WIRING DIAGRAMS
Note:Refer to the following Service Bulletin regarding this section.

SB 96-2 Water In Fuel Module (WIF) Warning Light

INDEX
Table of Contents
Page
Wiring Colors for MerCruiser Diesel . . . . . . . . . . . . . 4E -1
Wire Color Abbreviations . . . . . . . . . . . . . . . . . . . . . . 4E -1
Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . 4E -2
MCM - D3.0L/150, D3.6L/180
and D4.2L/220 - Mando Alternator . . . . . . . . . . . 4E -2
MCM - D3.0L/150, D3.6L/180
and D4.2L/220 - Prestolite Alternator . . . . . . . . . 4E -3
MIE - D3.0L/150, D3.6L/180 and D4.2L/220
- Mando Alternator . . . . . . . . . . . . . . . . . . . . . . . . 4E -4
MIE - D3.0L/150, D3.6L/180 and D4.2L/220
- Prestolite Alternator . . . . . . . . . . . . . . . . . . . . . . 4E -5
Quicksilver Instrumentation . . . . . . . . . . . . . . . . . . . . 4E -6
MCM - D3.0L/150, D3.6L/150 and D4.2L/220 . . 4E -6
MIE - D3.0L/150, D3.6L/180 and D4.2L/220 . . . 4E -7
MCM - Second Station Instrumentation . . . . . . . 4E -8
MIE - Second Station Instrumentation . . . . . . . . 4E -9
Wiring Harness Connections
MCM - (Standard) . . . . . . . . . . . . . . . . . . . . . . . . 4E -10
MCM - (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 4E -11
MIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E -12

NOTE: If using other than Quicksilver instrumenta-

tion and harnesses, refer to manufacturers’ instruc-
tions.

- WIRING
4E -0 DIAGRAMS
- WIRING DIAGRAMS 90-806934 1194
INDEX
Wiring Colors for MerCruiser Diesel
Where Used
Color Code
Primary Usage Secondary Usage
Black All Grounds
Black/Yellow Engine Stop
Blue Instrument Lighting
Blue/Black Glow Plug Wait Switch
Blue/Tan Glow Plug Wait Lamp
Blue/White Glow Plugs
Brown Alternator Charge Lamp Reference Electrode-MerCathode
Brown/White Trim Sender to Trim Gauge
Gray Tachometer Signal
Green Glow Plug Temperature Sensor
Green/White Trim -“Down” Switch
Lt. Blue Oil Pressure Sender to Gauge
Lt. Blue/White Trim- “Up” Switch
Orange Alternator DC Output Anode Electrode-MerCathode
Pink Fuel Gauge Sender to Gauge
Purple Ignition Switch (+12 V)
Purple/White Trim-“Trailer” Switch
Red Unprotected Wires from Battery
Red/Purple Protected (Fused) Wires from Battery Protected (+ 12V) to Trim Panel
Tan Water Temperature Sender to Gauge
Tan/Black Water Temperature Switch Transmission Fluid Temperature Switch
Tan/Blue OIl / Water Alarms
Tan/White Oil Pressure Switch Drive Oil Level Switch
White/Green Spare
Yellow/Black Transmission Neutral Safety Switch
Yellow/Red Starter Switch to Starter Solenoid to
Neutral Start Switch

Wire Color Abbreviations

BLK Black RED Red
BLU Blue TAN Tan
BRN Brown WHT White
GRY Gray YEL Yellow
GRN Green LIT or LT Light
ORN Orange DRK Dark
PNK Pink
PUR or PPL Purple

90-806934 1194 WIRING DIAGRAMS - 4E -1

INDEX
Engine Wiring Diagrams See NOTE 4. BLK
BLU
BRN
=
=
=
BLACK
BLUE
BROWN
GRY = GRAY
GRN = GREEN
17 ORN = ORANGE
MCM - D3.0L/150, D3.6L/180 PPL
RED
=
=
PURPLE
RED

and D4.2L/220 - Mando Alternator TAN

WHT
=
=
TAN
WHITE

Electrical Box
16 YEL
LT
=
=
YELLOW
LIGHT
DRK = DARK

10
18
9
14
11 12

19
13 See NOTE 5.

15

1
2

See NOTE 1.

See NOTE 2.
4 See NOTE 3.
20
B A
3
4
5 2
1
8 6 5 1 - MerCathode Controller Negative (–)
2 6 3 7 Connection
7 2 - Trim Sender
1
10 4 6 BLK (1) 3 - Water Temperature Sender/Audio
5 A LT BLU (8) Warning Switch
4 - Starter
B TAN/BLK (3)
BRN (4) GRY (2)
NOT USED 5 - Oil Pressure Switch (Audio Warning)
WHT/GRN (5)
6 - Oil Pressure Sender
TAN (3) YEL/RED (7)
BLU/TAN (2) NOT USED 7 - Tachometer Magnetic Pickup
8 - Audio Warning Delay Relay
BRN/WHT (10)
BLK/YEL (1) NOT USED RED/PPL (6) 9 - Power Relay
TAN/BLU (4) 10- Start Relay
NOT USED PPL (5) 11- Pre-Glow Relay
12- 60 Amp Circuit Breaker
NOTE 1 : Wires - Not Used On MCM Engines 13- 60 Amp Circuit Breaker
NOTE 2 : Spare Wire - Not Used 14- Gear Lube Monitor Bottle
NOTE 3 : Connect wires together with screw and hex nut; apply liquid neoprene to connec- 15- Engine Ground [Negative (–)]
tion and slide rubber sleeve over connection. 16- Fuel Injection Pump
NOTE 4 : Items not present on 5-Cylinder models. 17- Glow Plugs
NOTE 5 : GRAY wire may be connected to alternator “P” terminal for tachometer signal. If con- 18- Fuel Solenoid 74420
nected in this manner, the GRAY and BLACK wire terminal ends at the Magnetic Pickup (Item 7) 19- Alternator - Mando
MUST be disconnected and protected with at least two layers of electrical tape. 20- Battery

4E -2 - WIRING DIAGRAMS 90-806934 1194

INDEX
MCM - D3.0L/150, D3.6L/180 See NOTE 4. BLK
BLU
=
=
BLACK
BLUE
and D4.2L/220 - Prestolite Alternator 17 BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PPL = PURPLE
RED = RED
TAN = TAN
16 WHT = WHITE
Electrical Box 14 YEL
LT
=
=
YELLOW
LIGHT
DRK = DARK

10
18
9
14
11 12

19

See NOTE 5.
13
15

1
2

See NOTE 1.

See NOTE 2.
4 See NOTE 3.

B A 20

3
4
5 2
1
8 6 5 1 - MerCathode Controller Negative (–)
Connection
2 6 3 7 2 - Trim Sender
1 7 3 - Water Temperature Sender/Audio
10 4 6
Warning Switch
5
NOTE 1 : Wires - Not Used On MCM Engines 4 - Starter
NOTE 2 : Spare Wire – Not Used 5 - Oil Pressure Switch (Audio Warning)
NOTE 3 : Connect wires together with screw and hex nut; apply liquid neoprene to connection 6 - Oil Pressure Sender
and slide rubber sleeve over connection. 7 - Tachometer Magnetic Pickup
NOTE 4 : Items not present on 5-Cylinder models. 8 - Audio Warning Delay Relay
NOTE 5: GRAY wire may be connected to alternator “AC” terminal for tachometer signal. If con- 9 - Power Relay
nected in this manner, the GRAY and BLACK wire terminal ends at the Magnetic Pickup (Item 7) 10- Start Relay
MUST be disconnected and protected with at least two layers of electrical tape. 11- Pre-Glow Relay
BLK (1) 12- 60 Amp Circuit Breaker
A LT BLU (8) 13- 60 Amp Circuit Breaker
B TAN/BLK (3)
BRN (4)
WHT/GRN (5)
GRY (2)
NOT USED
14- Gear Lube Monitor Bottle (Two Styles)
15- Engine Ground [Negative (–)]
TAN (3) YEL/RED (7)
16- Fuel Injection Pump
BLU/TAN (2) NOT USED 17- Glow Plugs
BRN/WHT (10) 18- Fuel Solenoid 74297
BLK/YEL (1) NOT USED RED/PPL (6) 19- Alternator - Prestolite
TAN/BLU (4)
NOT USED PPL (5)
20- Battery

90-806934 1194 WIRING DIAGRAMS - 4E -3

INDEX
MIE - D3.0L/150, D3.6L/180 and See NOTE 3. BLK = BLACK
D4.2L/220 - Mando Alternator BLU
BRN
=
=
BLUE
BROWN
17 GRY
GRN
=
=
GRAY
GREEN
ORN = ORANGE
PPL = PURPLE
RED = RED
TAN = TAN

Electrical Box
16 WHT
YEL
=
=
WHITE
YELLOW
LT = LIGHT
DRK = DARK

10
18
9
11 12

19
13 See NOTE 4.
14
15

See NOTE 1.

See NOTE 1.

4 See NOTE 2. 3

B A

3
4
5 2
1
8 6 5 1 - Water Temperature Sender/Audio
Warning Switch
2 6 3 7 2 - Transmission Fluid Temperature Audio
1 7 Warning Switch
10 4 6 BLK (1) 3 - Transmission Neutral Safety Start Switch
5
A LT BLU (8) 4 - Starter
5 - Oil Pressure Switch (Audio Warning)
B TAN/BLK (3)
BRN (4) GRY (2)
NOT USED 6 - Oil Pressure Sender
WHT/GRN (5)
7 - Tachometer Magnetic Pickup
TAN (3) YEL/RED (7)
BLU/TAN (2) NOT USED 8 - Audio Warning Delay Relay
9 - Power Relay
BRN/WHT (10)
BLK/YEL (1) RED/PPL (6) 10- Start Relay
NOT USED TAN/BLU (4) 11- Pre-Glow Relay
NOT USED PPL (5)
12- 60 Amp Circuit Breaker
13- 60 Amp Circuit Breaker
14- Wires Not Used on MIE Engines
NOTE 1 : Wires - Not Used On MIE Engines 15- Engine Ground [Negative (–)]
NOTE 2 : Spare Wire – Not Used 16- Fuel Injection Pump
NOTE 3 : Items not present on 5 cylinder models. 17- Glow Plugs
NOTE 4 : GRAY wire may be connected to alternator “P” terminal for tachometer signal. If 18- Fuel Solenoid 74432
connected in this manner, the GRAY and BLACK wire terminal ends at the Magnetic Pickup 19- Alternator - Mando
(Item 7) MUST be disconnected and protected with at least two layers of electrical tape. 20- Battery

4E -4 - WIRING DIAGRAMS 90-806934 1194

INDEX
MIE - D3.0L/150, D3.6L/180 and D4.2L/220 - Prestolite Alternator
See NOTE 3.

16

Electrical Box
15
10

18
17

11 12

See NOTE 4.
9

See NOTE 1.
13
14
8

See NOTE 1.

See NOTE 1.

See NOTE 2.
4
BLK = BLACK 19
BLU = BLUE
B A BRN = BROWN
6 5 3
GRY = GRAY
GRN = GREEN
ORN = ORANGE
4 1 PPL = PURPLE
3 5 2 8 1 - Water Temperature Sender/Audio
RED = RED
2 6 3 7 TAN = TAN Warning Switch
WHT = WHITE 2 - Transmission Fluid Temperature Audio
1 7 YEL = YELLOW
10 4 6 LT = LIGHT Warning Switch
5 DRK = DARK 3 - Transmission Neutral Safety Start Switch
A BLK (1)
LT BLU (8)
4 - Starter
5 - Oil Pressure Switch (Audio Warning)
B BRN (4) GRY (2)
NOT USED 6 - Oil Pressure Sender
TAN/BLK (3) WHT/GRN (5)
7 - Tachometer Magnetic Pickup
TAN (3) YEL/RED (7) 8 - Audio Warning Delay Relay
BLU/TAN (2) NOT USED
9 - Power Relay
BRN/WHT (10) 10- Start Relay
BLK/YEL (1) NOT USED RED/PPL (6)
TAN/BLU (4) 11- Pre-Glow Relay
NOT USED PPL (5) 12- 60 Amp Circuit Breaker
13- 60 Amp Circuit Breaker
NOTE 1 : Wires - Not Used On MIE Engines 14- Engine Ground [Negative (–)]
NOTE 2 : Spare Wire – Not Used 15- Fuel Injection Pump
NOTE 3 : Items Not Present On 5 Cylinder Engines 16- Glow Plugs
NOTE 4 : GRAY wire may be connected to alternator “AC” terminal for tachometer signal. If 17- Fuel Solenoid
connected in this manner, the GRAY and BLACK wire terminal ends at the Magnetic Pickup 18- Alternator – Prestolite
(Item 7) MUST be disconnected and protected with at least two layers of electrical tape. 74327
19- Battery

90-806934 1194 WIRING DIAGRAMS - 4E -5

INDEX
Quicksilver Instrumentation
MCM - D3.0L/150, D3.6L/150
and D4.2L/220
1 -
Oil Pressure 8 - Light Switch and Audio Test 1
2 -
Tachometer 9 - Stop Switch
3 -
Trim Gauge 10- Keyswitch
4 -
Coolant Temperature 11- 20-Amp Fuse and Holder
5 -
Voltmeter 12- Audio Warning Buzzers
6 -
Cruise Log (Engine Hour 13- Spare Wires - (Not Used)
Meter) (See NOTE 1.) 14- Remote Control - 2
7 - Engine System Monitor - (Neutral Safety Circuit)
a.-PreHeat, b.-Alternator,
c.-Oil Pressure, d.-Coolant Temp.
NOTE 1: May be wired to any PPL (that is key switched),
and BLK.
3
NOTE 2: Connect wires together with screw and hex nut;
apply Liquid Neoprene to connection and slide rubber sleeve
over connection.

12 4

12 11 6

10

I S
B
9

14 8

13
a

b
7
c
A B See NOTE 2.
d
8 1 2 7
6
5
7 3 4
UP

4 1 3 8
10 6 5 2

BLK = BLACK
A BLK (1)
GRY (2)
B BLK (7)
TAN/WHT (6)
WHT/GRN (5)
BLU
BRN
=
=
BLUE
BROWN
LT BLU (8) GRY = GRAY
BRN/WHT (10) GRN = GREEN
ORN = ORANGE
BLK (8) BRN (4) PPL = PURPLE
YEL/RED (7) TAN (3) RED = RED
TAN = TAN
WHT = WHITE
BLK/YEL (1) TAN/BLK (3) YEL = YELLOW
RED/PPL (6) TAN/BLU (4)
BLU/TAN (2) LT = LIGHT
PPL (5) DRK = DARK 74066

4E -6 - WIRING DIAGRAMS 90-806934 1194

INDEX
MIE - D3.0L/150, D3.6L/180 and
D4.2L/220

1 - Oil Pressure 8 - Light Switch and Audio Test 1

2 - Tachometer
3 - Wires Not Used
(See NOTE 1.)
4 - Coolant Temperature
5 - Voltmeter
6 - Cruise Log (Engine Hour
Meter) (See NOTE 2.)
7 - Engine System Monitor -
a.-PreHeat, b.-Alternator,
c.-Oil Pressure, d.-Coolant Temp.
9 - Stop Switch
10- Keyswitch
11- 20-Amp Fuse and Holder
12- Audio Warning Buzzers
13- Spare Wires - (Not Used)
2

NOTE 1 : Tape each wire separately with at least two layers of elec- 3
trical tape.
NOTE 2 : May be wired to any PPL (that is key switched), and BLK.

12 4

12 11 6

10

13
a

b
7
A B c

d
8 1 2 7
6
5
7 3 4
UP

4 1 3 8
10 6 5 2
73603
BLK (1)
A GRY (2)
B TAN/WHT (6)
BLK = BLACK RED = RED
LT BLU (8) BLK (7) WHT/GRN (5)
BLU = BLUE TAN = TAN
BRN/WHT (10) BRN = BROWN WHT = WHITE
BLK (8) GRY = GRAY YEL = YELLOW
BRN (4)
YEL/RED (7) TAN (3) GRN = GREEN LT = LIGHT
ORN = ORANGE DRK = DARK
PPL = PURPLE
BLK/YEL (1) TAN/BLK (3)
RED/PPL (6) TAN/BLU (4)
BLU/TAN (2)
PPL (5)

90-806934 1194 WIRING DIAGRAMS - 4E -7

INDEX
MCM - Second Station Instrumentation
1 -
Oil Pressure (See NOTE 4.) 8 - Stop Switch 1
2 -
Tachometer 9 - Start Switch
3 -
Trim Gauge (See NOTE 4.) 10- 20-Amp Fuse and Holder
4 -
Wire(s) Not Used 11- Audio Warning Buzzers
(See NOTE 1.) 12- Spare Wires - (Not Used)
5 - Voltmeter (See Note 3 and 4.) 13- Remote Control - 2
6 - Engine System Monitor (Neutral Safety Circuit)
7 - Light Switch and Audio Test

NOTE 1: Tape each wire separately with at least two layers

of electrical tape.
NOTE 2: Connect wires together with screw and hex nut;
apply Liquid Neoprene to connection and slide rubber 3
sleeve over connection.
NOTE 3: May be wired to any PPL (that is key switched),
and BLK.
NOTE 4: Items 1, 3, and 5 are not included in this Second
Station Kit. Order separately, if desired.

4 See Note 1.
11
5

11 10 See
Note 1.
3

7
13
12

6
a b See NOTE 2.

8 1 2 7
6
5
7 3 4
UP

4 1 3 8
10 6 5 2

BLK (1)
a b TAN/WHT (6)
GRY (2) BLK = BLACK RED = RED
LT BLU (8) BLK (7) WHT/GRN (5)
BLU = BLUE TAN = TAN
BRN/WHT (10) BRN = BROWN WHT = WHITE
BLK (8) GRY = GRAY YEL = YELLOW
BRN (4)
YEL/RED (7) TAN (3) GRN = GREEN LT = LIGHT
ORN = ORANGE DRK = DARK
PPL = PURPLE
BLK/YEL (1) TAN/BLK (3)
RED/PPL (6) TAN/BLU (4)
BLU/TAN (2)
PPL (5)
74065

With Remote Control Neutral Safety Switch Wired at Instrumentation

4E -8 - WIRING DIAGRAMS 90-806934 1194

INDEX
MIE - Second Station Instrumentation

1 - Oil Pressure 5 - Engine System Monitor 1

(See NOTE 4.) 6 - Light Switch and Audio Test
2 - Tachometer 7 - Stop Switch
3 - Wire(s) Not Used 8 - Start Switch
(See NOTE 1.) 9 - 20-Amp Fuse and Holder
4 - Voltmeter 10- Audio Warning Buzzers 2
(See NOTE 4.) 11- Spare Wires - (Not Used)

NOTE 1: Tape each wire separately with at least two layers

of electrical tape.
NOTE 2: Connect wires together with screw and hex nut;
apply Liquid Neoprene to connection and slide rubber
sleeve over connection.
NOTE 3: May be wired to any PPL (that is key switched),
and BLK. 3 See Note 1.
NOTE 4: Items 1 and 4 are not included in this Second Sta-
tion Kit. Order separately, if desired.

3 See Note 1.
10
4

10 9 See
Note 1.
3

11

5
a b

8 1 2 7
6
5
7 3 4
UP

4 1 3 8
10 6 5 2

BLK (1)
a b TAN/WHT (6)
GRY (2) BLK = BLACK RED = RED
LT BLU (8) BLK (7) WHT/GRN (5)
BLU = BLUE TAN = TAN
BRN/WHT (10) BRN = BROWN WHT = WHITE
BLK (8) GRY = GRAY YEL = YELLOW
BRN (4)
YEL/RED (7) TAN (3) GRN = GREEN LT = LIGHT
ORN = ORANGE DRK = DARK
PPL = PURPLE
BLK/YEL (1) TAN/BLK (3)
RED/PPL (6) TAN/BLU (4)
BLU/TAN (2)
PPL (5)
74067

90-806934 1194 WIRING DIAGRAMS - 4E -9

INDEX
Wiring Harness Connections
MCM - Wiring Harness Connections (Standard)
Secondary Station Primary Station

See Note.

c See Note.

b
a

d
a - “Y” Harness
b - “T” Harness
c - Extension Harnesses (Primary to Secondary Instrumentation)
d - Extension Harnesses (To Engine)

Note: Connect these wires together with a screw and

nut. Coat with Liquid Neoprene and slide rubber sleeve
over connection.
74069

MCM - With Remote Control Neutral Safety Switches Wired at Instrumentation

4E -10 - WIRING DIAGRAMS 90-806934 1194
INDEX
MCM - Wiring Harness Connections (Optional)
Secondary Station Primary Station

b
a

c See Note:
See Note:

d
a - “Y” Harness
b - “T” Harness
c - Extension Harnesses (Primary to Secondary Instrumentation)
d - Extension Harnesses (To Engine)

Note: Connect these wires together with a screw and

nut. Coat with Liquid Neoprene and slide rubber sleeve
over connection.

74068

MCM - With Remote Control Neutral Safety Switches Wired at Harnesses

90-806934 1194 WIRING DIAGRAMS - 4E -11

INDEX
MIE - Wiring Harness Connections
Secondary Station Primary Station

See Note.

c See Note.

b
a

d
a - “Y” Harness
b - “T” Harness
c - Extension Harnesses (Primary to Secondary Instrumentation)
d - Extension Harnesses (To Engine)

Note: Connect these wires together with a screw and

nut. Coat with Liquid Neoprene and slide rubber sleeve
over connection.

74070

MIE - Harnesses

4E -12 - WIRING DIAGRAMS 90-806934 1194

INDEX
FUEL SYSTEMS
1
A
2
A
3
A
4
A
74475
5
FUEL DELIVERY PUMP
and FUEL FILTER
A
Note:Refer to the following Service Bulletins regarding this section.

SB 95-16 Low Sulfur Diesel Fuels

6
SB 95-9 Diesel Fuel Filters and Fuel Additives

A
A 7
INDEX
Table Of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Fuel Pump Specifications . . . . . . . . . . . . . . . . . . . . . 5A-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Tools / Lubricants / Sealants . . . . . . . . . . . . . . . . . . 5A-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Fuel Pump and Filter Description . . . . . . . . . . . 5A-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Exploded View - Fuel Pump and Fuel Filter . . . . . 5A-3
Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Fuel Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6
Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 5A-8
Water Separating Fuel Filter Replacement . . . . . . 5A-9
Water Bleed Valve Operation . . . . . . . . . . . . . . . . . 5A-10
Purging Air from Fuel System
- Priming Injection Pump . . . . . . . . . . . . . . . . . . . . . 5A-11

5A––FUEL
5A-0 FUELDELIVERY
DELIVERYPUMP
PUMPAND
ANDFUEL
FUELFILTER
FILTER 90-806934 1194
INDEX
Identification General

Fuel Pump and Filter Description

The fuel delivery pump is of the diaphragm type and
is mounted on the side of the engine block. It is
operated by the camshaft, and on all models is
equipped with an external lever to assist in priming
the injection pump and purging air from fuel system.
The fuel filter is mounted next to the fuel pump. It is
a water-separating filter and is equipped with a water
bleed valve at the bottom of the canister.
70163

Precautions

Fuel Pump Specifications ! WARNING

SPECIFICATIONS ALWAYS disconnect battery cables from battery
Measured at 2500 RPM, No Load BEFORE working on fuel system to prevent fire.
This eliminates the engine wiring as a potential
85 U. S. Qts. (80 L)
Fuel Flow per Minute source of ignition.
at 2500 RPM
2-5 PSI
Pressure ! WARNING
(13.8 - 34.5 kPa)
Be careful when changing fuel system
components; diesel fuel is flammable. Be sure
Torque Specifications that ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
DESCRIPTION Lb. Ft. N·m fuel system components. Wipe up any spilled
Filter Header-to-Bracket 24 32 fuel immediately. DO NOT allow fuel to come into
contact with any hot surface which may cause it
Pump-to-Block 18 24 to ignite.
Hand Tighten
Fuel Filter-to-Header Only, Until
Secure
All Fasteners Not Otherwise Tighten
Listed Securely

Tools / Lubricants / Sealants

PART
DESCRIPTION
NUMBER
Quicksilver Perfect Seal 92-34227
Quicksilver Needle Bearing As-
92-825265A1
sembly Lubricant
#592 Loctite Pipe Sealant
with Teflon
Obtain Locally
Fuel Pressure Gauge [0-15 PSI
(0-103.35 kPa)]

90-806934 1194 FUEL DELIVERY PUMP AND FUEL FILTER – 5A-1

INDEX
 ! WARNING
Dispose of fuel soaked rags, paper, etc. in an
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
Make sure that no fuel leaks exist, before closing
engine hatch.
! CAUTION
DO NOT operate engine without cooling water
being supplied to seawater pickup pump or
pump impeller will be damaged, and subsequent
overheating damage may result.
5A-2 – FUEL DELIVERY PUMP AND FUEL FILTER
INDEX
Fuel Lines
! WARNING
Boating industry standards (NMMA, ABYC, etc.)
federal standards and Coast Guard regulations
must be adhered to when installing fuel delivery
system.
The fuel lines must be well secured. Fuel line with a
5/16 in. (10 x 8) ID must be used. The holes where
the line runs through bulkheads should be carefully
rounded off or protected with rubber grommets. This
prevents damage to the lines from abrasion.
A fuel return line between engine and fuel tank is
required, having the same size ID as the fuel supply
line.
1. Fuel pickup should be at least 1 in. (25mm) from
the bottom of fuel tank, to prevent picking up
impurities.
2. Dual installations: use a separate pickup, supply
line and separate fuel return line, for each
engine.
3. On installations requiring long lines or numerous
fittings, larger size lines should be used.
4. Fuel line(s) should be installed free of stress and
firmly secured to prevent vibration and/or chaf-
ing.
5. Sharp bends in fuel line should be avoided.
6. A flexible fuel line must be used to connect fuel
line to inlet on fuel pump, to absorb deflection
when engine is running. Injector pump fuel
return line must also have a flexible rubber hose
segment.
90-806934 1194
Exploded View - Fuel Pump and Fuel Filter

21

22 10

23

8 17
16
15 18
13 19 b 20

14 2 11

12 10
9
14

10
3
9 10
a 4
A
1

c 5

7
74475
1 - Bracket 20- Fuel Inlet Fitting
2 - Screw 21- Fuel Pump Cover (Removed for visual clarity
3 - Lockwasher of Items 19 - 20.)
4 - Nut 22- Diaphragm
5 - Fuel Filter 23- Diaphragm Spring
6 - O-Ring
7 - Drain Cap
8 - Pipe, Pump-to-Filter Header Lubricant/Sealant Application Points
9 - Banjo Bolt (3)
10- Sealing Washer A Clean Motor Oil
11- Filter Bracket
12- Pipe, Filter Header-to-Injection Pump Torque Specifications
13- Banjo Bolt
14- Sealing Washers a 24 lb. ft. (32 N·m)
15- Fuel Pump b 18 lb. ft. (24 N·m)
16- O-Ring
17- Stud (2) c Hand Tighten Only
18- Lockwasher (2)
19- Nut (2)

90-806934 1194 FUEL DELIVERY PUMP AND FUEL FILTER – 5A-3

INDEX
Fuel Pump Removal 3. Remove banjo bolt at fuel filter. Discard sealing
washers.

! WARNING b b a
ALWAYS disconnect battery cables from battery
BEFORE working on fuel system to prevent fire
or explosion.
a
1. Disconnect battery cables from battery.

! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
b
serious bodily injury or death.

! WARNING
Be careful when changing fuel system
components; diesel fuel is flammable. Be sure 73332
that ignition key is OFF. DO NOT smoke or allow a - Banjo Bolt
sources of open flame in the area while changing b - Sealing Washers
fuel system components. Wipe up any spilled
fuel immediately. Dispose of rags appropriately. 4. Remove mounting nuts and remove pump.
DO NOT allow fuel to come into contact with any Discard O-ring.
hot surface which may cause it to ignite.
b
2. Remove fuel supply hose. Plug hose to prevent
fuel from leaking into boat. a

73332

a - Fuel Supply Hose 73332

a - Mounting Nut With Lockwasher (2)

b - O-Ring

5A-4 – FUEL DELIVERY PUMP AND FUEL FILTER 90-806934 1194

INDEX
Fuel Pump Repair 3. Remove cover exposing pump diaphragms and
one-way valves.
DISASSEMBLY
1. Remove banjo bolts and fuel lines. Discard
sealing washers.

70194

a - Pump Diaphragms
b - One-Way Valves
4. Remove one-way valve carrier from cover.

70162

a - Banjo Bolts, with Sealing Washers

b - Fuel Lines
2. Take note of fuel line positions or mark cover to
70164
aid in reassembly. Remove 6 cover screws.

70206

a - One-Way Valve Carrier

b - Cover

70169

a - Fuel Line Positions

b - Cover Screws, with Washers
c - Mark Cover (if so desired)

90-806934 1194 FUEL DELIVERY PUMP AND FUEL FILTER – 5A-5

INDEX
5. Remove from cover and inspect O-ring and 7. Remove spacer from between diaphragms.
spacer for damage.

70165 70166

a - Spacer
b - Diaphragms
8. Clean parts in solvent. Dry with compressed air.

ASSEMBLY
1. Install spacer between diaphragms.

70168

a - Cover
b - O-ring
c - Spacer
6. Press down and turn diaphragm 1/4 turn to
disengage rod from pump arm.

70166

a - Spacer
b - Diaphragms

70167

a - Diaphragm
b - Rod
c - Pump Arm

5A-6 – FUEL DELIVERY PUMP AND FUEL FILTER 90-806934 1194

INDEX
2. Place spring on rod and install in pump housing. 4. Install one-way valve carrier in cover, as shown.
Push in and turn diaphragm 1/4 turn to hold
in place.

70164

a - One-Way Valve Carrier

b - Cover

5. Install cover on pump housing in position as

noted or marked during disassembly.

70167

a - Spring
b - Rod, Diaphragm
c - Pump Housing

3. Install spacer and O-ring in cover, as shown.

70163

a - Cover (Position Properly)

b - Pump Housing

70165

a - Spacer
b - O-ring
c - Cover

90-806934 1194 FUEL DELIVERY PUMP AND FUEL FILTER – 5A-7

INDEX
6. Align holes in cover, diaphragm, spacer, and 2. Using a new O-ring, install fuel pump on engine
housing. Install screws and tighten securely. block. Tighten mounting nuts securely.
3. Using 2 new sealing washers on banjo bolt,
attach fuel line to filter mount. Tighten all banjo
bolts securely.
4. Connect fuel supply hose. Tighten clamp
securely.

a b b a

b e
70169
d
a - Screws (6)

Fuel Pump Installation

IMPORTANT: Avoid a decrease in engine perfor- c
mance. Restrictions of either fuel supply or fuel
return circuits will adversely affect engine per- d
formance.
1. Using 2 new sealing washers on each banjo bolt,
attach fuel lines to fuel pump as shown. Leave
banjo bolts finger-tight to aid in alignment with
fuel filter mount. 73332

a - Banjo Bolt
b - Sealing Washer
c - O-Ring
d - Mounting Nuts and Lockwashers
e - Hose Clamp
f - Fuel Supply Hose

70162

a - Banjo Bolts, with Two New Sealing Washers Each

b - Fuel Lines (Attach as Shown)

5A-8 – FUEL DELIVERY PUMP AND FUEL FILTER 90-806934 1194

INDEX
Water Separating Fuel Filter IMPORTANT: Element cannot be cleaned and
reused. It must be replaced.
Replacement 3. Turn water bleed valve counterclockwise and re-
move from old filter. Install it on new filter turning
! WARNING clockwise. Tighten securely. (Note position of O-
ring seal.)
ALWAYS disconnect battery cables from battery
BEFORE working on fuel system to prevent fire.
This eliminates the engine wiring as a potential
source of ignition.
! WARNING
Be careful when changing water separating fuel
filter. Diesel fuel is flammable. Be sure ignition
key is OFF. Do not allow fuel to come into contact
with any hot surface which may cause it to ignite.
Do not allow sources of open flame in the area.

1. Disconnect battery cables from battery.

NOTE: Use a suitable container to catch excess fuel.

! WARNING
Wipe up any spilled fuel immediately and
dispose of fuel soaked rags, paper, etc., in an
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and 70160
result in a fire hazard which could cause serious
bodily injury or death. a - Water Bleed Valve
b - O-ring Seal
2. Remove filter element from header mounting. A 4. Coat sealing ring on new filter with clean motor
filter wrench may be needed to loosen element. oil. Thread filter clockwise onto bracket and tight-
en securely by hand. Do not use a filter wrench.

73332

a
a

71370

70161 a - Water Separating Fuel Filter

b - Sealing Ring (Lubricate)
a - Fuel Filter Element
c - Fuel Filter Header

90-806934 1194 FUEL DELIVERY PUMP AND FUEL FILTER – 5A-9

INDEX
5. Follow instructions “a” - “c”: Water Bleed Valve Operation
1. Using a suitable container to catch water, push
NOTE: Place a suitable container under fuel filter to
water bleed valve in (UP), as shown.
catch excess fuel.

a. Loosen bleed screw (on header flange).

b. Operate pump/primer lever UP and DOWN
until bubble-free fuel flows from bleed screw.
c. Close bleed screw.
b

a
a
71370

a - Water Bleed Valve

2. Release valve when clear fuel flows from nozzle.

Valve is spring-loaded and will shut-off when
73332
released.
a - Pump/Primer Lever on Fuel Pump
b - Bleed Screw

6. Connect battery cables.

7. Start engine, check for fuel leaks.

5A-10 – FUEL DELIVERY PUMP AND FUEL FILTER 90-806934 1194

INDEX
Purging Air from Fuel System 2. Loosen bleed screw on injection pump.

- Priming Injection Pump

! WARNING
ALWAYS disconnect battery cables from battery
BEFORE working on fuel system to prevent fire.
This eliminates the engine wiring as a potential
source of ignition.

! WARNING 73321

Make sure that no fuel leaks exist, before closing

engine hatch.

! WARNING
a
Be careful when changing fuel system
components; diesel fuel is flammable. Be sure
that ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled
fuel immediately. DO NOT allow fuel to come into
contact with any hot surface which may cause it 71371
to ignite.

a - Bleed Screw, Injection Pump

! WARNING
3. Operate pump/primer lever UP and DOWN until
Dispose of fuel soaked rags, paper, etc. in an
bubble-free fuel flows from bleed screw.
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.

NOTE: Place suitable container under fuel filter and

injection pump to catch excess fuel.
1. Bleed air from Water Separating Fuel Filter as
outlined previously (refer to Water Separating
Fuel Filter Replacement section).
71371
a

73332
a - Pump/Primer Lever

4. Close bleed screw on injection pump. Tighten se-

curely.
5. Connect battery cables.
6. Start engine. Check for leaks.

90-806934 1194 FUEL DELIVERY PUMP AND FUEL FILTER – 5A-11

INDEX
FUEL SYSTEM
1
A
2
A
3
A
4
A
50397
5
INJECTION PUMP
B
6
A
A 7
Index
Table Of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
Pump Code and I.D. Number Location . . . . . . 5B-1
Pump Code and Identification Number . . . . . . . . . 5B-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
Lubricants / Sealants . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . 5B-4
Diesel Fuel in Cold Weather . . . . . . . . . . . . . . . 5B-4
Fuel Injection Pump Repair and Service . . . . . . . . 5B-4
Exploded Views - Injection Pump and
Related Components . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . 5B-6
Fuel Injection Pump Installation . . . . . . . . . . . . . . . 5B-10
Installation With Engine Assembled . . . . . . . . . 5B-10
Installation During Engine Reassembly . . . . . . 5B-12
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . 5B-14
Checking Timing . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Setting Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Starting Engine – After Fuel Injection Pump
Installation and Timing . . . . . . . . . . . . . . . . . . . . . . 5B-18

Index
5B –– INJECTION
5B-0 INJECTION PUMP
PUMP 90-806934 1194
Identification Pump Code and
Identification Number
Pump Code and I.D. Number Location Engine - MCM Pump Code and Identification
and MIE Number
Code: VE 5/11F 1900 L179
Bosch Part Number:
D3.0L/150 0460 415007
(Quicksilver Part Number:
801763706)
Code: VE 6/11F 1900 L178
Bosch Part Number:
D3.6L/180 0460 416035
(Quicksilver Part Number:
801763466)
Code: VE 6/11F 1800 L363
Bosch Part Number:
D4.2L/220 0460 416064
50536
(Quicksilver Part Number:
816550)

Specifications
Manufacturer Robert Bosch Corporation
Distributor Type VE-L with
Type of Injection
Manifold-Pressure
Pump
Compensator
Ejection Pressure at 2248.12 psi
Fuel Injectors (15,500 kPa)
Delivery Begins 6° BTDC
Governor Type Centrifugal

50397 Torque Specifications

a - Pump Code and I.D. Number Location
DESCRIPTION Lb. Ft. N·m
Pump Mounting Nuts 23 31
Pump Gear 66 90
Fuel Line Fittings
13 18
(High Pressure)

Index
90-806934 1194 INJECTION PUMP – 5B-1
Special Tools Description
QUICKSILVER
General
DESCRIPTION PART NUMBER
Graduated Disc 91-801333500 MerCruiser Diesel Engines use Bosch, Type VE,
Distributor Fuel Injection Pumps. The pump is
Crankshaft Tool 91-814827 engine driven off the camshaft gear. It is timed to
Injection Pump Gear deliver the correct amount of fuel to the fuel injectors.
91-818371 Injection pump pressure, at the fuel injectors,
Puller (Note 1.)
Injection Pump Gear exceeds 2000 P.S.I. (13,790 kPa). Pressure valves
91-818372 on the outlets of the pump make sure that a certain
Puller (Note 2.)
initial pressure is always in the lines leading to the
Injection Pump Adaptor injectors. Because these engines are turbo-
91-801333510
Tool, Metric charged, the injection pump uses a manifold
Injection Pump Adaptor pressure compensator to reduce the amount of fuel
91-813658
Tool, S.A.E. injected during low turbo boost conditions. This
reduces exhaust smoke at low engine RPM.
Note 1 : For use on D3.0L/150 and D3.6L/180 engines.
Note 2 : For use on D4.2L/220 engines. The timing-advance device advances timing up to 24
crankshaft degrees. There is also a governor built into
the injection pump. The pump’s high speed screw is
Lubricants / Sealants preset and sealed at the Bosch factory. Do not attempt
to adjust this screw. Diesel engines are stopped by
DESCRIPTION PART NUMBER shutting off the fuel supply. The injection pump is
equipped with two means of fuel shut off, electrical and
Quicksilver RTV Sealer 92-91601 1
mechanical. The electrical shut off is a solenoid valve
Loctite 242 Obtain Locally operated by the stop button in the instrument panel.
The mechanical shut off is a lever location on the
injection pump. A cold start lever is also located on the
side of the pump. It is used to help start the engine
when outside air temperature is below 50
F (10
C).

Index
5B-2 – INJECTION PUMP 90-806934 1194
Precautions
! WARNING
Electrical system components on this engine are
not external ignition protected. DO NOT STORE
OR UTILIZE GASOLINE ON BOATS EQUIPPED
WITH THESE ENGINES, UNLESS PROVISIONS
HAVE BEEN MADE TO EXCLUDE GASOLINE
VAPORS FROM ENGINE COMPARTMENT (ref: 33
CFR). Failure to comply could result in fire,
explosion and/or severe personal injury.
! WARNING
Always disconnect battery cables from battery
BEFORE working on fuel system to prevent fire.
This eliminates the engine wiring as a potential
source of ignition.
! CAUTION
It is good practice to ventilate the engine
compartment prior to servicing any engine
components to remove any fuel vapors which
may cause difficulty breathing or be an irritant.
Index
90-806934 1194
! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
serious bodily injury or death. Careful periodic
inspection of entire fuel system is mandatory,
particularly after storage. All fuel components
including fuel tanks, whether plastic, metal or
fiberglass, fuel lines, primers, fittings, and fuel
filters should be inspected for leakage,
softening, hardening, swelling or corrosion. Any
sign of leakage or deterioration requires
replacement before further engine operation.
! WARNING
Be careful when changing fuel system
components; diesel fuel is flammable. Be sure
that ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled
fuel immediately. Dispose of rags appropriately.
DO NOT allow fuel to come into contact with any
hot surface which may cause it to ignite.
! WARNING
Dispose of fuel soaked rags, paper, etc. in an
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
INJECTION PUMP – 5B-3
Fuel Requirements Diesel Fuel in Cold Weather

! WARNING ! WARNING
Under   

should gasoline be Under   

should gasoline be
mixed with diesel fuel for any reason. This mixture
of gasoline and diesel fuel is highly flammable and
produces a significant risk to the user.
IMPORTANT: Use of improper or water
contaminated diesel fuel can damage the engine
seriously. Use of improper fuel is considered
misuse of engine, and damage caused thereby
will not be covered by warranty.
Grade 2-D diesel fuel is required, meeting ASTM
Standards D975 (or fuel rated Diesel DIN 51601),
and having a minimum cetane rating of 45.
The Cetane number is a measure of the ignition
quality of diesel fuel. Increasing the cetane number
will not improve overall engine performance, but it
may be necessary to raise the cetane rating for low
temperature, or high altitude use.
Sulphur content of the above fuel is rated at 0.50%
by weight, maximum (ASTM). Limits may vary in
countries outside of the United States.
On intermittent use engines, high sulphur content
diesel fuel will greatly increase:
D Corrosion of metal parts.
D Deterioration of elastomer and plastic parts.
D Corrosion and extensive damage, and excessive
wear of internal engine parts, particularly
bearings.
D Starting and operating difficulties.
Index
5B-4 – INJECTION PUMP
mixed with diesel fuel for any reason. This mixture
of gasoline and diesel fuel is highly flammable and
produces a significant risk to the user.
Unaltered diesel fuels thicken and “gel” in cold
temperatures, unless treated. Virtually all diesel fuels
are “climatized” to allow their use in the particular
region for that time of the year. If it becomes
necessary to further treat diesel fuel, it is the
owner/operator’s responsibility to add a commercial
“standard brand” “anti-gel” diesel fuel additive,
following that product’s directions.
Fuel Injection Pump Repair
and Service
The Robert Bosch Corporation has a network of
authorized Bosch Service Dealers throughout the
world to service their products.
The pump and injectors must be sent to an
authorized Bosch Service Center.
When shipping an injection pump to a service center
for adjustments or repairs, the fuel return line banjo
bolt must accompany the unit. The banjo bolt
incorporates a sized orifice (is calibrated) for proper
pressure which is matched to the pump. The pump
cannot be properly adjusted without the matched
orifice.
Contact the Bosch distributor nearest you for the
location of an authorized Bosch Service Center.
90-806934 1194
Exploded Views - Injection Pump and Related Components

27

29
26
30
32
31

28
9 19
10
8 14
13 11
6 7
13 20
16

5 2 12

4 15
18
A 3 22

a 23
1 21

17
24
73911
25 b
1 - Injection Pump 25- Plain Washer, Lockwasher and Nut (3 of each)
2 - Lever 26- Boost Pressure Tube
3 - Gasket 27- Banjo Bolt and Sealing Washers
4 - Traction Rod 28- Clamp
5 - Ball Pin 29- Screw, Lockwasher and Nut (1 of each)
6 - Washer and Nut for Ball Pin 30- Support Bracket
7 - Washer (2) 31- Screw and Lockwasher (1 of each)
8 - Screw (2) 32- Connector
9 - Bearing Angle
10- Fuel Shut-Off Solenoid and Nut Lubricant/Sealant Application Points
11- Sealing Washer
12- Lever A Quicksilver Perfect Seal - 92-34227
13- Bushing (2)
14- Lockwasher (1) Torque Specifications
15- Lockwasher (1)
16- E-Ring a 66 lb. ft. (90 N·m)
17- Clamping Set (For Cable Controlled Cold Start) b 23 lb. ft. (31 N·m)
18- Support Angle
19- Screw (2)
20- Cable Barrel Anchor Stud with Hardware
21- Cable End Guide Anchor Stud with Hardware
22- Key
23- Lockwasher and Nut (Gear-to-Pump Shaft)
24- Stud (3)
Index
90-806934 1194 INJECTION PUMP – 5B-5
Fuel Injection Pump Removal 2. Using balancer bolts or suitable, attach crankshaft
tool 91-814827 to crankshaft balancer.

! WARNING
Safety glasses should be worn while working on
fuel injection system. The fuel injection pump
will generate pressures in excess of 2000 psi
(13790 kPa). Use caution when removing
injectors, injector lines, or bleeding air from
injection system.

1. Follow instructions “a” or “b”:
a. On MCM (Stern Drive) D3.0L/150 and
D3.6L/180 Engines:
(1) Remove power steering belt.
70485
a - Crankshaft Tool 91-814827
3. Remove oil fill cap from valve cover.

(2) Remove power steering drive pulley.

(3) Remove three allen-head screws retain- a
ing the flange to which the power steering
pulley was mounted.
(4) Remove the flange.

d
a

b c 73777

a - Power Steering Pulley

b - Screws (4)
c - Power Steering Pulley Flange
d - Screws (3)
73322
(5) Proceed to Step 2. a - Oil Fill Cap

b. On MIE (Inboard) D3.0L/150 and D3.6L/180

Engines and All D4.2L/220 Engines:
(1) Remove three of the six allen-head
screws retaining the crankshaft balancer
to the drive pulley assembly.
(2) Proceed to Step 2.

Index
5B-6 – INJECTION PUMP 90-806934 1194
4. Look through oil fill cap hole into the valve cover, NOTE: Seawater pump shown removed for visual
while using a suitable inspection light. Proceed clarity only.
as follows:
a. Slowly rotate engine CLOCKWISE (looking
from water pump end toward flywheel end)
while watching the first rocker arm and valve
(front-most is Number 1 cylinder’s intake
valve).
b. After the intake valve has OPENED (rocker
arm moved down) and then CLOSED (rocker d
arm moved up), continue to rotate engine 70485
clockwise until crankshaft pulley notch aligns
with mark on timing gear cover as shown.
c. Number 1 piston is at Top Dead Center (TDC)
on its compression stroke at this point.
a
NOTE: On D4.2L/220 engines the crankshaft pulley
notch is on smaller power steering pulley edge, be-
hind the larger drive pulleys.

b
c
74370

a- Adaptor Plate, (Retains Graduated Disc to Balancer)

b – Graduated Disc-to-Adaptor Retaining Screws (3)
c - Graduated Disc
d - Crankshaft Tool
Typical Engine Shown

6. Using wire, make a pointer and attach it to a suit-

able location on engine. Align pointer to zero
(“0”) as shown.

70281

a - Crankshaft Pulley Notch

b - Timing Cover Mark
Typical Engine Shown

5. Attach graduated disc adaptor and graduated

disc 91-801333500 to crankshaft balancer with
zero positioned as shown.

70664

a - Wire Pointer
Typical Engine Shown

7. Refer to SECTION 4C and remove alternator

belt.
Index
90-806934 1194 INJECTION PUMP – 5B-7
IMPORTANT: Banjo bolts, used to hold fuel inlet
and return lines to injection pump, are calibrated
and MUST remain with pump in their original
location.
8. Refer to the following and remove:
! CAUTION
Do not bend fuel injector lines. Bending may
cause metal to flake off inside lines, causing
injectors or injection pump to malfunction.

D Fuel Return Line (Plug hose after removal.) 9. Carefully loosen fittings and remove high pressure
fuel lines from injection pump and fuel injectors.
D Injection Pump Inlet Line (Plug hose after
removal.)
D Throttle Cable and Bracket
D Turbo Pressure Line

23284

17MM

c d 70148

71261 a - Injection Pump Fuel Line Fittings

b - Fuel Line Fittings At Injectors
a - Fuel Return Line c - Fuel Line(s)
b - Hose Clamp, Fuel Return Line
c - Fuel Injection Pump Inlet Line
d - Banjo Bolt With Sealing Washers NOTE: At this time return to Fuel Injection Pump
e - Throttle Cable and Bracket Timing – “Setting Timing” if Steps 1-10 were
f - Turbo Pressure Line and Fitting accomplished for injection pump timing purposes.
For continuing injection pump removal proceed to
! CAUTION the following Step 10.

Keep injectors and injection pump fittings clean.

Do not allow dirt to enter fittings when removing
lines. Dirt will cause injectors or injection pump
to malfunction.
Index
5B-8 – INJECTION PUMP 90-806934 1194
10. Remove injection pump gear cover following 11. Remove injection pump gear nut and lockwasher.
instructions “a” or “b”:
12. With central bolt of tool backed out, install
a. On D3.0L/150 and D3.6L/180 Engines: appropriate injection pump gear puller tool (refer
Remove 4 hex nuts and cover. to Special Tools chart). Puller will hold gear
against gear housing while pump is removed.

NOTE: Gear puller is bolted to injection pump gear,

with the exception of the D4.2L/220 puller which
screws into timing cover housing.

70762

a - Hex Nuts (4) (One Hidden In This View)

b - Cover

b. On D4.2L/220 Engines: Using a suitable de-

vice remove threaded, round cover by turning
COUNTERCLOCKWISE. 70765

a - Timing Cover
b - Gear Puller Tool
c - Central Bolt of Tool
D3.0L/150 and D3.6L/180 Puller Shown Installed

70761

a - Cover

70770

a - Timing Cover
b - Gear Puller Tool
c - Central Bolt of Tool
D4.2L/220 Gear Puller Shown Installed

Index
90-806934 1194 INJECTION PUMP – 5B-9
13. Remove pump mounting nuts and washers. IMPORTANT: If engine has been disturbed,
number one piston will have to be brought up to
IMPORTANT: The injection pump shaft and
top dead center (TDC) of its compression stroke
timing gear use a key to stay in alignment. Be
and then rotated COUNTERCLOCKWISE 25 to 30
careful not to drop key into engine when
degrees as previously outlined before installing
removing pump.
injection pump. Take care not to wedge pump
14. Slowly turn central bolt of gear puller tool gear in gear housing while turning crankshaft.
CLOCKWISE until pump and gear separate.
IMPORTANT: Do not turn crankshaft after 2. Move cold start lever to “OFF” position as shown.
injection pump is removed. Battery cables 2
should remain disconnected and a notice
attached to ignition switch to alert others that
engine should not be disturbed.
15. Paying special attention to key, carefully remove
pump and place aside. Back central bolt out of
puller tool.
NOTE: If key does fall into engine, on D3.0L/150 and
D3.6L/180 engines remove lower cover of timing
cover as shown following. Pour oil into pump opening
to attempt to flush key out lower opening. If this is not
successful, and on D4.2L/220 engines, you must
remove the timing cover to recover the key. Refer to
SECTION 3A – Engine, “Timing Gear Cover.”
50397

a - Cold Start Lever

3. Temporarily install original shaft nut and a

suitable jam nut on injection pump shaft (Do not
damage pump shaft threads with improper nuts
or over-tightening). Rotate shaft to align keyway
with number one injector port.
NOTE: Nuts have been removed for visual clarity.

70661

a - Lower Cover Location (Cover Removed)

Fuel Injection Pump

Installation

Installation With Engine Assembled

1. Make certain crankshaft has not been turned and 70420
pump gear is held in the same position as when
a - Shaft Keyway
pump was removed.
b - Cylinder Number 1 Injector Port

Index
5B-10 – INJECTION PUMP 90-806934 1194
4. Remove any pump backlash by rotating shaft 7. Using a heavy grease to hold in place, install in-
COUNTERCLOCKWISE (facing unit) until resis- jection pump key in pump shaft slot. Be certain
tance is felt. key is positioned properly.
Keyway will be at 11 o’clock position as shown.
IMPORTANT: Do not drop key into engine. If key
is dropped into engine, remove as described in
“Fuel Injection Pump Removal” instructions as
previously outlined.

8. Insert pump shaft into gear, being careful not to

dislodge key. Do not turn pump shaft from 11
o’clock position. Rotate pump body in slotted
holes to help align key with gear slot.
b a
9. Install hex nuts with flat washers and
lockwashers finger tight.
10. Remove gear puller tool. Make certain key is in
position.
70421
11. Using new lockwasher, secure gear to shaft with
hex nut. Torque to 66 lb. ft. (90 N·m).
12. Using new O-ring in groove, install and
appropriately, depending on model, tighten
injection pump gear cover on timing cover.
b a 13. Rotate pump to end of adjustment slot travel in
70767
direction shown.
a - Shaft – Rotate COUNTERCLOCKWISE
b - Keyway at 11 O’clock

5. Being careful not to disturb shaft alignment,

remove nuts temporarily installed to rotate shaft.
6. Install new gasket on pump mounting studs.
Upper pump gear slot should be positioned
approximately as shown to be in alignment with
key when injection pump is installed.

70422

a - Direction to Rotate
70768

a - Gasket 14. Timing of the injection pump MUST BE

b - Pump Mounting Studs (3) accomplished. Refer to “Fuel Injection Pump
c - Upper Pump Gear Slot Timing” for instructions, following in this section.

Index
90-806934 1194 INJECTION PUMP – 5B-11
Installation During Engine Reassembly
1. Install flywheel holder tool and install crankshaft
pulley. Using Loctite 222 on threads, install pulley
nut and torque to 114 lb. ft. (155 N·m). Remove
flywheel holder.
4. Using a suitable gauge wire, make a pointer and
being careful not to damage mating surfaces
attach to a suitable location on the block. Align
wire pointer to zero degrees (“0”) as shown.

! CAUTION
To avoid severe engine damage the engine MUST
BE set on Number One Cylinder’s COMPRES-
SION STROKE at Top Dead Center (TDC) before
proceeding.

IMPORTANT: If crankshaft position was

disturbed after assembly (rotated), it may be
necessary to slowly rotate the crankshaft, in the
direction of rotation, numerous revolutions to
align the crankshaft gear, idler gear, and
camshaft gear alignment marks. Refer to
SECTION 3A – Engine, “Camshaft – Installation,”
and verify alignment to establish number one
TDC on compression stroke in the following.

2. Turn crankshaft until number 1 piston is at Top 70419

Dead Center on its compression stroke and tim-
ing marks are aligned.
3. Attach graduated disc adaptor and graduated
disc 91-801333500 to crankshaft balancer with
zero positioned as shown.
a - Wire Pointer
b - Zero (“0”) Degree Mark
IMPORTANT: Cold start lever must be in the
“OFF” position (forward, toward the shaft end of
the pump) before timing the pump or proceeding.

5. Move cold start lever to “OFF” position as shown.

d 70485

b
c
74370 50397

a - Adaptor Plate (Retains Graduated Disc to Balancer) a - Cold Start Lever

b - Graduated Disc-to-Adaptor Retaining Screws (3)
c - Graduated Disc
d - Crankshaft Tool
Typical Engine Shown
Index
5B-12 – INJECTION PUMP 90-806934 1194
6. Using a heavy grease to hold in place install 8. Remove gear.
injection pump key in pump slot. Temporarily
9. Install injection pump using new gasket. Install
install gear on injection pump shaft (Do not
hex nuts with flat washers and lockwashers
secure gear at this time). Rotate shaft and gear
finger tight. Rotate pump to end of adjustment
to align keyway with number one injector port.
slot travel in direction shown.
NOTE: Gear has been removed for visual clarity.

70420

a - Shaft Keyway
b - Cylinder Number 1 Injector Port
c - Key

7. Remove any pump backlash by rotating gear

COUNTERCLOCKWISE until resistance is felt. 70426
Upper keyway will be at approximately the 11
o’clock position as shown.

70422
70421 a - Gasket
b - Hex Nuts With Flat Washers and Lockwashers (3 Total)
a - Rotate Counterclockwise c - Direction to Rotate
b - Upper Keyway at 11 O’clock
Index
90-806934 1194 INJECTION PUMP – 5B-13
10. Be certain injection pump key is properly
positioned. Apply heavy grease to hold key in slot
of pump.
IMPORTANT: Due to a change in production
Engines with VM Serial Number 56945 and up
have a different injection pump gear than earlier
number engines. Injection pump gears are not
interchangeable. Be certain to order the proper
gear for your engine should it require
replacement.
IMPORTANT: Do not force gear on shaft.
11. Install gear on injection pump, using whichever
key slot on gear that allows gear to be installed
the easiest.
12. Make certain key is still in position.
13. Using a new lockwasher, install gear on shaft with
hex nut. Torque to 66 lb. ft. (90 N·m).
70424
a - Gear
b - New Lockwasher
c - Hex Nut
14. Timing of the injection pump MUST BE
accomplished. Refer to “Fuel Injection Pump
Timing” for instructions, following in this section.
Index
5B-14 – INJECTION PUMP
Fuel Injection Pump Timing
Checking Timing
On completely assembled and/or installed engines,
and for the purpose of “checking” fuel injection pump
timing refer to instructions previously outlined under
– Fuel Injection Pump Removal, and accomplish
Steps 1 through 9, in that section, dealing with
installation of crankshaft tool, graduated disc,
positioning of crankshaft and removal of parts to gain
access to rear of fuel injection pump and vent screw.
Then proceed to following, Fuel Injection Pump
Timing – “Setting Timing.”
Setting Timing
Having accomplished previously outlined Steps 1
through 9 of “Fuel Injection Pump Removal,” or on
pumps just installed, due to repair or service, or upon
engine reassembly with pump just installed, follow
these instructions.
1. Remove vent screw and sealing washer from
rear of injection pump.
NOTE: Pump shown removed for visual clarity.
23286
a - Injection Pump
b - Vent Screw with Sealing Washer
IMPORTANT: Cold start lever must still be in the
“OFF” position (forward, toward shaft end of
pump) before proceeding.
90-806934 1194
2. Be certain cold start lever is positioned as shown. 4. Watch dial indicator needle and SLOWLY rotate
the crankshaft COUNTERCLOCKWISE (viewed
from water pump end looking toward flywheel)
toward 0° until dial indicator STOPS moving.
5. Set the dial indicator to Zero [ 0 in. 0.00 mm) ],
as shown.

70426
70431

3. Install adaptor tool and dial gauge as shown.
Pre-load the dial indicator with at least 0.10 in.
(2.54 mm).
NOTE: Internal bore of adaptor tool is of two different
sizes. Adaptor tool 91-813658 is designed to use
with SAE inch dial indicator. Adaptor tool
91-801333510 is designed to use with millimeter dial
indicator.
a - Indicator at 0 Degrees
6. SLOWLY rotate crankshaft CLOCKWISE
(viewed from water pump end looking toward
flywheel) until 0 Degrees (engine Top Dead
Center) is indicated on graduated disc as shown
(or until notch on crankshaft damper, or power
steering pulley, aligns with timing mark on gear
housing cover).

70430

a - Suitable Adaptor Tool

b - Dial Gauge

70432

NOTE: The dial indicator follows this rotational

movement of crankshaft and STOPS when the Num-
ber One piston is at T.D.C., when the crankshaft is
not turned further.
Index
90-806934 1194 INJECTION PUMP – 5B-15
7. AT THIS MOMENT, the dial indicator should read
0.34 in. (0.88 mm). If not, loosen the injection
pump mounting nuts and rotate the pump in ei-
ther direction to obtain the correct specifications.
8. Tighten hex nuts securely.
! CAUTION
Dial gauge indication MUST NOT be allowed to
change when mounting nuts are tightened.
Failure to maintain setting will result in engine
damage.
70422
70433
a - Direction to Rotate
b - Dial Gauge Indication MUST BE .034 in. (0.88mm)
9. Remove dial gauge and adaptor. Reinstall fuel in-
jection pump vent screw using new sealing
washer. Tighten securely.
Index
5B-16 – INJECTION PUMP
! CAUTION
Keep injectors and injection pump fittings clean.
Do not allow dirt to enter fittings when installing
lines. Dirt will cause injectors or injection pump
to malfunction.
! CAUTION
Do not bend fuel injector lines. Bending may
cause metal to flake off inside lines, causing
injectors or injection pump to malfunction.
10. Follow instructions “a” or “b”:
a. During Engine Reassembly: Continue
engine reassembly. Refer to following
instructions “b” after all other necessary
engine reassembly steps are complete.
b. With Engine Assembled or After Checking
Timing:
(1) Install high pressure lines on injection
pump pressure valves and fuel injectors.
Torque fittings to 13 lb. ft. (18 N·m).
IMPORTANT: Banjo bolts, used to hold fuel inlet
and return lines to injection pump, are calibrated
and MUST remain with pump in their original
location.
IMPORTANT: Use new sealing washers on fuel
line banjo bolts to prevent leaks.
11. Refer to the following and install as indicated:
D Fuel Return Line - Tighten hose clamp securely.
D Injection Pump Inlet Line - Use new sealing
washers. Tighten banjo bolts securely.
D Throttle Cable Bracket - Using the two original
allen head screws. Tighten screws securely.
D Turbo Pressure Line - Tighten fitting securely.
90-806934 1194
 12. Install throttle cable(s) following these instruc-
tions:
IMPORTANT: When installing throttle cable(s), be
sure that cables are routed in such a way as to
avoid sharp bends and/or contact with moving
parts. DO NOT fasten any items to throttle cables.
a. Place remote control lever(s) in neutral/idle
position.
b. Lightly push on throttle cable end guide and
turn barrel to align anchor points with studs.
Install cable and secure with hardware as
23284
shown.
c. Tighten locknuts until they bottom and back
off 1/2 turn.
f

a
e b

d
c

c d d
71261 71261

a - Throttle Cable
g b - Barrel
c - Lock Nuts
h d - End Guide

h
d. Place remote control lever in full forward
a - Fuel Return Line
wide-open-throttle (W.O.T.) position.
b - Hose Clamp, Fuel Return Line
c - Fuel Injection Pump Inlet Line
d - Banjo Bolt With Sealing Washers
! CAUTION
e - Throttle Cable and Bracket
The injector pump lever WOT-stop-screw adjusts
f - Turbo Pressure Line and Fitting
g - Banjo Bolt(s) the engine speed governor, and is factory set and
h - Sealing Washer(s) sealed. DO NOT readjust this setting.
Readjusting the governed speed, and operating
above the specified RPM will cause extensive
engine damage, and/or failure. Removal of the
seal, and/or readjustment of the WOT-stop-screw
is considered misuse of engine and resulting
damages will not be covered by the limited
warranty.

Index
90-806934 1194 INJECTION PUMP – 5B-17
 e. Check to ensure injector pump lever is con-
tacting “W.O.T. Stop Screw.” DO NOT at-
tempt to adjust screw (screw is sealed).
15. Follow instructions “a” or “b”:
Check to ensure that remote control and
cable are providing proper output.
14. Remove graduated disc and adaptor ring, crank-
shaft tool and wire pointer from front of engine.
a. On D3.0l/150 and D3.6L/180 Engines:
(1) Install the flange, if so equipped, to which
the power steering pulley mounts. Install
the three allen-head screws removed
previously. Torque balancer bolts on to
37 lb. ft. (50 N·m).
(2) Install the power steering pump pulley, if
so equipped, to flange. Torque power
steering pulley to 8 lb. ft. (11 N·m).

b
c

23728 d a

a - W.O.T. Stop Screw (DO NOT ADJUST – Read “Caution”
above)
b - Lever
c - Seal
d - Remote Control Throttle Cable Lever
e - Contact Point – Lever/W.O.T. Stop Screw
IMPORTANT: Check throttle operation to ensure
full throttle access, and full return.
f. Place remote control lever in neutral/idle
position and if necessary, readjust throttle
cable barrel.
13. Recheck injection pump lever contacts idle screw
and stop.
22217
a - Power Steering Pulley Flange
b - Screws (3)
c - Power Steering Pulley
d - Screws (4)
(3) On D4.2L/220 Engines: Install the three
balancer screws previously removed.
Torque screws to 37 lb. ft. (50 N·m).
16. Refer to Section 5B – MAINTENANCE, “Replace
Drive Belts,” and install alternator belt, power
steering belt, if so equipped, and optional belts,
if so equipped. Tighten power steering mounting
and adjusting bolts as instructed. Torque upper
alternator tensioning nut to 16 lb. ft. (22 N·m) and
lower alternator mounting bolt to 35 lb. ft. (47
N·m).

Starting Engine – After Fuel

Injection Pump Installation
and Timing
After installing fuel injection pump, checking or
setting timing it will be necessary to “Fill” the fuel
injection system. Follow instructions:

23728 1. Fill the water separating fuel filter:

a - Idle Screw a. Loosen bleed screw on fuel filter header.
b - Lever
c - Stop b. A lever is located on the fuel pump.
d - Jam Nut

Index
5B-18 – INJECTION PUMP 90-806934 1194
 c. Move fuel pump lever UP and DOWN ! CAUTION
repeatedly, until an air free stream of fuel
flows from bleed screw. When installing battery, be sure to connect
POSITIVE (+) battery cable to POSITIVE (+)
b battery terminal FIRST, and NEGATIVE (–) battery
cable to NEGATIVE (–) battery terminal LAST. If
battery cables are reversed, or connection order
is reversed, electrical system damage will result.

3. Install fully charged battery. Clean battery cable

clamps and terminals and reconnect cables (see
CAUTION listed above). Secure each cable
clamp when connecting.
a
! WARNING
Be certain area around propeller is clear to avoid
personal injury.
73332

a - Pump/Primer Lever on Fuel Pump ! WARNING

b - Bleed Screw
Water must be supplied to seawater pickup pump
d. Tighten bleed screw. to avoid engine damage due to overheating.

2. Fill fuel injection pump:

a. Loosen vent screw on back of fuel injection
pump.
b. A lever is located on the fuel pump.
c. Move fuel pump lever UP and DOWN
repeatedly, until an air free stream of fuel
flows from vent screw.
b injectors, injector lines, or bleeding air from
! CAUTION
To prevent damage to starter motor, do not
operate starter for more than 15 seconds at one
time. Allow at least 2 minutes for starter motor to
cool before reusing.
! WARNING
Safety glasses should be worn while working on
fuel injection system. The fuel injection pump
will generate pressures in excess of 2000 psi
(13790 kPa). Use caution when removing
injection system.

! WARNING
71371
a Do not use your fingers to feel for fuel leaks at
fittings. Fuel pressure is high enough to
penetrate the skin.

73332
a - Pump/Primer Lever
b - Vent Screw

d. Tighten vent screw.

Index
90-806934 1194 INJECTION PUMP – 5B-19
IMPORTANT: After lengthy repairs or lay-up
(several months) it is necessary to pre-lubricate
the turbo-charger. To do this, move the “STOP”
switch toggle lever DOWN and hold in this
position while you turn the key switch to
“START” position. Doing this TOGETHER turns
the engine without starting it. DO NOT engage
starter for more than 15 seconds; allow at least
one minute cool down time before re-engaging
starter for another 15 seconds. Watch that starter
does not overheat.
4. Pre-lubricate turbocharger (following preceding
“IMPORTANT” information) and attempt to start
engine:
IF ENGINE STARTS: Run engine at idle. Check
all fuel connections for fuel leaks. If leaks exist,
stop engine and refer to following Step 5, and
correct as needed.
IF ENGINE WILL NOT START: Air will have to
be bled from injector lines. Follow instructions:
a. Wear safety glasses when bleeding air from
injector lines. Slightly loosen each injector
fuel line fitting. Use starter motor to crank
engine while observing injectors.
70148
a - Fuel Line Fitting
Index
5B-20 – INJECTION PUMP
b. Tighten each fuel line fitting when fuel
appears at fitting until all fittings are
tightened.
NOTE: Engine may start during this operation.
c. When engine starts, injectors may still be
bled by loosening fuel line fittings at
individual injectors if required. Tighten each
after bleeding.
d. After bleeding injectors, torque all fuel line
fittings at injectors to 13 lb. ft. (17 N·m).
5. Check for fuel leaks at injection pump fittings and
injector fittings using a piece of paper placed
near the suspect fitting to be checked. The paper
should show leaks if present. DO NOT use your
fingers to feel for leaks! Watch for fuel spray on
paper. Repair as needed. Retest until certain no
leaks are present.
NOTE: Be certain to observe precautions about the
use of safety glasses! It is sometimes helpful to use
compressed air to “dry” area near fittings when
checking for fuel leaks.
6. Allow engine to reach operating temperature.
Once again check for leaks as previously
outlined and correct as needed.
! WARNING
Dispose of fuel soaked rags, paper, etc. in an
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
Make sure no fuel leaks exist, before closing
engine hatch.
90-806934 1194
FUEL SYSTEMS
1
A
2
A
3
A
4
A
50442
5
FUEL INJECTORS
C
6
A
A 7
Index
Table Of Contents
Page
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-0
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Bosch Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Fuel Injector (Cutaway View) . . . . . . . . . . . . . . . . . . . 5C-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Bleeding Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . 5C-6
Injector Test (Engine Misfiring) . . . . . . . . . . . . . . . . . . 5C-7

Index
5C –– FUEL
5C-0 FUEL INJECTORS
INJECTORS 90-806934 1194
Identification
The Bosch throttling pintle-type injector nozzle can
be identified as shown.
Specifications
Manufacturer
Type of Injector
Opening Pressure
Spray Angle
Spray Hole Diameter
73780
Robert Bosch Corporation
Throttling Pintle Nozzle
2248.12 PSI (15500.79 kPa)
0

.039 in. (1mm)
Description
The D3.0L/150, D3.6L/180 and D4.2L/220 diesel
engines use a throttle pintle type injector nozzle. This
type of nozzle is used with a turbulence chamber
(prechamber), which is located in the cylinder head.
Fuel from the injection pump pushes against a
spring-loaded needle in the nozzle. The spring is
calibrated to allow the needle to unseat at about
2200 PSI (15500 kPa). The needle has a specially
shaped pintle at the end. The pintle restricts the
amount of fuel injected when the needle first starts to
open. Not until the needle is completely open is the
full amount of fuel injected. Because it promotes a
gradual pressure rise, this action gives “soft”
combustion and therefore a smooth running engine.
Fuel Injector (Cutaway View)
FUEL
FLOW

Torque Specifications
Clamping Shoe Nut 20 lb. ft. (27 N·m)
Injector Fuel Line Fittings 13 lb. ft. (17 N·m)
Fuel Return Line Banjo Bolts Tighten Securely

Bosch Special Tools

Robert Bosch Corporation
2800 South 25th Avenue
Broadview, IL 60153
Mailing Address:
P.O. Box 4601
North Suburban, IL 60197
Phone: (312) 865-5200
EFEP60H Nozzle Tester 0 681 200 502

50442

a - Pressure Line Union Nut

b - Filter
c - Pressure Passage
d - Nozzle Retaining Nut
e - Fuel Return Line
f - Pressure Shim
g - Pressure Spring
h - Pressure Spindle
i - Pintle Nozzle

Index
90-806934 1194 FUEL INJECTORS – 5C-1
Precautions
! WARNING
Always disconnect battery cables from battery
BEFORE working on fuel system to prevent fire
or explosion.
! WARNING
Be careful when changing fuel system
components; diesel fuel is flammable. Be sure
that ignition key is OFF. DO NOT smoke or allow
sources of open flame in the area while changing
fuel system components. Wipe up any spilled
fuel immediately. DO NOT allow fuel to come into
contact with any hot surface which may cause it
to ignite.
! WARNING
Dispose of fuel soaked rags, paper, etc. in an
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
Make sure that no fuel leaks exist, before closing
engine hatch.
! CAUTION
DO NOT operate engine without cooling water
being supplied to seawater pump, or impeller will
be damaged and subsequent overheating damage
to engine may result.
! WARNING
Electrical system components on this engine are
not external ignition protected. DO NOT STORE OR
UTILIZE GASOLINE ON BOATS EQUIPPED WITH
THESE ENGINES, UNLESS PROVISIONS HAVE
BEEN MADE TO EXCLUDE GASOLINE VAPORS
FROM ENGINE COMPARTMENT (ref: 33 CFR).
Failure to comply could result in fire, explosion
and/or severe personal injury.
Index
5C-2 – FUEL INJECTORS
! WARNING
FIRE HAZARD: Fuel leakage from any part of the
fuel system can be a fire hazard which can cause
serious bodily injury or death. Careful periodic
inspection of entire fuel system is mandatory,
particularly after storage. All fuel components
including fuel tanks, whether plastic, metal or
fiberglass, fuel lines, primers, fittings, and fuel
filters should be inspected for leakage, softening,
hardening, swelling or corrosion. Any sign of
leakage or deterioration requires replacement
before further engine operation.
! WARNING
Safety glasses should be worn while working on
fuel injection system. The fuel injection pump will
generate pressures in excess of 2000 P.S.I. (13790
kPa). Use caution when removing injectors,
injector lines, or bleeding air from injection
system.
IMPORTANT: Mercury Marine does not
recommend fuel injectors be disassembled for
service. If an injector tester is not available,
substitute a new injector for any injectors thought
to be faulty.
! CAUTION
Due to fuel injector design changes the 530 D-TA,
636 D-TA, D183 and D219 Model fuel injector MUST
NOT be used in a D254, D3.0L/150, D3.6L/180 or a
D4.2L/220 engine under any conditions. However,
the new-style D254 or a D4.2L/220 fuel injector
CAN BE used in all engines as a replacement.
(Refer to QUICKSILVER PARTS CATALOG.)
IMPORTANT: Always wash hands and use clean
tools when working on fuel injection system.
90-806934 1194
Fuel Injectors 5. Remove clamping shoe after removing hex nut
and lockwasher. Remove spacer. Retain all
components.
Removal
! CAUTION
Keep injectors and injection pump fittings clean.
Do not allow dirt to enter fittings when removing
or installing lines. Dirt will cause injectors or
injection pump to malfunction.

! CAUTION
Do not bend fuel injector lines. Bending may
cause metal to flake off inside lines, causing
injectors or injection pump to malfunction.

1. Wearing safety glasses, clean dirt from around fuel

injectors using clean rags and compressed air.
2. Remove valve covers. 70144

3. Remove fuel return line banjo bolts. Discard

sealing washers. a - Clamping Shoe
b - Spacer
c - Hex Nut
d - Lockwasher

! CAUTION
To prevent injector nozzle from rusting, wet
hands with diesel fuel before handling injectors.

70142

a - Fuel Return Line

b - Banjo Bolts
c - Sealing Washers (Two Per Banjo Bolt and Fitting) 70147

a - Fuel Injector Nozzle

4. Remove injector fuel lines by completely loosen-
ing fuel line fittings. Remove clamps as required.
6. Remove fuel injector. Discard copper sealing
washer.

70180 70147

a - Injector Fuel Lines a - Fuel Injector

b - Fuel Line Fittings b - Copper Sealing Washer
c - Clamps
Index
90-806934 1194 FUEL INJECTORS – 5C-3
Testing ! CAUTION
Mercury Marine recommends the EFEP60H nozzle
Do not bend fuel injector lines. Bending may
tester from the Robert Bosch Corporation. Follow
cause metal to flake off inside lines, causing
instructions with injector tester for checking nozzle
injectors or injection pump to malfunction.
opening pressure and spray pattern.

! CAUTION
To prevent injector nozzle from rusting, wet
hands with diesel fuel before handling injectors.

70147

a - Fuel Injector Nozzle

1. Place new copper sealing washer on injector

seat as shown.

74442

EFEP60H Nozzle Tester

Installation

! CAUTION
70146
Due to fuel injector design changes the 530 D-TA,
636 D-TA, D183 and D219 Model fuel injector a - Copper Sealing Washer (Renew)
MUST NOT be used in a D254 Model engine under
any conditions. However, the new-style D254 fuel
injector CAN BE used in 530 D-TA, 636 D-TA, D183
and D219 Model engines as a replacement. (Refer
to QUICKSILVER PARTS CATALOG.)

! CAUTION
Keep injectors and injection pump fittings clean.
Do not allow dirt to enter fittings when removing
or installing lines. Dirt will cause injectors or
injection pump to malfunction.

Index
5C-4 – FUEL INJECTORS 90-806934 1194
2. Install injector with fuel return hole facing rocker 4. Install clamping shoe around flat sides of fuel
arms. injector as shown. Install lockwasher and hex
nut. Tighten to 20 lb. ft. (27 N·m).

70144

a - Clamping Shoe
70145 b - Lockwasher
c - Hex Nut
a - Fuel Return Hole
5. Install injector fuel lines. Tighten fuel line fittings
3. Place spacer as shown.
to 13 lb. ft. (17 N·m). Install and tighten clamps as
required.

70180

a - Injector Fuel Lines

70143 b - Fuel Line Fittings
a - Spacer c - Clamps

Index
90-806934 1194 FUEL INJECTORS – 5C-5
6. Using 2 new sealing washers for each banjo bolt,
install fuel-return line. Tighten banjo bolts
securely.
70142
a - Fuel Return Line
b - Banjo Bolts
c - Sealing Washers (Two Per Banjo Bolt and Fitting)
7. Install valve covers. (Refer to SECTION 3A - En-
gine.) Torque fasteners to 7 lb. ft. (10 N·m).
Bleeding Fuel Injectors
! CAUTION
To prevent damage to starter motor, do not use
for more than 15 seconds at one time. Allow at
least 2 minutes for starter motor to cool before
reusing.
! WARNING
Wipe up any spilled fuel immediately and
dispose of fuel soaked rags, paper, etc., in an
appropriate air tight, fire retardant container.
Fuel soaked items may spontaneously ignite and
result in a fire hazard which could cause serious
bodily injury or death.
! WARNING
Safety glasses should be worn while working on
fuel injection system. The fuel injection pump
will generate pressures in excess of 2000 P.S.I.
(13790 kPa). Use caution when removing
injectors, injector lines, or bleeding air from
injection system.
1. Start engine. If engine will not start, air will have
to be bled from injector lines, as outlined in the
following.
Index
5C-6 – FUEL INJECTORS
2. Wear safety glasses when bleeding air from in-
jector lines. Slightly loosen each injector fuel line
fitting. Use starter motor to crank engine, while
observing injectors.
17 MM
70148
a - Fuel Line Fitting
3. Tighten each fuel line fitting when fuel appears at
fitting until all fittings are tightened. (NOTE:
Engine may start during this operation.)
4. When engine starts, injectors may still be bled by
loosening fuel line fittings at individual injectors,
if required. Tighten each after bleeding.
5. After bleeding injectors, torque all fuel line fittings
to 13 lb. ft. (17 N·m).
! WARNING
Do not use your fingers to feel for fuel leaks at
fittings. Fuel pressure is high enough to
penetrate the skin.
6. Allow engine to reach operating temperature.
Check for fuel leaks at injection pump fittings and
injector fittings using a piece of paper placed
near the suspect fitting to be checked. The paper
should show leaks if present. DO NOT use your
fingers to feel for leaks! Watch for fuel spray on
paper. Repair as needed. Retest until certain no
leaks are present.
NOTE: Be certain to observe precautions on this
page about the use of safety glasses! It is sometimes
helpful to use compressed air to dry area near fittings
when checking for fuel leaks.
! WARNING
Make sure no fuel leaks exist, before closing
engine hatch.
90-806934 1194
Injector Test
(Engine Misfiring)
! WARNING
Safety glasses should be worn while working on
fuel injection system. The fuel injection pump
will generate pressures in excess of 2000 P.S.I.
(13790 kPa). Use caution when removing
injectors, injector lines, or bleeding air from
injection system.

1. Follow instructions “a” - “d”:

a. Wear safety glasses when testing injectors.
b. With engine running at idle, carefully loosen
fuel line fitting at injectors, one cylinder at a
time.
(1) If idle RPM changes, injector is operating.
(2) If idle RPM does not change, injector may
be faulty.
c. Stop engine and replace injector.
d. Check all injectors one at a time.
2. If engine continues to misfire, check for mechani-
cal problems (faulty injection pump, burned
valves, etc.).

Index
90-806934 1194 FUEL INJECTORS – 5C-7
COOLING SYSTEM
1
A
2
A
3
A
4
A
5
SEAWATER SYSTEM
Note:Refer to the following Service Bulletin regarding this section.
A
SB 97-2 MerCruiser MCM/MIE Inline Diesel Heat Exchanger End
Cover Torque
6
A
A 7
INDEX
Table Of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
D3.0L/150 and D3.6L/180 Engines . . . . . . . . 6A-1
D4.2L/220 Engines . . . . . . . . . . . . . . . . . . . . . 6A-1
Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
Cooling System Cleaners . . . . . . . . . . . . . . . . . . . . . . 6A-1
Seawater Pickup Connection . . . . . . . . . . . . . . . . . . . 6A-1
Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Sea Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Exploded Views and Diagrams . . . . . . . . . . . . . . . . . 6A-3
D3.0L/150 and D3.6L/180 Seawater Pump . . . . 6A-3
D4.2L/220 Seawater Pump . . . . . . . . . . . . . . . . . 6A-4
Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6
Cleaning And Inspection . . . . . . . . . . . . . . . . . 6A-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14
Sea Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17
Oil / Power Steering / Transmission Fluid Coolers 6A-17
Location of Coolers . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . 6A-20
Transmission Fluid Cooler . . . . . . . . . . . . . . 6A-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . 6A-22
Transmission Fluid Cooler . . . . . . . . . . . . . . 6A-23

NOTICE
For instructions on Cleaning Seawater Strainer,
Flushing Seawater Cooling System or Draining
Seawater Section refer to SECTION 1B - “Main-
tenance.”

6A –– SEAWATER
6A-0 SEAWATER SYSTEM
SYSTEM 90-806934 1194
INDEX
Torque Specifications Cooling System Cleaners
Tighten All Fasteners Securely PART
DESCRIPTION
NUMBER
Quicksilver Cooling System Cleaner 91-814825
Fleetguard Restore CC2610
Specifications
Seawater Pump
Seawater Pickup Connection
D3.0L/150 AND D3.6L/180 ENGINES Seawater Pickup and Hose: Water pickup must be
large enough to permit sufficient water flow to engine
Seawater Pump Delivery Rates
seawater pickup pump for adequate engine cooling.
Engine R.P.M. U.S. Gal. (L)
SEAWATER PICKUP FLOW REQUIREMENT
1000 7.3 (27.7)
FLOW RATE
2000 14.5 (55) MODEL
(Minimum)
3000 21.1 (80) 30 U.S. Gal. per min.
D3.0L/150 and D3.6L/180
4000 24 (91) (114 L per min.)
40 U.S. Gal. per min.
D4.2L/220
(150 L per min.)
D4.2L/220 ENGINES
IMPORTANT: DO NOT install water pickup
Seawater Pump Delivery Rates directly in line with propeller, as pickup may
Engine R.P.M. U.S. Gal. (L) create turbulence and allow air to flow into the
1000 10 (37.8) “propeller slipstream.” This will cause propeller
ventilation and will adversely affect boat
2000 19 (71) performance.
3000 26 (98) Pickup also must supply a positive head while
3600 30 (113.5) underway. Water pickup should be located as close
to seawater pickup pump inlet as possible and in an
area where an uninterrupted, solid stream of water
will flow past when boat is underway.
Lubricants/Sealants Connect water pickup to seawater inlet hose with
PART
dimensions as shown in the following.
DESCRIPTION
NUMBER
SEAWATER PICKUP HOSE SIZE REQUIREMENT
Quicksilver 2-4-C Marine Lubricant 92-90018A12
DIAMETER
Special Lubricant 101 92-13872A12 MODEL
(Minimum)
Shell Alvania No. 2 Obtain Locally D3.0L/150 and D3.6L/180 1-1/4 in. (32mm)
Quicksilver Perfect Seal 92-34227--1 D4.2L/2200 1-1/2 in. (38mm)
Loctite Master Gasket 92-12564--1
Use only ID wire reinforced hose of adequate wall
Loctite Pipe Sealant (With Teflon) Obtain Locally thickness to prevent it from collapsing from pump
suction. Be sure to secure hose connections with
hose clamps.

90-806934 1194 SEAWATER SYSTEM – 6A-1

INDEX
Seacock Sea Strainer
If a seacock is being used, it must be installed The strainer, if so equipped, must be of sufficient size
between water pickup and seawater pickup pump (or to ensure that an adequate supply of water will be
sea strainer), to allow operator to shut off the maintained for cooling engine. A minimum flow rate
seawater in case of a leak or when boat is not in use. is required as shown in the following.
This will also allow the operator to flush or drain the
engine, or clean the sea strainer while boat is in the SEA STRAINER FLOW REQUIREMENT
water. Install seacock in an area where it will be FLOW RATE
MODEL
easily accessible and support adequately to prevent (Minimum)
hose fatigue. 30 U.S. Gal. per min.
D3.0L/150 and D3.6L/180
To prevent restricting water flow seacock used must (114 L per min.)
have an internal cross-sectional area (equal to or 40 U.S. Gal. per min.
D4.2L/220
greater than hose) as shown in the following. (150 L per min.)

SEACOCK SIZE REQUIREMENT

DIAMETER
MODEL
(Minimum)
D3.0L/150 and D3.6L/180 1-1/4 in. (32mm)
D4.2L/220 1-1/2 in. (38mm)

c
70355

a - Wire Reinforced Hose

b - Seacock
c - Seawater Pickup
Quicksilver MIE (Inboard) D4.2L/220 Compo-
nents Shown - All Similar

6A-2 – SEAWATER SYSTEM 90-806934 1194

INDEX
Exploded Views and Diagrams

D3.0L/150 and D3.6L/180 Seawater Pump

8
10 9
B 9 11
12
14 13
15
16
a
5

a 18 17
7

6
4

A
3
2
1

73947

1 - Pump Housing Lubricant/Sealant Application Points

2 - Screw
3 - Housing Pin A Shell Alvania No. 2 (See NOTE.)
4 - Ball Bearing
5 - Spacer B Loctite Master Gasket
6 - Snap Ring
7 - Shaft NOTE: In cases where high-speed or heavy duty will
8 - Thrust Washer (Align Notch with Housing Pin) not be encountered, it is permissible to use Quicksil-
9 - Oil Seal ver 2-4-C Marine Lubricant or Special Lubricant
10- Spreader
11- O-Ring
101.)
12- Cam (Apply Sealer Indicated to Back-Side) Torque Specifications
13- Impeller
14- Gasket a Tighten Securely
15- Cover
16- Screw
17- O-Ring
18- Nut with Washer (4 - Washers not shown)

90-806934 1194 SEAWATER SYSTEM – 6A-3

INDEX
D4.2L/220 Seawater Pump

11
10
9
7 8
A 15
6
5
4
3
16
a 17
14
2
a
13

73946
1 12 a

1 - Pump Housing Lubricant/Sealant Application Points

2 - Screw
3 - Cover A Loctite Master Gasket
4 - Gasket
5 - Impeller Torque Specifications
6 - Cam (Apply Sealer Indicated to Back-Side)
7 - Thrust Washer (Align Notch with Housing Pin) a Tighten Securely
8 - Retaining Ring
9 - Spacer
10- Seal
11- Oil Seal
12- Screw
13- Sealed Ball Bearing
14- Shaft
15- O-Ring
16- Lockwasher (4)
17- Nut (4)

6A-4 – SEAWATER SYSTEM 90-806934 1194

INDEX
Water Flow Diagram

4
5

c
2
1 a
d

10 b
7
e

g
f 6
9

71954

SEAWATER COOLING CIRCUIT CLOSED COOLING CIRCUIT

(RAW WATER) (FRESH WATER/COOLANT)
1 - Seawater Inlet - a - Circulating Pump - Closed Coolant
Thru Drive - MCM (Stern Drive) b - Engine Block - Upper Section of Liners
Thru Hull - MIE (Inboard) c - Water Manifold
2 - Seacock (If So Equipped) d - Cylinder Heads
3 - Seawater Strainer e - Turbocharger
4 - Seawater Pump f - Exhaust Manifold
5 - Intercooler g - Thermostat Housing and Thermostats
6 - Engine Oil Cooler
7 - Heat Exchanger (Seawater Circuit)
8 - Fluid Cooler -
Power Steering Fluid - MCM (Stern Drive)
Transmission Fluid - MIE (Inboard)
9 - Exhaust Pipe Water Jacket
10- Seawater Outlet (Exhaust)

Typical - All Engines

90-806934 1194 SEAWATER SYSTEM – 6A-5

INDEX
Seawater Pump Repair
Removal
DISASSEMBLY
1. Clamp pump in vise as shown. Remove 6 cover
! CAUTION screws.
If boat is in water while working on seawater
pump, when removing seawater inlet hose, close
seacock, if so equipped. If boat is not equipped
with a seacock, remove and plug seawater inlet
hose to prevent a siphoning action that may
occur, allowing seawater to enter boat.
1. Remove and plug seawater pump inlet hose.
Loosen 6 cover screws to drain water into a
suitable container. Remove outlet hose.

a d

c b

70625

a - Cover Screws

2. Remove gasket from cover and pump housing.

3. Using 2 screwdrivers, carefully remove impeller
as shown.
73320

a - Seawater Pump
b - Inlet Hose
c - Cover Screws (6)
d - Outlet Hose
Typical Seawater Pump and Connections
2. Remove 4 hex nuts with lockwashers. Remove
pump.

70423 70626

a - Location of Hex Nuts (Shown Already Removed)

b - Pump

6A-6 – SEAWATER SYSTEM 90-806934 1194

INDEX
4. Follow instructions “a” or “b”: (2) Remove spacer (washer) from shaft.
a. On D3.0L/150 and D3.6L/180 pumps: Re-
move internal snap ring from pump body.

70695

a - Spacer (Washer)

70628 5. Using a soft hammer, tap shaft and bearing

a - Snap Ring assembly out of pump housing.

b. On D4.2L/220 pumps: Follow instructions

(1) and (2).
(1) Remove external retaining ring from
pump shaft.

70638

a - Shaft and Bearing Assembly

b - Pump Housing
Typical

70694

a - Retaining Ring, External

90-806934 1194 SEAWATER SYSTEM – 6A-7

INDEX
6. Follow instructions “a” or “b”: 7. Remove screw from between inlet and outlet to
allow cam removal.
IMPORTANT: Take note of factory markings on
bearings (if visible), or suitably mark each
bearing, to ensure installation in original position
if reused.
a. On D3.0L/150 and D3.6L/180 pumps: Us-
ing an arbor press and suitable hardware, re-
move one bearing at a time from pump shaft
to avoid damaging spacer. Press off toward
splines of shaft and on inner race of bearings
only.

70635

a - Bearing(s) 70638
b - Spacer
c - Pump Shaft
70632

b. On D4.2L/220 pumps: Using an arbor press a - Screw and Location

and suitable hardware, remove one bearing b - Cam
at a time from pump shaft (spacer is ma- Typical Pump and Cam Shown
chined as part of shaft). Press one bearing off
toward splines of shaft and the other oppo-
8. Remove thrust washer from its position on
site. Press on inner race of bearings only.
locating pin in pump housing.

70696

a - Bearing(s)
b - Spacer (Is machined as part of shaft)
c - Pump Shaft

70631

a - Thrust Washer
Typical Pump and Thrust Washer Shown

6A-8 – SEAWATER SYSTEM 90-806934 1194

INDEX
9. Follow instructions “a” or “b”: NOTE: Although different in appearance the front
seal will press out like a normal seal.
a. On D3.0L/150 and D3.6L/180 pumps: Us-
ing a suitable tool, remove two seals, one O-
ring, and one flat washer from pump housing.
Notice positioning.

a - Seal, Front (Assembly)

b - Pump Housing
70637 c - Seal, Rear

a - Seal, Rear
b - O-ring
c - Flat Rubber Washer CLEANING and INSPECTION
d - Seal, Front
! WARNING
b. On D4.2L/220 pumps: Follow instructions
(1) and (2): Always wear safety glasses when using
(1) Being careful not to gouge or nick pump compressed air.
housing, remove rear seal by inserting a
screwdriver through holes in pump hous- 1. Clean metal parts in solvent and blow dry with
ing and carefully pry (push). compressed air.
IMPORTANT: On those models with open (not
sealed) Ball Bearings, do not spin bearings at
high speed when drying with compressed air, as
bearings may be scored and damaged.
2. After cleaning, apply a coat of light engine oil to
shaft and bearings to prevent rusting.
3. Clean all gasket material and sealer from sealing
surfaces.
4. Inspect bearing housing. Examine surfaces
(where bearings contact housing) for evidence of
bearing outer racers turning in housing.
5. Inspect bearings for worn or defective condition.
Examine “sealed” bearings for evidence of loss
of factory grease, or evidence of internal
70697 contamination by engine oil.
a - Screwdriver 6. Inspect seals from bearing housing.
b - Seal, Rear
c - Pump Housing (Do Not gouge or nick) 7. Inspect pump shaft for grooves in surface where
seals contact shaft. Inspect drive key on shaft.
(2) Using a suitable tool, press front seal as- Also, inspect surface, where bearings contact
sembly out front of pump housing from shaft for evidence of inner races turning on shaft.
rear.
8. Inspect impeller splines and shaft splines.
9. Inspect pump body.
10. Inspect cam for scratches or gouging.

90-806934 1194 SEAWATER SYSTEM – 6A-9

INDEX
11. Inspect pump impeller for wear on sides and tips housing. Using a suitable tool, install seal (lip
of blades. Also inspect blades for cracks in area facing out – back of seal visible) as shown.
where blades flex. Replace impeller, if blades
have taken a set (remain in curved position).
12. Replace all parts that do not conform to standards.

ASSEMBLY
1. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 pumps:

IMPORTANT: In the following steps press on inner

races of bearings ONLY. Do not crush spacer.
(1) Using an arbor press, install first bearing
against shoulder of pump shaft beginning
from splined end.
(2) Install plastic spacer and press second
bearing on shaft, in positions shown. 70630

c b a a - Rubber Washer (Installed First, Hidden In This View)

b - Impeller Seal

b. On D4.2L/220 pumps: Install front (impeller)

seal assembly using a suitable tool. Plastic
collar around lip MUST face impeller.
70634

a - First Bearing
b - Spacer (Plastic)
c - Second Bearing

b. On D4.2L/220 pumps:

IMPORTANT: In the following steps press on

inner races of bearings ONLY.
(1) Using an arbor press, install rear bearing
against shoulder of spacer. Press from
rear of shaft.
(2) Press front bearing against shoulder of
spacer. Press from splined end.
c a
b

70630

a - Front Seal (Assembly)

b - Plastic Collar Around Lip (MUST FACE Impeller)
70443

a - Rear Bearing
b - Spacer (Machined As Part of Shaft)
c - Front Bearing
2. Install front seal following instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 pumps:
Install flat rubber washer into impeller side of

6A-10 – SEAWATER SYSTEM 90-806934 1194

INDEX
3. Install rear seal following instructions “a” or “b”: 4. Install thrust washer into pump housing. Align
washer notch with pin in housing.
a. On D3.0L/150 and D3.6L/180 pumps:
Install O-ring into bearing side of housing.
Using a suitable tool, install seal (lip facing
out – back of seal visible) as shown.

70630

a - Thrust Washer
b - Washer Notch
c - Housing Pin

70629
Typical Pump and Thrust Washer
a - O-ring
b - Seal
5. Coat backside of cam with Loctite Master Gasket
and install cam in housing as shown. Tighten
b. On D4.2L/220 pumps: Using a suitable tool, screw securely. Remove excess Loctite and
install seal (lip facing out – back of seal allow to dry before continuing assembly.
visible) as shown.

70444
70633

a - Cam
b - Screw (Hidden in This View)

Typical Pump and Cam Shown

90-806934 1194 SEAWATER SYSTEM – 6A-11

INDEX
6. Follow instructions “a” or “b”: 8. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 pumps: a. On D3.0L/150 and D3.6L/180 pumps:
Install internal snap ring into pump body
IMPORTANT: It is recommended that Shell
groove.
Alvania No. 2 grease be used when packing seals
and bearings in the following steps. If not
available, it is permissible to use Quicksilver
2-4-C Marine Lubricant or Special Lubricant 101.
However, 2-4-C or 101 are not recommended
where continuous high-speed, heavy-duty
operation will be encountered.
(1) Pack bearings with recommended
grease.
(2) Coat lips of seals in pump housing with
recommended grease.
b. On D4.2L/220 pumps: Bearings are sealed
with lubricant from the factory. Coat lips of
seals in pump housing with recommended
grease.
7. Install shaft and bearing assembly into housing
as shown. Tap lightly with soft hammer if needed
to seat assembly.

70628

a - Snap Ring

b. On D4.2L/220 pumps: Install spacer

(washer) on shaft next to front seal assembly.
Install external retaining ring into groove of
shaft.

70638

Typical Pump and Shaft With Bearings Shown

70694

a - Front Seal Assembly

b - Spacer (Washer)
c - Retaining Ring, External

6A-12 – SEAWATER SYSTEM 90-806934 1194

INDEX
9. Hold pump housing in soft-jaw vise. Install 11. Install gasket and cover. Tighten screws evenly
impeller into housing by turning clockwise while in a diagonal pattern. Tighten securely.
simultaneously pushing inward as shown.

70624

Typical Pump and Impeller Shown

10. Push rubber button seal into end of impeller.

70625

a - Cover
b - Gasket (Wide Surface On Cam Side)
c - Screws (6)
Typical Pump and Cover Shown

70627

a - Rubber Button Seal

b - Impeller

90-806934 1194 SEAWATER SYSTEM – 6A-13

INDEX
Installation 3. Install pump on timing gear cover studs. Tighten
hex nuts with washers securely.
1. Install O-ring on pump housing shoulder.

70423

70628

a - O-ring
Typical Pump Shown
2. Turn pump shaft in direction shown to align drive
slot with camshaft.

23161

a - Studs
b - Hex Nuts With Washers
Typical Pump Installation Shown
a

70628

70442

a - Drive Slot
b - Camshaft
Typical Pump and Camshaft End Shown

6A-14 – SEAWATER SYSTEM 90-806934 1194

INDEX
4. Install inlet and outlet hoses. Tighten hose Sea Strainer
clamps securely.

Exploded View

70636

a - Inlet Hose
b - Outlet Hose
c - Hose Clamps
Typical Pump and Hoses Shown

5. Open seacock, if so equipped, or remove plug

from seawater inlet hose and reconnect hose.
Tighten hose clamps securely.
a - Drain Plug and Gasket
6. Start engine; check for leaks. b - Filter Housing
c - Filter Element
d - O-ring Seal
e - Clear Lens
f - Lens Cover
g - Nozzle (2)
h - Cover Screw with Washer (2)

90-806934 1194 SEAWATER SYSTEM – 6A-15

INDEX
Removal b. Models Without Seacock:
(1) If not equipped with seacock, disconnect
seawater inlet hose, from seawater
! CAUTION
strainer inlet.
If boat is in water while working on seawater (2) Quickly plug seawater inlet hose.
strainer, close seacock, if so equipped. If boat is
not equipped with a seacock, remove and plug
seawater inlet hose to prevent a siphoning action
that may occur, allowing seawater to flow from
the drain holes or removed hoses and enter boat.

IMPORTANT: Be certain engine is off and cooling 70062

system is cold.
a - Seawater Inlet Hose
b - Seawater Strainer
1. Follow “a” or “b” instructions: c - Seawater Strainer Inlet
d - Suitable Plug
a. Models Equipped With Seacock:
(1) Close seacock (seawater inlet valve), if 2. Remove outlet hose. Drain into a suitable
so equipped. container.

70062

a - Seawater Outlet Hose

b - Seawater Strainer
70355

a - Seacock (Seawater inlet valve) 3. Remove mounting bolts. Remove strainer.

(2) Disconnect seawater inlet hose from sea-

water strainer.

50226

a - Seawater Inlet Hose

b - Seawater Strainer

6A-16 – SEAWATER SYSTEM 90-806934 1194

INDEX
Installation 3. Check drain plug and lens cover bolts. Tighten
securely. Do not overtighten cover bolts or cover
IMPORTANT: Mount seawater strainer in a may warp and leak water into boat.
vibration-free location. Never mount it on the
engine or transmission. Hoses must not be
kinked or allowed to come in contact with hot or
moving engine or transmission parts.

1. Mount seawater strainer. Note the following:

D Arrow must point towards seawater pump.

D Tighten mounting bolts securely.

50226

a - Drain Plug
b - Lens Cover Bolts – (2, One Hidden In This View)

Oil/Power Steering/
Transmission Fluid Coolers
Cooling efficiency of an engine and components is
50226 greatly dependent upon heat transfer through the
a - Seawater Strainer tubes within the coolers (heat exchanger or
b - Arrow exchangers, if equipped with more than one). During
c - Mounting Bolt Hole Location (Bolts Not Shown) engine operation, contaminants within the seawater
(such as salt, silt, lime, etc.) collect on the inside of
the tubes, thus reducing heat transfer and greatly
2. Install inlet and outlet hoses. Use 2 hose clamps decreasing cooler (heat exchanger) efficiency.
on each hose connection. Tighten clamps
securely. It is therefore, recommended that the seawater
coolers be cleaned every 200 hours of operation or
at least once a year, or whenever decreased cooling
efficiency is suspected.
Additionally, inspect cooler hoses and clamps:
D For Saltwater Use: Every 50 hours of operation
or 60 days, at least once yearly.
50226 D For Freshwater Use: Every 100 hours of
operation or 120 days, at least once yearly.
a - Seawater Inlet Hose
b - Seawater Strainer IMPORTANT: If the possibility of freezing exists,
c - Double Hose Clamps seawater section, and associated heat exchang-
ers, MUST BE drained to prevent freeze damage
to cooling system and engine. Seawater section
also should be drained if boat is to be stored for
an extended period of time, to prevent corrosion
damage.

90-806934 1194 SEAWATER SYSTEM – 6A-17

INDEX
 ! CAUTION
Seawater cooling system MUST BE completely
drained for storage, or trapped water may cause
freeze and/or corrosion damage to engine and/or
components.

! CAUTION
If boat is in the water, seacock (if so equipped)
MUST BE left closed until engine is to be
restarted, to prevent water from flowing back into
the cooling system and to prevent contaminated
water from entering the system. If boat is not
fitted with a seacock, water inlet hose MUST BE
left disconnected and plugged to prevent water
from flowing into cooling system and/or boat. As
a precautionary measure, attach a tag to the
ignition switch or steering wheel with the
WARNING that the seacock MUST BE opened or
the water inlet hose reconnected prior to starting
the engine.
IMPORTANT: A wire should be repeatedly
inserted into drain holes to ensure that foreign
material is not obstructing the drain holes.
IMPORTANT: To prevent threads from rusting out
during storage, reinstall plugs using Perfect Seal
on threads. NEVER leave drain plugs out after
cleaning or during storage.
Location of Coolers
Refer to the following for location of oil, power
steering and transmission fluid coolers.
a
b
73522
a - Transmission Fluid Cooler
b - Engine Oil Cooler
MIE (Inboard) D4.2L/220 Shown (All Similar)
Inspection
1. Refer to Section 1B – Maintenance, “Cold
Weather or Extended Storage, Draining
Instructions” (and precautions in this section)
and drain the seawater system.
2. Remove hose clamp or end cover from INLET
end (refer to Seawater Flow Diagrams) of the ap-
propriate cooler(s).
3. Inspect passages:
a. If passages appear blocked or restricted with
contaminants, cleaning is required. Refer to
the following section - “Cleaning”..
b. If blockage or restriction is not present, refit
hose or end cover. Torque end cover to spec-
ification or securely tighten hose clamp.

72470

a - Power Steering Cooler

b - Engine Oil Cooler
MCM (Stern Drive) Models (All Similar)

6A-18 – SEAWATER SYSTEM 90-806934 1194

INDEX
Cleaning
1. Refer to Section 1B – Maintenance, “Cold
Weather or Extended Storage, Draining
Instructions” (and precautions in this section)
and drain the seawater system, if not already
accomplished.
2. Remove hoses from both ends of cooler to be
cleaned.
3. Temporarily attach a suitable hose to inlet end of
cooler and place end of hose in a suitable
container to catch water in the following.
4. Attach a suitable adaptor to the outlet end of
cooler to which a tap water hose may be
connected.
5. Open tap water faucet and “backflush” cooler
until discharge water is clean.
6. Remove temporary hose and adaptor and
inspect cooler passages:
D If passages are clear, reconnect seawater
hoses and tighten hose clamps securely.
IMPORTANT: MerCruiser does not recommend
the immersion of oil/power steering/ transmis-
sion fluid coolers in cleaning solutions. If back-
flushing of the problem cooler does not satisfac-
torily clear the passages replacement of the
cooler is recommended.
Removal
POWER STEERING
1. Refer to Section 1B – Maintenance, “Cold
Weather or Extended Storage, Draining
Instructions” (and precautions in this section)
and drain the seawater system, if not already
accomplished.
2. Follow instructions “a” – “e”:
NOTE: Obtain two clean, suitable devices and plug
hoses in following instructions to avoid loss of power
steering fluid.
a. Mark fore and aft fluid hoses to aid in
reassembly.
b. Using a suitable container to catch excess
fluid, disconnect power steering fluid hoses
as shown. Plug hoses quickly.
c. Disconnect attached seawater hoses.
NOTE: On later engines a shift bracket fastener must
be removed to allow removal of cooler.
d. If fitted as shown, remove shift bracket
fastener and stud extension.
e. Remove cooler with J-clamp.
a

D If passages are still obstructed, follow

instructions “a” - “c”: 72470

a. Clean tubes in heat exchanger and coolers e d

by running a suitable wire brush of the proper
size thru each tube.
a

d b
b
71724
c
a - Wire Brush, Sized to Fit Passages
b. Rinse out heat exchanger and cooler tubes 74447
with tap water from a hose to remove loos-
ened particles. a - Power Steering Cooler
b - Power Steering Fluid Hoses
c. Replace unit if it cannot be satisfactorily c - Shift Bracket Fastener and Stud Extension
cleaned. Refer to the following section. d - Seawater Hoses
e - J-Clamp
Typical Power Steering Cooler Installation
(All Similar)

90-806934 1194 SEAWATER SYSTEM – 6A-19

INDEX
ENGINE OIL COOLER c. Disconnect seawater and closed cooling
hoses as required to allow removal of heat
1. Refer to SECTION 1B – Maintenance, “Cold exchanger, as shown following.
Weather or Extended Storage, Draining d. Disconnect turbocharger coolant vent hose
Instructions” (and precautions in this section) on upper-port side of expansion tank.
and drain the seawater system, if not already
e. Remove the two large screw clamps retaining
accomplished.
the heat exchanger to the port and starboard
2. Refer to SECTION 6B – “Draining Closed brackets.
Cooling Section” instructions (and precautions in
f. Remove combination heat exchanger and
this section) and drain system, if not already
engine oil cooler.
accomplished.
g. If cooler is to be replaced, it will be necessary
3. Follow instructions “a” – “g”:
to replace the complete heat exchanger
NOTE: Obtain clean, suitable devices and plug assembly.
hoses in following instructions to avoid loss of engine
oil. a
b
a. Mark port and starboard oil hoses to aid in
reassembly.
a a
b. Disconnect engine oil filter head-to-oil cooler b
line fittings (near each end of oil cooler) on
heat exchanger. Quickly plug hoses.

c
b

a a
74446

74484

a - Remove End Of Hoses Where Indicated For Ease Of

Disassembly and Reassembly
b - Clamps
Engine Oil Cooler/Heat Exchanger and Related
Components
a
b
c

72470

a - Engine Oil Cooler (Combined With Heat Exchanger)

b - Starboard Oil Hose Line and Fitting
c - Port Oil Hose Line and Fitting (Fitting Not Visible)

6A-20 – SEAWATER SYSTEM 90-806934 1194

INDEX
TRANSMISSION FLUID COOLER Installation
1. Refer to Section 1B – Maintenance, “Cold POWER STEERING
Weather or Extended Storage, Draining
Instructions” (and precautions in this section) 1. Follow instructions “a” – “c”:
and drain the seawater system, if not already
accomplished. a. Install cooler with J-clamp into connecting
seawater hoses. Position fittings as shown
2. Follow instructions “a” – “f”: and tighten seawater hose clamps.
NOTE: Obtain clean, suitable devices and plug b. If fitted as shown, install shift bracket stud
hoses in following instructions to avoid loss of extension and fastener. Torque both to 24 lb.
transmission fluid. ft. (32 N·m).
a. Disconnect seawater hoses from c. Remove plugs from fluid hoses and connect
transmission fluid cooler. to fittings as marked on disassembly. Tighten
b. Mark fore and aft transmission fluid hoses to fluid hose clamps securely.
aid in reassembly.
a
e d
c. Disconnect transmission fluid hoses from
cooler.
d. Remove fasteners from clamps retaining
cooler to manifold.
e. Remove transmission fluid cooler.
f. If cooler is to be replaced, note position of 90° d b
elbow connectors and remove to retain. b
c
a

74447

a - Cooler, Power Steering

b - Hose, Seawater-to-Cooler
c - Hose Clamp, Seawater
d - Cooler Fittings
e - Hose, Power Steering Fluid
f - Hose Clamp, Fluid
Typical Power Steering Cooler
d d
2. Refer to Section 1B, Maintenance – “Check
Power Steering Fluid” and refill power steering
e reservoir.
b f b
f 3. Open seacock if so equipped, or unplug
c seawater inlet hose and reconnect. Tighten hose
clamps securely.
4. Run-test engine briefly (to fill cooler); check for
a - Transmission Fluid Cooler leaks. Stop engine.
b - Seawater Hoses 5. Refer to Section 1B, Maintenance – “Checking
c - Transmission Fluid Hoses
Power Steering Fluid” and refill power steering
d - Retaining Clamps
e - Fasteners reservoir.
f - 90° Elbow Connectors
Typical Transmission Fluid Cooler

90-806934 1194 SEAWATER SYSTEM – 6A-21

INDEX
ENGINE OIL COOLER e. Install the two large screw clamps retaining
the heat exchanger to the port and starboard
1. Follow instructions “a” – “e”:
brackets.
NOTE: Prior to installing the heat exchanger, put a
f. Reconnect turbocharger coolant vent hose .
small amount of petroleum jelly on the brackets and
Tighten hose clamp securely.
hose ends to ease installation.
2. Refer to SECTION 6B – “Filling Closed Cooling
a. Install the combination heat exchanger and
Section” instructions and fill the system.
engine oil cooler.
3. Open seacock if so equipped, or unplug
b. Make all necessary seawater and closed
seawater inlet hose and reconnect. Tighten hose
cooling hose connections. Tighten hose
clamps securely.
clamps securely.
4. Pre-lube the turbocharger. Start the engine. Run
c. To minimize oil loss, quickly install engine oil
briefly (to fill cooler) and check for leaks. Stop en-
filter head-to-oil cooler lines, as marked upon
gine.
disassembly, to fittings (near each end of oil
cooler, on heat exchanger). IMPORTANT: Use only specified engine oil.
d. Reconnect coolant recovery bottle hose. 5. Check engine oil level. Fill to proper level with
specified oil.

c
b f

e
A
b
a
74446

b b
a

c 74484

74487
a - Heat Exchanger/Oil Cooler
b - Clamps
c - Starboard Oil Hose Line and Fitting
d - Port Oil Hose Line and Fitting
e - Turbocharger Coolant Vent Hose Connection
f - Coolant Recovery Bottle Hose

A - Petroleum Jelly Obtain Locally

Engine Oil Cooler/Heat Exchanger and Related

6A-22 – SEAWATER SYSTEM 90-806934 1194

INDEX
TRANSMISSION FLUID COOLER
1. Follow instructions “a” – “c” :
a. If cooler is being replaced, coat threads of
90° elbow connectors retained previously
with Loctite Pipe Sealant (with Teflon) and
install on cooler in positions noted on
disassembly.
a 4. Check transmission fluid level. Fluid should be
2. Open seacock if so equipped, or unplug
seawater inlet hose and reconnect. Tighten hose
clamps securely.
3. Start engine. Run briefly (to fill cooler) and check
for leaks. Stop engine.
IMPORTANT: Use only ATF (Automatic
Transmission Fluid), such as Dexron II-D.
between “MIN” and “MAX” marks on dipstick. Fill
transmission to proper level.

a - Transmission Fluid Cooler

b - 90° Elbow Connectors
Typical Transmission Fluid Cooler Shown
b. Install transmission fluid cooler on manifold.
Secure with clamps and fasteners. Torque to
18 lb. ft. (25 N⋅m).
c. Connect transmission fluid hoses to cooler,
where noted upon disassembly, as shown.
Tighten hoses securely.
d. If cooler is to be replaced, note position of 90°
elbow connectors and remove to retain.
a

d d

e
b f b
f
c

a - Transmission Fluid Cooler

b - Seawater Hoses
c - Transmission Fluid Hoses
d - Retaining Clamps
e - Fasteners
f - 90° Elbow Connectors
D4.2L/220 Transmission Fluid Cooler Installation
Shown (All Similar)

90-806934 1194 SEAWATER SYSTEM – 6A-23

INDEX
COOLING SYSTEMS

73793

CLOSED COOLING SYSTEM

6
B
Index
Table of Contents
Page Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 6B-15
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16
Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Water Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . 6B-17
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17
Lubricants / Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 6B-17
Cooling System Cleaners . . . . . . . . . . . . . . . . . . . . . . 6B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Water Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Exploded Views and Diagrams . . . . . . . . . . . . . . . . . . 6B-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 6B-18
Heat Exchanger / Coolant Tank, Water Manifold, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
and Related Components . . . . . . . . . . . . . . . . . . . 6B-4 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19
Engine Water Circulating Pumps . . . . . . . . . . . . . 6B-5 Auxiliary Hot Water Heater Connections . . . . . . . . . 6B-20
D3.0L/150 and D3.6L/180 Engines . . . . . . . . 6B-5
D4.2L/220 Engines . . . . . . . . . . . . . . . . . . . . . . 6B-5
Sea Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5 NOTICE
Thru-Hull Pickup and Seacock . . . . . . . . . . . . . . . 6B-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-6 For instructions on Cleaning Seawater Strainer,
Maintaining Coolant Level . . . . . . . . . . . . . . . . . . . . . . 6B-6 Flushing Seawater Cooling System or Draining
Changing (Replacing) Coolant . . . . . . . . . . . . . . . . . . 6B-7 Seawater Section refer to SECTION 1B - “Main-
Coolant Requirement . . . . . . . . . . . . . . . . . . . . . . . 6B-7
Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7 tenance.”
Draining Closed Cooling Section . . . . . . . . . . . . . . . . 6B-8
Closed Cooling Section Draining Diagram . . . . . 6B-8
Cleaning Closed Cooling Section . . . . . . . . . . . . . . . . 6B-9
Heat Exchangers and Coolers . . . . . . . . . . . . . . . 6B-9 NOTICE
Filling Closed Cooling Section . . . . . . . . . . . . . . . . . 6B-10
Testing The System . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 For information on other heat exchangers
Testing Coolant for Alkalinity . . . . . . . . . . . . . . . . 6B-10 cooled by seawater refer to SECTION 6A - Sea-
Pressure Testing System . . . . . . . . . . . . . . . . . . . 6B-10
Testing for Cylinder Head Gasket Leak . . . . . . . 6B-11 water System, “Oil/Power Steering/Transmis-
Testing Pressure Cap . . . . . . . . . . . . . . . . . . . . . . 6B-12 sion Fluid Coolers.”
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 NOTICE
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 For information on Oil Filter Head and Oil Ther-
For Internal Leak: . . . . . . . . . . . . . . . . . . . . . . . 6B-14
For Blockage: . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 mostat refer to SECTION 3A - Engine, “Oil Ther-
mostat.”

Index
6B –- CLOSED COOLING SYSTEM
6B-0 90-806934 1194
Torque Specifications Thermostats
TORQUE Operating Tempera-
DESCRIPTION Model Location
Lb. In. Lb. ft. (N⋅m) ture
Engine Water Circulat- Two In
1 at 160° F (70° C), and
ing Pump All Thermostat
1 at 180° F (82° C)
22 30 Housing
Thermostat Housing-
to-Manifold IMPORTANT: It is not necessary to position either
Thermostat Housing thermostat in a certain location within the ther-
132 16 mostat housing. Ensure however, that one of
Cover
each specified operating temperature is present.
Port Heat Exchanger
22 30
Bracket
Water Pump Pulley Pressure Cap
72 8.5
(D4.2L/220)
Water Manifold 84 10 Model Operating Pressure
Heat Exchanger Main All 14 PSI (97 kPa)1
16 22
Tank End Covers
1: Must hold rated pressure for 30 seconds without
Heat Exchanger Lower
Tank (Oil Cooler) End 96 11 going below 11 psi (76 kPa).
Covers
All Fasteners Not Tighten Securely
Listed Coolant
Model Required Coolant
Quicksilver Premixed Marine
Specifications All Engine Coolant -
92-813054A2

Capacity NOTE: The premixed formula listed above requires

no mixing with water or other additives. The low sili-
System Capacity cate formula prevents silicate gelling which can re-
strict engine cooling passages. Engine coolant pro-
U.S. Gal. (L) vides protection down to –33° F. ( –38° C).
Model
(Approximate)
IMPORTANT: Quicksilver Premixed Marine En-
D3.0L/150 11.5 (11)
gine Coolant contains special low silicate ethy-
D3.6L/180 12.5 (12) lene glycol, special additives, and purified water.
D4.2L/220 13.7 (13) Use of other coolant may cause fouling of the
heat exchangers, and overheating of the engine.

Index
90-806934 1194 CLOSED COOLING SYSTEM – 6B-1
Lubricants / Sealants Special Tools
DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubri- Pink Litmus Paper Obtain Locally
92-825407A2
cant Thermostat Tester Obtain Locally
Special Lubricant 101 92-13872A1
Heat Exchanger Cleaning Brush Obtain Locally
Quicksilver Perfect Seal 92-34227--1
Loctite Master Gasket 92-12564--1
Gasket Sealer 92-72592--1
Shell Alvania No. 2 Obtain Locally
Loctite Pipe Sealant with Teflon Obtain Locally

Cooling System Cleaners

DESCRIPTION PART NUMBER
Quicksilver Cooling System
91-814825
Cleaner
CC2610 -Ob-
Fleetguard Restore
tain Locally

Index
6B-2 - CLOSED COOLING SYSTEM 90-806934 1194
Exploded Views and Diagrams

Water Flow Diagram

4
5

c
2
1 a
d

10 b
7
e

g
f 6
9

71954

SEAWATER COOLING CIRCUIT CLOSED COOLING CIRCUIT

(RAW WATER) (FRESH WATER/COOLANT)
1 - Seawater Inlet - a - Circulating Pump - Closed Coolant
Thru Drive - MCM (Stern Drive) b - Engine Block - Upper Section of Liners
Thru Hull - MIE (Inboard) c - Water Manifold
2 - Seacock (If So Equipped) d - Cylinder Heads
3 - Seawater Strainer e - Turbocharger
4 - Seawater Pump f - Exhaust Manifold
5 - Intercooler g - Thermostat Housing and Thermostats
6 - Engine Oil Cooler
7 - Heat Exchanger (Seawater Circuit)
8 - Fluid Cooler -
Power Steering Fluid - MCM (Stern Drive)
Transmission Fluid - MIE (Inboard)
9 - Exhaust Pipe Water Jacket
10- Seawater Outlet (Exhaust)
Index
90-806934 1194 CLOSED COOLING SYSTEM – 6B-3
Heat Exchanger / Coolant Tank, Water Manifold, and Related Components

22 20

c
A
19
21

18 A
c
b 10
9 A
c

11
8 73793

17

16
4
12
7

1 14
a
6
5 15

3 13 a
d

e
73793
2
1 - Heat Exchanger / Coolant Tank 21- Hose and Clamps (To Exhaust Manifold End Cover)
2 - Circulating Pump-to-Heat Exchanger Hose 22- Hose (To Heat Exchanger Fitting)
3 - Thermostat Housing-to-Heat Exchanger Hose
4 - Pressure Cap - Hose Connection to Turbocharger Banjo Fitting
5 - Thermostat Housing With Exchanger Bracket
6 - Screw with Lockwasher (2 of 2 Different Lengths) Lubricant/Sealant Application Points
7 - Thermostats [2 of Different Opening Temperatures - (Al-
ways install before gasket.)] A Loctite Master Gasket - 92-12564--1
8 - Gasket (1)
9 - Thermostat Housing Cover Torque Specifications
10- Screw and Lockwasher (4 Each)
11- Thermostat Housing Cover-to-Heat Exchanger Hose a 22 lb. ft. (30 N·m)
12- Water Circulating Pump Bypass Hose
13- Port Side Exchanger Bracket b 132 lb. in. (16 N·m)
14- Engine Lifting Eye
15- Intercooler-to-Engine Oil Cooler Hose c 84 lb. in. (10 N·m)
16- Heat Exchanger-to-Fluid Cooler Hose
17- Fluid Cooler - (MCM - Power Steering Fluid; MIE - Trans- d 16 lb. ft. (22 N·m)
mission Fluid Cooler)
18- Fluid Cooler-to-Exhaust Elbow Connector
19- Connector at Exhaust Elbow
e 96 lb. in. (11 N·m)
20- Water Manifold and Related (Across Cylinder Heads)
Index
6B-4 - CLOSED COOLING SYSTEM 90-806934 1194
Engine Water Circulating Pumps Sea Strainer

D3.0L/150 AND D3.6L/180 ENGINES 2 1

1 2 3
3

4 a 73944

1 - Water Circulating Pump (With Pulley) 6

2 - Gasket
3 - Stud(s)
4 - Hex Nuts with Washers
7
Torque Specifications
a 22 lb. ft. (30 N·m) 72673

1 - Screws and Washers

2 - Cover
D4.2L/220 ENGINES 3 - Glass
4 - Gasket
5 - Strainer
6 - Housing
7 - Drain Plug and Sealing Washer
3
1 Quicksilver Seawater Strainer Shown

Thru-Hull Pickup and Seacock

2
1

2
4 a
73948

1 - Water Circulating Pump

2 - Pulley
3 4
3 - Gasket 70355
4 - Screws With Washers
Torque Specifications 1 - Hose Connector [1-1/2 In. (38 mm) I.D.] to Seawater
Strainer Inlet
a 22 lb. ft. (30 N·m) 2 - Seacock [1-1/2 In. (38 mm)] Brass Ball or Gate Valve
3 - Seawater Pickup
4 - Direction of Seawater Flow
Quicksilver Components Shown - MIE (Inboard)
Index
90-806934 1194 CLOSED COOLING SYSTEM – 6B-5
Description Maintaining Coolant Level
The closed cooling system is composed of two sepa- Before starting engine each day, check to ensure that
rate sub-systems; the seawater system (Discussed coolant is visible in coolant recovery bottle.
in SECTION 6A.) and the closed cooling system. The
If coolant is not visible, check coolant (fresh water)
heat from the closed cooling system is absorbed by
section of cooling system (including coolant recovery
the seawater system as seawater passes through
system) for leaks and repair, as necessary. Refill
cooling tubes in the coolant tank (usually referred to
coolant section with recommended coolant solution,
as “the heat exchanger”). The closed cooling system
as outlined under “Changing Closed Cooling System
is similar in function, therefore, to the cooling system
Coolant,” as outlined in the following section.
in an automobile.
If coolant is visible, start engine and run until it
Coolant (antifreeze mixture) is circulated through the
reaches normal operating temperature, then recheck
engine block. turbocharger housing, exhaust man-
coolant level in coolant recovery bottle. Coolant level
ifold, and closed coolant tank by a belt driven water
MUST BE between the “Add” and “Full” marks (on
pump.
front of bottle). If level is low, remove fill cap from
All engines covered by this manual use an identical coolant recovery bottle and add required amount
triple cavity coolant tank, or heat exchanger, for the Quicksilver Premixed Marine Engine Coolant. If
closed cooling system to maintain engine coolant and frequent additions of coolant are required, check
engine oil temperatures, and to provide an expansion closed cooling section for leaks.
tank. The closed coolant tank mounted on the front a
of the engine has separate cooling tube sections for
engine coolant and engine oil.
On these engines seawater flows through the cooling
tubes, which are joined inside the coolant tank. Oil
and coolant flow around the outside of the cooling
tubes in separated cavities. Engine coolant circula-
tion and temperature are controlled by two thermo-
stats in a remote engine mounted housing. Oil tem-
perature is controlled by a block mounted thermostat
in the oil filter header, which controls oil circulation to
the separated cooling tubes.
The third cavity, on top of the heat exchangers with
the filler neck and pressure cap, serves as the expan-
sion tank. The systems are pressurized to raise the
boiling point of the coolant - s special, Quicksilver
Premixed Marine Engine Coolant.
71712
Each engine has a coolant recovery system which
keeps the closed coolant tank full. This system ac-
cepts overflow during warm-up and then, allows cool- a - Fill Cap
ant to be drawn into the closed coolant tank as the en-
gine cools. As long as there is coolant in the recovery ! CAUTION
bottle, the reservoir in the expansion tank should re-
Alcohol or methanol base antifreeze or plain wa-
main completely full. If the recovery bottle does not
ter are not recommended for use in cooling sys-
function properly, there is a vacuum leak, usually at
tem at any time.
the hose leaving the reservoir, or the gasket under the
pressure cap. The pressure cap gasket seals against
the outer rim of the filler neck, unless it is defective,
and causing a vacuum leak.

Index
6B-6 - CLOSED COOLING SYSTEM 90-806934 1194
 ! WARNING
DO NOT remove coolant pressure cap when the
engine is hot - coolant may discharge violently,
causing severe burns.
! CAUTION
If the coolant should get extremely low and the
engine very hot, let the engine cool for approxi-
mately 15 minutes before adding coolant; then,
with the engine running, add coolant slowly. Ad-
ding cold coolant to a hot engine may crack the
cylinder head or crankcase. Never use water
alone.
Occasionally, check to ensure that coolant recovery
system is functioning properly by removing pressure
cap from heat exchanger and checking level. After
engine has cooled down, turn pressure cap
1/4-turn to allow any pressure to escape slowly,
then push down and turn cap all-the-way off.
Coolant level should be up to bottom of heat
exchanger filler neck. If low, inspect entire closed
cooling coolant (fresh water) section (especially
coolant recovery system) for leaks and repair, as
necessary.
IMPORTANT: When reinstalling pressure cap, be
sure to tighten it until its contact stops on filler
neck.
Index
90-806934 1194
Changing (Replacing)
Coolant
Coolant Requirement
! CAUTION
Alcohol or methanol base antifreeze or plain wa-
ter are not recommended for use in cooling sys-
tem at any time.
IMPORTANT: Quicksilver Premixed Marine En-
gine Coolant contains special low silicate ethy-
lene glycol, special additives, and purified water.
Use of other coolant may cause fouling of the
heat exchangers, and overheating of the engine.
It is required that the coolant section of the Closed
Cooling Section be filled with Quicksilver Premixed
Marine Engine Coolant. this premixed formula re-
quires no mixing with water or other additives; low sili-
cate formula prevents silicate gelling which can re-
strict engine cooling passages. Quicksilver engine
coolant provides protection down to –33°F (–38°C).
DO NOT MIX the new antifreeze/coolant mixture with
the old solution or it will cause particles to form in the
coolant. These small particles can settle in the heat
exchangers and restrict coolant flow. Drain and flush
the old coolant from the closed cooling system as re-
quired.
Change Interval
The old coolant should be drained from the closed
cooling system every 200 hours of use or once yearly,
whichever occurs first. Refer to “Cleaning Closed
Cooling System”, whenever decreased cooling effi-
ciency is experienced.
CLOSED COOLING SYSTEM – 6B-7
Draining Closed Cooling
Section
! WARNING
Allow engine to cool before removing pressure
cap. Sudden loss of pressure could cause hot
coolant to boil and discharge violently. After en-
gine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
turn cap all the way off.
IMPORTANT: A wire should be repeatedly in-
serted into drain holes to ensure that foreign ma-
terial is not obstructing the drain holes.
IMPORTANT: Engine must be as level as possible
to ensure complete draining of cooling system.
IMPORTANT: Closed cooled section must be kept
filled year round with recommended coolant. If
engine will be exposed to freezing temperatures,
make sure closed cooled section is filled with an
ethylene glycol antifreeze and water solution
Closed Cooling Section Draining Diagram
d
71381
71364
a - Pressure Cap
b - Drain Petcock on Intake/Exhaust Manifold
c - Drain Petcock on Engine Block
d - Coolant Recovery Bottle
Typical
Index
6B-8 - CLOSED COOLING SYSTEM
properly mixed to protect engine to lowest tem-
perature to which it will be exposed.
IMPORTANT: Do not use Propylene Glycol Anti-
freeze in the closed cooled section of the engine.
1. Allow engine to cool down. Remove pressure cap
from coolant tank.
2. Drain coolant from intake/exhaust manifold by
opening the petcock.
3. Drain coolant from the engine block by opening
the petcock.
4. After coolant has drained completely, securely
close petcocks.
5. Remove coolant recovery bottle from mounting
bracket and pour out coolant.
6. If required, clean system as outlined in “Cleaning
System.”
7. Fill system as outlined in “Filling Closed Cooled
Section.”
a
72706
NOTICE
For instructions on Draining Seawater Section
refer to SECTION 1B - “Maintenance.”
90-806934 1194
Cleaning Closed Cooling
Section
Cooling System Cleaners
1. Drain coolant from engine as previously outlined.
NOTE: Properly dispose of old coolant.
2. Add one liter of Quicksilver Cooling System
Cleaner 92-814825 or add Fleetgaurd Restore
CC2610 to cooling system following the manufac-
turer’s instructions.
3. Fill the cooling system with tap water to within 1/2
to 3/4 in. (13 - 19 mm) of bottom of filler neck.
NOTE: During system cleaning leave auxiliary heat-
er, if so equipped, connected to engine. Otherwise,
the engine will contaminated when the heater is re-
connected.
4. Operate the engine in open water at wide open
throttle at normal operating temperature for thirty
minutes minimum to circulate cleaner.
5. Stop engine and after cool down, drain cleaner
from cooling system.
NOTE: Properly dispose of contaminated cleaner.
6. Flush closed cooling system as follows:
a. Remove thermostat housing cover and ther-
mostats. Temporarily install cover.
b. Remove large hex plug from exhaust man-
ifold rear cover. On engines equipped with
auxiliary hot water heater, remove heater
hose from fitting (in place of hex plug). Then,
install an adaptor to this opening, suitable for
connecting a tap water hose.
70192
Hex Plug Drain (Similar With Hot Water
Connection)
Index
90-806934 1194
c. Attach tap water hose to adaptor.
d. Follow instructions “(1)” or “(2)”:
(1) On engines with Auxiliary Hot Water
Heaters: Proceed to “e”.
(2) On engines without Auxiliary Hot Wa-
ter Heaters: Open cylinder block drain
petcocks.
e. Run tap water through system until discharge
water is clean.
NOTE: Catch expelled water (from either the open
cylinder block petcocks, or the loose end of the auxil-
iary hot water hose previously disconnected) in a suit-
able container and dispose of properly.
f. Shut off tap water.
g. Remove tap water hose and adaptor. Install
large hex plug, with new sealing washer, on
intercooler, or reconnect heater hose. Close
cylinder block petcocks if previously opened.
h. Install thermostats. Position thermostats in
housing and then, position a new thermostat
housing gasket on housing. Torque housing
cover screws to 132 lb. in. (16 N·m).
7. Refer to “Filling Closed Cooling Section” and refill
with Quicksilver Premixed Marine Engine
Coolant.
NOTICE
For instructions on Flushing Seawater Section
refer to SECTION 1B - “Maintenance.”
Heat Exchanger and Cooler Cleaning
1. Clean tubes in heat exchanger and coolers by running
a suitable wire brush thru each tube.
a
71724
a - Wire Brush, Sized to Fit Passages
2. Rinse out heat exchanger and cooler tubes with tap
water from a hose to remove loosened particles.
3. Replace unit if it cannot be satisfactorily cleaned.
CLOSED COOLING SYSTEM – 6B-9
Filling Closed Cooling
Section
1. Remove pressure cap from heat exchanger and
fill section with Quicksilver Premixed Marine
Engine Coolant through heat exchanger fill
neck. Continue filling until coolant level is 1 in. (25
mm) below filler neck.
! CAUTION
Avoid seawater pickup pump impeller damage
and subsequent overheating damage to stern
drive unit. DO NOT operate engine without water
being supplied to seawater pickup pump.
2. With pressure cap off, start engine and run at fast
idle (1500-1800 RPM). Add recommended cool-
ant solution to heat exchanger, as required, to
maintain coolant level 1 in. (25 mm) below filler
neck.
3. After engine has reached normal operating tem-
perature (thermostats are fully open), and coolant
level remains constant, fill heat exchanger to bot-
tom of filler neck.
4. Observe engine temperature gauge to make sure
that engine operating temperature is normal. If
gauge indicates excessive temperature, stop en-
gine immediately and examine for cause.
5. Install pressure cap on heat exchanger.
6. Remove cap from coolant recovery reservoir and
fill to FULL mark with recommended coolant solu-
tion. Reinstall cap.
7. With engine still running, check hose connec-
tions, fittings and gaskets for leaks. Repeat
Step 4.
Testing The System
Testing Coolant for Alkalinity
! WARNING
Allow engine to cool before removing pressure
cap as sudden loss of pressure could cause hot
coolant to boil and discharge violently. After en-
gine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
turn cap all the way off.
Index
6B-10 - CLOSED COOLING SYSTEM
Coolant in closed cooling (fresh water) section should
be changed every two years and should be checked
for alkalinity at least once between change intervals.
To check coolant for alkalinity, proceed as follows:
1. Obtain pink litmus paper from a local supplier
(drug store, pet shop, etc.).
2. Remove pressure cap from heat exchanger and
insert one end of litmus paper into coolant.
3. If pink litmus paper turns blue, coolant is alka-
line and need not be replaced.
4. If pink litmus paper remains pink, coolant is not
alkaline and MUST BE REPLACED, as explained
under “Changing Coolant.”
Pressure Testing System
! WARNING
Allow engine to cool before removing pressure
cap. Sudden loss of pressure could cause hot
coolant to boil and discharge violently. After en-
gine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
turn cap all the way off.
If coolant section of closed cooled section is sus-
pected of leaking or not holding sufficient pressure,
and no visible signs of leakage can be found, perform
the following test:
1. Remove pressure cap from heat exchanger or
reservoir.
2. Clean, inspect and pressure test pressure cap, as
outlined under “Testing Pressure Cap,” to elimi-
nate the possibility that cap is not maintaining
proper pressure in system and is causing coolant
to boil over.
3. Clean inside of filler neck to remove any deposits
or debris. Examine lower inside sealing surface
for nicks or other damage. Surface must be per-
fectly smooth to achieve a good seal between it
and rubber seal on cap. Also check locking cams
on sides of filler neck to be sure that they are not
bent or damaged. If locking cams are bent or
damaged, pressure cap will not hold the proper
pressure.
4. Adjust coolant level in fresh water section to 1 in.
(25 mm) below filler neck.
90-806934 1194
5. Attach an automotive-type cooling system pres-
sure tester to filler neck and pressurize closed
cooled section to amount specified in following
chart, based on pressure cap rating for your en-
gine.
Amount of Pressure
Pressure Cap Rating Applied to Closed
Cooled Section
14 PSI (97 kPa) 20 PSI (137 kPa)
6. Observe gauge reading for approximately two
minutes; pressure should not drop during this
time. If pressure drops, proceed with the following
steps until leakage is found.
7. While maintaining specified pressure on closed
cooled section, visually inspect external portion of
cooling system (hoses, gaskets, drain plugs, core
plugs, circulating pump seal, etc.) for leakage.
Also listen closely for bubbling or hissing, as they
usually are a sure indication of a leak.
8. Refer to “Testing Heat Exchanger” in this section
and test as outlined.
9. If no leakage could be found in above steps, en-
gine is leaking internally, and it probably is due to
one or more of the following: (1) loose cylinder
head bolts or damaged gasket, (2) loose turbo-
charger bolts or damaged gasket, (3) loose ex-
haust elbow or damaged gasket, (4) cracked or
porous cylinder head or block, or (5) cracked or
porous exhaust manifold. Proceed as follows until
location of internal leak is found.
a. Start engine. Pressurize system to previously
specified amount and observe pressure
gauge on tester. If needle in gauge vibrates,
compression or combustion is leaking into
closed cooled section from a leak in the com-
bustion chamber. Stop engine.
b. Remove glow plugs (one at a time) from cylin-
ders and examine for presence of coolant. A
glow plug that is perfectly clean or milky ap-
pearing is a sure indication of a leak.
c. Drain oil from engine and examine for pres-
ence of coolant. Oil usually will be milky if
coolant is present. If coolant is present, re-
move engine from boat and remove the oil
pan. With engine in the upright position, pres-
surize closed cooled section to previously
specified amount and examine internal sur-
faces of engine to locate leak.
d. If no leakage can be found in above steps, en-
tire engine must be disassembled and in-
spected for leakage.
Index
90-806934 1194
Testing for Cylinder Head Gasket
Leak
A leaking head gasket will cause combustion gas to
be forced into the cooling system. The mixture of
coolant and tiny air bubbles is a poor heat conductor
and will overheat an engine quickly. Compression
tests or cooling system pressure check normally will
not detect the leak because the test pressure is far
below the combustion pressures which cause the
leak. An effective test is as follows:
IMPORTANT: Run boat in lake for this test. It is
best to run the engine at or above cruising speed
during this test. Usually a failed head gasket will
not cause the engine to overheat below cruising
speed.
1. Install a clear plastic hose between the reservoir
and coolant recovery bottle. Use a 2-3 ft. (61-91
cm) long hose for this test.
2. Route this hose so a “U” is formed.
3. Put enough coolant into hose to fill the center 4 or
5 inches (10-13 cm) of the “U.”
4. Observe the “U” while the engine is running.
a. During Idle and Warm-Up: Some coolant
and/or air will leave the reservoir.
b. During Cruising Speed (2800 - 3200 RPM):
Coolant and/or air leaving the reservoir
should stop after approximately five minutes
running at a given RPM. A leaking head gas-
ket will produce air bubbling through the “U,”
going to the coolant recovery bottle. The fre-
quency and size of the bubbles will depend on
the size of the leak.
c. At Higher Speeds (3200 - 3800 on
D3.0L/150 and D3.6L/180 Engines or 3200
- 3600 on D4.2L/220 Engines): Normal op-
eration is the same as described in “b” above.
A failed head gasket will cause the bubbles to
come faster and may be accompanied by vio-
lent, intermittent bursts of coolant.
It is important not to confuse normal warm-up expan-
sion with a failed head gasket. Normal warm-up pro-
duces an intermittent flow of coolant which will stop
within approximately five minutes at a given RPM. A
head gasket leak will not stop because the one thing
that marks a failed head gasket is the continued pas-
sage of air. This may be accompanied by violent, in-
termittent bursts of coolant leaving the reservoir. If
coolant continues to flow (not in violent, intermittent
bursts) from the reservoir at cruising speed, some-
thing other than the head gasket is causing the en-
gine to overheat.
CLOSED COOLING SYSTEM – 6B-11
Testing Pressure Cap
Pressure cap is designed to maintain a pressure of
approximately its rated capacity (refer to “Specifica-
tions”) in closed cooled section once engine has at-
tained operating temperature. Cap should be
cleaned, inspected and pressure-tested at regular
tune-up intervals or whenever cap is suspected of
maintaining improper pressure as follows:
! WARNING
Allow engine to cool before removing pressure
cap. Sudden loss of pressure could cause hot
coolant to boil and discharge violently. After en-
gine has cooled, turn cap 1/4 turn to allow any 72716

pressure to escape slowly, then push down and

turn cap all the way off.
1. Carefully remove pressure cap from reservoir or
heat exchanger.
2. Wash cap with clean water to remove any depos-
its or debris from sealing surfaces.
3. Inspect gasket (if used) and rubber seal on cap for
tears, cuts, cracks or other signs of deterioration.
Replace gasket, if damaged, or entire cap if rub-
ber seal is damaged.
Typical Pressure Cap Tester
IMPORTANT: Before reinstalling cap in next step,
examine lower inside sealing surface in filler
neck to ensure that it is perfectly smooth and free
of debris. Also, inspect cam lock flanges on sides
of filler neck to be sure that they are not bent.
a

a
c

b
72715

a - Inspect for Damage

b - Cam Lock Flange
6. Reinstall cap on heat exchanger.
72714

a - Rubber Seal (Cap MUST BE Replaced if Damaged)

b - Gasket (Look for Cracks under Gasket)
c - Locking Tabs (1 Hidden)
4. Check that locking tabs on cap are not bent or
damaged.
5. Using a cooling system pressure tester (similar to
one shown), test cap to be sure that it releases at
proper pressure and does not leak. (Refer to in-
structions which accompany tester for correct test
procedure.) Cap must relieve pressure at 14 PSI
(97 kPa), and must hold rated pressure for 30 se-
conds without going below 11 PSI (76 kPa). Re-
place cap if it fails to fall within these lim-
its.
Index
6B-12 - CLOSED COOLING SYSTEM 90-806934 1194
Thermostats IMPORTANT: Do not allow old gasket material or
debris inside, which might foul cooling system
passages.
Removal
1. Refer to “Draining Closed Cooling Section” as Testing
previously outlined, and drain coolant.
1. Clean thermostats in soap and water to remove
2. Remove closed cooling system hose between any deposits or debris.
thermostat housing and heat exchanger.
2. Inspect thermostats for corrosion or other visible
3. Remove thermostat housing cover fasteners. damage.
NOTE: Components shown removed for visual clarity 3. If thermostats are suspected of producing insuffi-
only. It is not necessary to remove the housing itself. cient engine temperature, check thermostats for
leakage by holding them up to lighted back-
c ground. Light leakage around the thermostat
b valve indicates that thermostat is not closing com-
pletely and should be replaced. (A small amount
of leakage at one or two points around the valve
a perimeter is acceptable.)

73973 72717

a - Hose and Clamps a - Check for Light Leakage Around Perimeter of Valve
b - Thermostat Housing Cover
c - Fasteners (6) 4. Following the manufacturers recommendations
for usage, check opening and closing tempera-
4. Remove housing cover. ture. The thermostat opens when it drops off of
5. Remove old gasket. thread using a tester. Thermostat must open at
specified temperature stamped on thermostat.
6. Remove thermostats.

a b

a
b
b
c c

73973 72675
a - Thermometer
a - Thermostat Housing Cover b - Nylon String
b - Thermostat(s) c - Thermostat
c - Gasket
Typical Thermostat Tester In Use
Index
90-806934 1194 CLOSED COOLING SYSTEM – 6B-13
IMPORTANT: Refer to specifications and note
that the two thermostats have different opening
temperatures.
5. Continue to heat water until a temperature 25°F
(14°C) above opening temperature is obtained.
Thermostat valve must be completely OPEN at
this temperature.
6. Unplug tester and allow water to cool to a temper-
ature 10°F (5°C) below specified opening tem-
perature. The thermostat must be completely
CLOSED at this temperature.
7. Always replace a thermostat that fails to meet all
of the preceding tests with one of the same tem-
perature specification.
Installation
1. Installation is the reverse of procedures for re-
moval. Refer to the preceding instructions “Re-
moval.” Also, observe the following:
• Remove all old gasket material from mating sur-
faces.
• ALWAYS use a new thermostat housing gasket.
• Apply Quicksilver Perfect Seal to the new gasket.
• Torque the six housing screws evenly, in a diago-
nal pattern, to 132 lb. in. (16 N·m).
• Tighten hose clamps securely.
2. Refer to “Filling Closed Cooling Section” instruc-
tions and fill system with Quicksilver Premixed
Marine Engine Coolant.
3. Run test engine - observe temperature gauge
and check for leaks.
Index
6B-14 - CLOSED COOLING SYSTEM
Heat Exchanger
Testing
FOR INTERNAL LEAK:
An internal leak will cause coolant to go into the sea-
water circuit when pressure is put on the closed cool-
ing circuit.
1. Remove top seawater (inlet) hose from the ex-
changer. Do not drain the exchanger.
2. Pressurize the closed cooling circuit to 20 PSI
(137 kPa) with a radiator tester.
3. If seawater begins to flow from the nipple there is
a leak.
FOR BLOCKAGE:
IMPORTANT: Seawater flows THROUGH the
tubes in the exchanger. Closed cooling coolant
flows AROUND the tubes.
1. Remove end caps and inspect for any blockage
in the seawater circuit (weeds, etc.).
2. Remove closed cooling circuit hoses and inspect
the tubes just inside the nipples. Because the
complete heat exchanger cannot be inspected,
the heat exchanger should be replaced if block-
age is suspected.
Repair
IMPORTANT: Braze with BCUP 2 rod or silver sol-
der. Care must be taken not to melt other joints
during repair.
1. Internal leaks can be repaired by brazing shut the
ends of the leaking tube. This is only a temporary
fix because usually another tube will start leaking
after a short period of time and this also causes
a reduction in cooling capacity. Do not close more
than three tubes.
2. Nipples and drains that have been broken off the
heat exchanger can be reattached by brazing.
90-806934 1194
Removal
1. Refer to SECTION 1B – Maintenance, “Cold
Weather or Extended Storage, Draining
Instructions” (and precautions in this section) and
drain the seawater system, if not already
accomplished.
2. Refer to previously outlined “Draining Closed
Cooling Section” instructions (and precautions in
this section) and drain system, if not already
accomplished.
3. Follow instructions “a” – “f”:
NOTE: Obtain clean, suitable devices and plug hoses
in following instructions to avoid loss of engine oil.
a. Mark port and starboard oil hoses to aid in
reassembly.
b. Disconnect engine oil filter head-to-oil cooler
line fittings (near each end of oil cooler) on
heat exchanger. Quickly plug hoses.
c
b Components
a
74446
b Always wear safety glasses when using com-
c pressed air.
72470
a - Heat Exchanger (Combined With Engine Oil Cooler)
b - Starboard Oil Hose Line and Fitting
c - Port Oil Hose Line and Fitting (Fitting Not Visible)
c. Disconnect seawater and closed cooling
hoses as required to allow removal of heat ex-
changer, as shown following.
d. Remove the two large screw clamps retaining
the heat exchanger to the port and starboard
brackets.
e. Disconnect turbocharger coolant vent hose
on upper-port side of expansion tank.
Index
90-806934 1194
f. Remove combination heat exchanger and
engine oil cooler.
a
b
a a
b
a a
74484
a - Remove End Of Hoses Where Indicated For Ease Of
Disassembly and Reassembly
b - Clamps
Engine Oil Cooler/Heat Exchanger and Related
4. If either the closed cooling section or oil cooler
portion of the heat exchanger are defective, it will
be necessary to replace the complete assembly.
Cleaning and Inspection
! CAUTION
1. Clean water passages in heat exchanger by in-
serting a suitable sized wire brush on a proper
length rod into each passage. Use compressed
air to blow loose particles out of water passages.
2. Provided the passages for seawater are accept-
ably clean and free of debris, clean the exterior of
the with soap and water, scrubbing gently with a
brush as required.
NOTE: Use compressed air to blow loose particles
from between passages.
3. Visually inspect all exterior surfaces and water
passages for cracks or damage. Repair or re-
place as required.
CLOSED COOLING SYSTEM – 6B-15
Installation
1. Follow instructions “a” – “e”:
NOTE: Prior to installing the heat exchanger, put a
small amount of petroleum jelly on the brackets and
hose ends to ease installation.
a. Install the combination heat exchanger and
engine oil cooler.
b. Make all necessary seawater and closed
cooling hose connections. Tighten hose
clamps securely.
c. To minimize oil loss, quickly install engine oil
filter head-to-oil cooler lines, as marked upon
disassembly, to fittings (near each end of oil
cooler, on heat exchanger).
d. Install the two large screw clamps retaining
the heat exchanger to the port and starboard
brackets.
e. Reconnect turbocharger coolant vent hose .
Tighten hose clamp securely.
2. Refer to SECTION 6B – “Filling Closed Cooling
Section” instructions and fill the system with
Quicksilver Premixed Marine Engine Coolant.
3. Open seacock if so equipped, or unplug seawater
inlet hose and reconnect. Tighten hose clamps
securely.
4. Pre-lube the turbocharger and engine. Start the
engine and while observing the temperature
gauge, run briefly to operating temperature.
Check for leaks, and then stop the engine.
IMPORTANT: Use only specified engine oil.
5. Check engine oil level. Fill to proper level with
specified oil.

c
b

A
b
a

74446 e

b b
a

b
c
74484

74487

a - Heat Exchanger/Oil Cooler

b - Clamps
c - Starboard Oil Hose Line and Fitting
d - Port Oil Hose Line and Fitting
e - Turbocharger Vent Hose Connection

A - Petroleum Jelly Obtain Locally

Heat Exchanger/Engine Oil Cooler and Related
Index
6B-16 - CLOSED COOLING SYSTEM 90-806934 1194
Water Circulating Pump
IMPORTANT: Water circulating pump on
D4.2L/220 engines is a larger volume pump and
does NOT interchange with circulating pumps on
other diesel engines.
Removal
1. Refer to instructions in Changing (Replace) Cool-
ant - “Draining Coolant” and drain coolant from
closed cooling system.
2. Remove alternator drive belt.
3. If equipped with removable water circulating
pump pulley, remove fasteners and remove
pulley,
NOTE: Some water circulating pump pulleys are NOT
removable and can be identified by the absence of
fasteners on the face of the pulley.
4. Loosen hose clamps and disconnect hoses at
water pump.
5. Remove fasteners (and washers) retaining pump
and remove pump.
Cleaning and Inspection
1. Remove all traces of old gasket material from
pump body.
2. Inspect water pump for blockage, cracks, sand
holes, corrosion or other damage. Inspect pump
impeller for cracks and erosion. Replace com-
plete pump, if any damage exists.
3. Check impeller shaft and bearings for excessive
side play. If play can be felt, replace complete
pump.
4. Inspect pump pulley for bends, cracks, corrosion,
or other physical damage. Inspect pulley for rota-
tional trueness. Replace pulley, if removable, or
complete pump on those with permanent pulley,
if damaged or untrue.
Index
90-806934 1194
Installation
1. Remove all traces of old gasket material from en-
gine block (Do not allow debris inside, which
might foul cooling system passages.)
2. Coat both sides of new gasket with gasket sealer
92-72592-1 and position on engine block. Check
that hose clamps are still on hoses and insert wa-
ter pump fittings into hoses, while installing pump
using fasteners with washers removed during dis-
assembly. Torque evenly, in a diagonal pattern, to
22 lb. ft. (30 N m). Tighten hose clamps securely.
3. Install pulley on pump as shown if pulley was re-
moved previously. Torque fasteners to 72 lb. in.
(8.5 N·m).
73948
a - Pulley Fastener (With Washer) - (4)
b - Water Circulating Pump Pulley (Removable)
c - Water Circulating Pump Fasteners
D4.2L/220 Pump Shown (D3.0L/150 and
D3.6L/180 Similar)
4. Position drive belt(s) and tension following
instructions in SECTION 1B - “Replace Drive
Belts.”
NOTE: On all models, check belt tension by depress-
ing upper strand of belt at center point between pul-
leys. Belt must not deflect more than 3/16 in. (5mm).
CLOSED COOLING SYSTEM – 6B-17
Water Manifold
Removal
1. Refer to instructions in Changing (Replace) Cool-
ant - “Draining Coolant” and drain coolant from
closed cooling system.
2. Remove banjo bolt and sealing washers from
front manifold strip. Disconnect coolant vent
hoses.
3. Disconnect coolant hose from exhaust manifold
rear cover-to-rear manifold strip elbow.
4. Remove fasteners and washers retaining water
manifold assembly to cylinder heads.
Installation
1. Be certain mating surfaces of water manifold
sections are clean and free of all old gasket
material. Machined surfaces must not have nicks
or gouges, or coolant leaks may result.
2. Assemble water manifold as follows:
a. Replace cover gasket on front section. Install
cover. Tighten screws to 84 lb. in. (10 N·m).
b. When replacing the gasket between manifold
halves, align flanges using a straight edge as
shown. Tighten screws to 84 lb. in. (10 N·m).
b c e f
c

b
a

c
a

d h
70883

f
c

70883

a - Water Manifold Assembly

b - Fasteners with Washers g
c - Coolant Vent Hoses 70660

a - Front Cover
5. Remove water manifold assembly. b - Front Cover Gasket
6. Disassemble water manifold components as c - Front Manifold Strip
d - Screw With Washer (4)
needed for repair.
e - Gasket
f - Rear Manifold Strip
g - Straight Edge Device
Cleaning and Inspection h - Screw With Washer (4)

IMPORTANT: Do not allow old gasket material or

debris inside of engine, which might foul cooling
system passages.
1. Remove all traces of old gasket material.
2. Inspect for blockage, cracks, sand holes, corro-
sion or other damage. Inspect for cracks and ero-
sion. Replace complete manifold and/or section
of manifold , if any damage exists.

Index
6B-18 - CLOSED COOLING SYSTEM 90-806934 1194
3. Install new gaskets on cylinder head/manifold Corrosion Protection
studs.
There are anodes as part of the heat exchanger and
4. Slide water manifold assembly on studs. Install intercooler system, which serve as sacrificial anodes.
lockwashers and nuts. Torque nuts evenly in a
diagonal pattern to 24 lb. ft. (32 N·m). Replace when eroded more than 50%; check at least
once yearly. Refer to SECTION 1B - Maintenance, for
5. Install coolant vent hoses using new sealing more information.
washer with the banjo bolts. Install in order
shown. Tighten bolt securely.
6. Install hose clamp on hose from rear exhaust
manifold cover-to-rear manifold strip elbow.
Tighten securely.

b 73327

70883
73326

b
71368
71367
73793

a - Manifold Strip Assembly a - Length When New - 3/4 in. (19mm)

b - Coolant Hose with Clamps b - Diameter When New - 5/8 in. (15mm)
c - Fasteners
d - Gasket, Cylinder Head-to-Manifold Strips
e - Coolant Vent Tube and Banjo Fittings NOTE: Anode and plug are available as a unit if so de-
sired.

Index
90-806934 1194 CLOSED COOLING SYSTEM – 6B-19
Auxiliary Hot Water Heater Connections

f
d e
c

b g

a 72037

71898

k
J

72038

a - Plug, Rear Cover (Allen-Head or Hex-Head) f - Sealing Washer, (Existing)

b - Sealing Washer, (Existing) g - Hose Coupler Fitting (From Kit)
c - Hose Coupler Fitting (From Kit) h - Sealing Washer (From Kit)
d - Sealing Washer (From Kit) i - Supply Hose
e - Plug, On Closed Coolant Tank/Heat Exchanger or Outlet j - Heater
Fitting (Existing) k - Return Hose

Quicksilver Auxiliary Hot Water Heater Adaptor Kit (805984A1)

Index
6B-20 - CLOSED COOLING SYSTEM 90-806934 1194
INTAKE AND EXHAUST
SYSTEM
A 7

A A

A 3

A 4

A 5
INTERCOOLER

A 6

Index
Table Of Contents
Page
Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-0
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2
D3.0L/150 and D3.6L/180 Intercooler . . . . . . . . . 7A-2
D4.2L/220 Intercooler . . . . . . . . . . . . . . . . . . . . . . . 7A-3
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . 7A-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-10

Index
7A –– INTERCOOLER
7A-0 INTERCOOLER 90-806934 1194
Torque Specifications Description
Seawater is pumped through a radiator insert (heat
DESCRIPTION Lb. In. Lb. Ft. N·m
exchanger core) in the intercooler while the engine
Intake Duct 84 10 is running.
Intercooler End Covers 30 40 There is an anode in the front cover and a seawater
Intercooler Housing 24 32 drain plug in the rear cover of all intercoolers.
Anode Plug 120 13 All diesel engines covered in this manual use an in-
Water Temperature tercooler (sometimes referred to as an “aftercooler”
120 13 or “air cooler”) to cool the intake air before it enters
Sender
the cylinders. On D3.0L/150 and D3.6L/180 engines
Turbocharger Pressure the intercooler housing has a separate intake duct
Tighten Securely
Fitting retained with screws on the outer side. On the
D4.2L/220 engines the intercooler is a one-piece-
casting with a smaller intake duct screwed on the
rear-most end. On all engines the intake duct con-
Sealants nects to the turbocharger by a section of hose with
Loctite 514 92-75505-1 clamps.
Quicksilver Perfect Seal 92-34227--1

Index
90-806934 1194 INTERCOOLER – 7A-1
Exploded Views

D3.0L/150 and D3.6L/180 Intercooler

a - Radiator Insert (Heat Exchanger Core)

b - Intercooler Housing
c - Intake Duct
d - Front Cover
e - Rear Cover
f - O-ring (3 On Some Engines, 4 On Others Equipped With Plate)
g - Plate (On Some Engines)
h - Anode
i - Anode Plug With Sealing Washer
j - Drain Plug With Sealing Washer
k - Gasket [5 or 6, (Not Shown Here)]

Index
7A-2 – INTERCOOLER 90-806934 1194
D4.2/220 Intercooler)

70903

70904

a - Radiator Insert (Heat Exchanger Core)

b - Intercooler Housing
c - Intake Duct
d - Gasket (6)
e - Front Cover
f - Rear Cover
g - O-ring (3 On Some Engines, 4 On Others Equipped With
Plate)
h - Plate (On Some Engines)
i - Anode
j - Anode Plug With Sealing Washer
k - Drain Plug With Sealing Washer (Hidden In This View)

Index
90-806934 1194 INTERCOOLER – 7A-3
Intercooler

Removal
1. Refer to SECTION 6A and drain seawater from
seawater cooling section into a suitable con-
tainer.
2. Remove drain plug and sealing washer from rear
cover of intercooler.

70071
70911
a - Drain Plug With Sealing Washer, Intercooler
D4.2L/220 Engines
3. Remove boost pressure tube banjo bolt with
sealing washers from intercooler and remove
tube.

70912

a - Intercooler
b - Rear Cover
c - Drain Plug With Sealing Washer
D3.0L/150 and D3.6L/180 Engines

70913

a - Banjo Bolt With Sealing Washers

b - Boost Pressure Tube
D4.2L/220 Boost Pressure Tube Shown
(D3.0L/150 and D3.6L/180 Similar)

Index
7A-4 – INTERCOOLER 90-806934 1194
4. Follow instructions “a” or “b”: 6. Loosen hose clamp at turbocharger as shown.
a. On D3.0L/150 and D3.6L/180 Engines:
Proceed to Step 4.
b. On D4.2L/220 Engines: Remove banjo bolt
and sealing washers from wastegate valve
pressure line.

73940

70918

a - Hose
70916 b - Hose Clamp
c - Turbocharger
a - Banjo Bolt With Sealing Washers Typical Engine Shown
b - Wastegate Valve Pressure Line

5. Loosen hose clamps and disconnect seawater 7. Follow instructions “a” or “b”:
hoses from intercooler-to-heat exchanger and a. On D4.2L/220 Engines: Proceed to step 7
from seawater pump-to-intercooler. following.
b. On D3.0L/150 and D3.6L/180 Engines: Re-
b move intake duct from side of intercooler
housing.

70919

a - Intercooler Housing
b - Intake Duct
c - Allen-Head Screws With Wave Washers

73322

a - Seawater Hose, Seawater Pump-to-Intercooler

b - Seawater Hose, Intercooler-to-Heat Exchanger
Typical

Index
90-806934 1194 INTERCOOLER – 7A-5
8. Remove hex nuts retaining intercooler (housing) Disassembly
flanges to exhaust/intake manifold studs (12 on
six-cylinder and 10 on five-cylinder). ! CAUTION
Whenever intercooler is disassembled or radia-
tor insert removed from intercooler ALL O-ring
seals must be replaced to prevent seawater from
leaking into intake air duct and manifold which
could result in severe engine damage.
1. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Engines:
70920 (1) Remove front and rear covers. Note posi-
tion of plate and O-rings.
D3.6L/180 Engine Shown [All Engines Similar,
Except D4.2L/220 (Shown Below)] (2) Slide radiator insert out front of intercool-
er housing.

70922

70916
b

70923

70924

70921 a - Intercooler Housing

b - Front Cover
D4.2L/220 Engine c - Rear Cover
a - Intercooler/Intercooler Housing d - O-ring
b - Exhaust/Intake Manifold e - Plate
c - Hex Nuts f - Radiator Insert

! CAUTION
Use a magnet to remove ALL washers from studs
BEFORE lifting off intercooler/intercooler
housing. Do not drop anything into intake ports
or severe engine damage could occur.

9. Using a magnet remove all lockwashers from

studs where hex nuts were removed.
10. Remove intercooler/intercooler housing.

Index
7A-6 – INTERCOOLER 90-806934 1194
 b. On D4.2L/220 Engines: (3) Remove front cover and O-ring.
(1) Remove intake duct from rear of inter-
cooler.

70907

a - Intercooler Housing
b - Front Cover
c - O-ring

(4) Slide radiator insert out front of intercool-

er housing. Note position of O-ring.
70931

a - Intercooler Housing
b - Intake Duct

IMPORTANT: Some early D4.2L/220 engine

intercoolers may have a plate between the
intercooler housing and rear cover. These
intercoolers use two O-rings here, one on each
side of the plate. On those without the plate only
one O-ring is used between the rear cover and
intercooler.
(2) Remove rear cover. Note position of O-
ring, and if so equipped, plate and se-
cond O-ring position. 70905

a - Radiator Insert
b - O-ring

70906

a - Intercooler Housing
b - Rear Cover
c - O-ring (Two – If So Equipped)
d - Plate (If So Equipped)

Index
90-806934 1194 INTERCOOLER – 7A-7
Cleaning and Inspection 2. Install radiator insert into housing. Align insert
passages as shown.
1. Clean old gasket material and sealant from
flanges. Do not nick or gouge the surfaces which
would cause intake or water leaks.
2. Use a 11/64 in. (4.4mm) diameter by 24 in.
(610mm) long rod to clean out radiator insert
tubes, or take to a radiator shop for cleaning.
3. Inspect each part for cracks or other damage
which would render it unserviceable.
4. Refer to SECTION 1B – Maintenance, “Inspect/
Replace Cooling System Sacrificial Anodes,”
and check anodes.
5. Clean and paint exterior surfaces as required to
prevent corrosion.

70926
Assembly
IMPORTANT: Do not roll or twist O-ring(s) when D3.0L/150 and D3.6L/180 Intercooler
installing around radiator insert in the following.
1. Install O-ring on radiator insert against front
flange.

70925

a - Radiator Insert (Front Flange)

b - O-ring
Typical Radiator Insert Shown

70933

D4.2L/220 Intercooler
a - Intercooler Housing (Front)
b - Radiator Insert
c - Alignment Reference Mark

Index
7A-8 – INTERCOOLER 90-806934 1194
3. Place O-ring into groove of front cover. Fasten to
housing using 4 allen-head screws and wave
washers. Torque to 30 lb. ft. (40 N·m).
5. Following instructions “a” or “b”:
a. On intercoolers WITHOUT plate and
second O-ring: Proceed to step 6.
b. On intercoolers WITH plate and second
O-ring:
(1) Install plate on rear of intercooler.
(2) Install second O-ring around radiator in-
sert and against plate.

70926

70908

a - Front Cover
b - O-ring
c - Allen-Head Screws and Wave Washers
D4.2L/220 Intercooler Shown (All Similar)
70928
IMPORTANT: Do not roll or twist O-ring(s) when
a - Plate
installing around radiator insert in the following. b - O-ring (Second One Required)
4. Install O-ring on rear of intercooler housing. Typical
6. Using 4 allen-head screws and wave washers,
install rear cover with drain plug positioned as
shown. Torque to 30 lb. ft. (40 N·m).

70927

a - O-ring 70912
b - Rear of Intercooler Housing a - Rear Cover
Typical b - Drain Plug
c - Allen-Head Screws and Wave Washers
Typical

Index
90-806934 1194 INTERCOOLER – 7A-9
7. Follow instructions “a” or “b”: 3. Install intercooler housing. Install hex nuts (10 on
five cylinder, and 12 on six cylinder) with lock-
a. On D3.0L/150 and D3.6L/180 Engines:
washers and torque to 24 lb. ft. (32 N·m).
Proceed to the following “Installation” instruc-
tions.
b. On D4.2L/220 Engines: Apply Loctite 514
sealer on intake duct-to-intercooler housing
mating surface. Using 4 allen-head screws
and wave washers, install intake duct on rear
of intercooler as shown. Torque to 30 lb. ft.
(40 N·m).

70920

D3.6L/180 Manifold and Intercooler Shown [All

Engines Similar, Except D4.2L/220 (Shown Be-
low)]

70929

a - Intercooler Housing
b - Intake Duct
c - Allen-Head Screws and Wave Washers
D4.2L/220 Intercooler and Intake Duct Shown
70916
b

Installation
1. Being careful not to drop anything into intake
ports, clean old gasket material from manifold.
2. Install new intake port gaskets.

c
70921

a - Intercooler/Intercooler Housing
b - Exhaust/Intake Manifold
c - Hex Nuts and Lockwashers
D4.2L/220 Engine and Intercooler Shown

70881

a - Manifold
b - Intake Ports
c - Intake Port Gaskets
Typical
Index
7A-10 – INTERCOOLER 90-806934 1194
4. Follow instructions “a” or “b”: 5. Securely tighten hose clamp at turbocharger-to-
intake duct hose as shown.
a. On D4.2L/220 Engines: Proceed to step 5.
b. On D3.0L/150 and D3.6L/180 Engines:
(1) Apply Loctite 514 sealer to intake duct
flange.

a - Intake Duct
b - Flange (Apply Sealer Here)

70918
(2) Install intake duct on intercooler as
a - Hose
shown. Torque allen-head screws with b - Hose Clamp
wave washers to 7 lb. ft. (10 N·m). c - Turbocharger
d - Intake Duct
Typical

6. Follow instructions “a” or “b”:

a. On D3.0L/150 and D3.6L/180 Engines:
Proceed to Step 7.
b. On D4.2L/220 Engines: Connect boost
pressure tube using banjo bolt with two new
70919 sealing washers as shown. Tighten securely.
a - Intake Duct
b - Intercooler Housing c b
c - Allen-Head Screws With Wave Washers

(3) Install seawater hose and pipe, with oil

cooler or power steering cooler if so
equipped. Securely tighten hose clamps a
73940
on seawater hose(s) and pipe. Install
nuts and washers on seawater pipe
clamps.

70917

a - Banjo Bolt
b - New Sealing Washers
c - Wastegate Valve Pressure Line
Index
90-806934 1194 INTERCOOLER – 7A-11
7. Install seawater hoses from seawater pump-to- ! CAUTION
intercooler and from intercooler-to-heat ex-
changer. Securely tighten all hose clamps.. DO NOT operate an engine without water flowing
through seawater pickup pump, as pump impel-
ler may be damaged and subsequent overheat-
b ing damage to engine, transmission or stern
drive unit may result.

! CAUTION
Watch temperature gauge on dash to ensure that
a engine does not overheat.

9. Upon first running engine, after repair or service

of intake system and/or intercooler, observe tem-
perature gauge for normal engine operating tem-
peratures, and be certain to check for leaks. Stop
engine IMMEDIATELY in the event of leakage or
overheating, and repair as needed.
73322

a - Seawater Hose, Seawater Pump-to-Intercooler

b - Seawater Hose, Intercooler-to-Heat Exchanger
Typical

8. Securely tighten seawater drain cocks if so

equipped, and install all seawater system drain
plugs removed previously (coat threads of drain
plugs with Quicksilver Perfect Seal or use new
sealing washers on drain plugs so equipped).
Tighten each securely.

Index
7A-12 – INTERCOOLER 90-806934 1194
INTAKE AND EXHAUST
SYSTEM

7
B

28085

INTAKE / EXHAUST SYSTEM

Index
Table Of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
D3.0L/150 and D3.6L/180 Intake/Exhaust
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
D4.2L/220 Intake/Exhaust Manifold . . . . . . . . . . . 7B-2
MCM (Stern Drive) Exhaust Systems . . . . . . . . . 7B-3
MIE (Inboard) Exhaust Systems . . . . . . . . . . . . . . 7B-4
Representative View of Complete Exhaust
System – Inboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-5
Exhaust System - Stern Drive . . . . . . . . . . . . . . . . . . . 7B-6
Exhaust System - Inboard . . . . . . . . . . . . . . . . . . . . . . 7B-6
Exhaust Pipe - Stern Drive . . . . . . . . . . . . . . . . . . . . . 7B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-9
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . 7B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-10

Index
7B-0 – INTAKE/EXHAUST SYSTEM 90-806934 1194
7B – INTAKE/EXHAUST SYSTEM
Torque Specifications Description
All diesel engines covered in this manual use an
DESCRIPTION Lb. In. Lb. Ft. N·m
exhaust manifold which incorporates air passages
Exhaust Manifold Nuts 24 32 for both intake and exhaust in a single unit. Fresh
Rear Cover Bolts 30 40 water from the closed cooling system is pumped by
Water Temperature the engine water pump through the combined intake
120 13 and exhaust manifold when the engine is running.
Switch/Sender
Exhaust Pipe Bolts When reference is made to the exhaust manifold,
20-25 27-34
(MCM) keep in mind that it includes the intake air passages
Exhaust Elbow Clamp (or manifold).
Nut g
Tighten y
Securely Additionally, on D4.2L/220 engines the exhaust
Hose Clamps manifold includes a flange for mounting a turbo boost
wastegate and valve assembly.

Exploded View
D3.0L/150 and D3.6L/180 Intake/Exhaust Manifold

1
6
2
2 3
See NOTE.
4

8
4 7
4

2
4

1 - Exhaust Manifold
2 - Stud(s)
3 - Welch Plug
4 - Gasket(s)
5 - Drain Cock
6 - Screw
7 - Cover
8 - Water Temperature Switch/Sender

NOTE: Later engines have the water temperature switch/sender mounted on the last cylinder head (closest to
the flywheel). A hex-head plug replaces the switch/sender.

Index
90-806934 1194 INTAKE/EXHAUST SYSTEM – 7B-1
D4.2L/220 Intake/Exhaust Manifold

2
1

4
2

5
4
7

See NOTE.

28085

1 - Exhaust Manifold, With Wastegate Flange

2 - Stud(s)
3 - Welch Plug
4 - Gasket(s)
5 - Drain Cock
6 - Screw
7 - Cover
8 - Water Temperature Sender With Sealing Washer

NOTE: Later engines have the water temperature switch/sender mounted on the last cylinder head (closest to
the flywheel). A hex-head plug replaces the switch/sender.

Index
7B-2 – INTAKE/EXHAUST SYSTEM 90-806934 1194
MCM (Stern Drive) Exhaust Systems

3
2
11

b
b 4 5

6 1

6 71704

12

10 a

10 a
9

73942 73942

1 - Exhaust Elbow Torque Specifications

2 - Connector
3 - Plug a - 23 lb. ft. (30 N·m)
4 - Clamp
5 - Gasket b - Tighten Securely
6 - Hose Clamps (4 Total)
7 - Exhaust Hose
8 - Water Shutter Assembly - Not Present On Riser Equipped
Engines With Unique, Round-Inlet Exhaust Pipe
9 - Oval Exhaust Pipe (A Round Exhaust Pipe is used on
Riser Equipped Engines to match Riser outlet.)
10- Screw and Lockwasher (4)
11- D4.2L/220 Exhaust Riser Assembly (D3.0L/150 and
D3.6L/180 are similar.)
12- Round Exhaust Pipe for Exhaust Riser Equipped
D4.2L/220 Engines (No Water Shutter Assembly)

Index
90-806934 1194 INTAKE/EXHAUST SYSTEM – 7B-3
MIE (Inboard) Exhaust Systems

9
b

3 A

5 2

71704

7
1
6

70902 73942

1 - Exhaust Elbow Lubricant/Sealant Application Points

2 - Connector
3 - Plug A Loctite Pipe Sealant With Teflon
4 - Clamp
5 - Gasket
6 - Hose Clamps (4 Total In This Example)) Torque Specifications
7 - Short Exhaust Hose (If So Equipped)
8 - Exhaust Pipe Oval-to-Round Adaptor (If So Equipped) Tighten all fasteners securely.
9 - D4.2L/220 Exhaust Riser Assembly (D3.0L/150 and
D3.6L/180 are similar.)

Typical

Index
7B-4 – INTAKE/EXHAUST SYSTEM 90-806934 1194
Representative View of Complete Exhaust System – Inboard
(Use diagrams for parts identification only.)

70902

a - Exhaust Elbow With Gasket and Clamp

b - Hose
c - Outlet With Water Shutter and Flapper
d - Water Lift Muffler
e - Oval-to-Round Adaptor (On Some Engines)
Typical

Index
90-806934 1194 INTAKE/EXHAUST SYSTEM – 7B-5
Exhaust System - Stern Drive The D4.2L/220 engine is equipped with a factory
installed exhaust riser. Verify that the riser pro-
IMPORTANT: It is the responsibility of the boat vides the required dimension “c”, or a distance great-
manufacturer, or installing dealer, to properly er than “c”, as indicated.
locate the engine and install the exhaust system.
Improper installation may allow water to enter Model (c) = (a) Minus (b)
the exhaust manifolds and combustion cham- (c) Must Be 13 in. (330 mm)
bers and severely damage the engine. Damage D4.2L/220
or More
caused by water in the engine will not be covered
by MerCruiser Warranty, unless this damage is
the result of defective part(s).
d b
Determine if an exhaust riser kit or a water lift muffler a
kit is required, by taking measurements (a) and (b), c
with boat at rest in the water and maximum load
aboard. Subtract (b) from (a) to find (c). If (c) is less
than specified in chart, an exhaust riser kit must be
installed.
Model (c) = (a) Minus (b)
D3.0L/150
(c) Must Be 13 in. (330 mm)
and
or More
D3.6L/180
74298

d b a - From Waterline to Top of Transom

a b - From Highest Point on Exhaust Riser to Top of Transom
c c - From (a) minus (b)
d - Waterline at Rest
MCM D4.2L/220 Engine

Exhaust System - Inboard

IMPORTANT: It is the responsibility of the boat
manufacturer, or installing dealer, to properly
locate the engine and install the exhaust system.
Improper installation may allow water to enter
the exhaust manifolds and combustion cham-
23160
bers and severely damage the engine. Damage
a - From Waterline to Top of Transom
caused by water in the engine will not be covered
b - From Highest Point on Exhaust Elbow to Top of Transom by MerCruiser Warranty, unless this damage is
c - From (a) minus (b) the result of defective part(s).
d - Waterline at Rest
MCM D3.6L/180 Engine (MCM D3.0L/150 Similar)

Index
7B-6 – INTAKE/EXHAUST SYSTEM 90-806934 1194
Determine if an exhaust riser kit or a water lift
muffler kit is required, by taking measurements (a)
and (b), with boat at rest in the water and maximum
load aboard. Subtract (b) from (a) to find (c). If (c) is
less than specified in chart, an exhaust riser kit
must be installed.
3. System must not cause excessive back pres-
sure when measured at exhaust elbow outlets.
Back pressure MUST NOT exceed a 39-1/2 in.
(1000 mm) water column, or 3 in. (76mm) of
mercury when measured with a mercury ma-
nometer [approximately 1-1/2 PSI (10.3 kPa)].
Minimum exhaust hose size is 4 in. (102 mm).

b
e d c a
d a c
c f
b

g
71774
73592
a - Exhaust Elbow
b - Measurement - 13 in.. (330 mm) Minimum
a - From Waterline to Top of Transom c - Exhaust Hose or Pipe (Slope to Specifications)
b - From Highest Point on Exhaust Elbow to Top of Transom d - Muffler (If So Equipped)
c - From (a) minus (b) e - Exhaust Outlet Internal Shutter
d - Waterline at Rest f - Exhaust Flapper Valve
g - Waterline
Model (c) = (a) Minus (b) Typical Continuously Sloping Exhaust Line
D3.6/150
and (c) Must Be 13 in. (330 mm) or More b
D4.2L/180 g
a

Additional information: d
1. If an exhaust riser or a water lift muffler kit is NOT
f
required, the exhaust outlet (for routing exhaust c
to outside of boat) must be located so that a
minimum of 1/2 in. (13mm) per 12 in. (305mm)
downward pitch (drop) exists in the exhaust e
hose or pipe from the engine exhaust elbow to
the outlet, with a minimum drop of 4 in. (100mm)
71775
overall. (This is an American Boat & Yacht Coun-
a - Vent Line [1/4 in. (6 mm)]
cil recommendation.) The drop must be constant b - Transom
so that a low spot does not exist at any point in c - Water Line
the exhaust hose or pipe. d - Exhaust Hose
e - Drain Cock
2. Exhaust outlet must be slightly above the water f - Water Lift Muffler
line with boat at rest in the water and a full load g - Exhaust Elbow
aboard. Exhaust outlet should be equipped with Typical Waterlift Muffler Exhaust System
an internal shutter to prevent seawater from run-
ning back into exhaust system. The use of an 4. An oval-to-round exhaust adaptor (818184T)
exhaust flapper on each outlet also is recom- and tube (32-815529) is available to assist in
mended. exhaust connection from the oval turbocharger
exhaust elbow to 4 in. (102mm) round exhaust
outlet pipes.

Index
90-806934 1194 INTAKE/EXHAUST SYSTEM – 7B-7
Exhaust Pipe - Stern Drive
Removal
IMPORTANT: Engine must be removed to gain
access to exhaust pipe. Refer to Section 2A for
engine removal and installation.
1. Remove 4 bolts and thick lockwashers retaining
exhaust pipe to gimbal housing.
2. Remove exhaust pipe.
3. Remove O-ring seal and discard.
24841
a - Bolts and Thick Lockwashers (4)
b - Exhaust Pipe
Index
7B-8 – INTAKE/EXHAUST SYSTEM
Installation
IMPORTANT: Exhaust pipe and gimbal housing
assembly mating surfaces must be clean and
free of nicks and scratches. O-ring must be
properly seated in groove, or water and exhaust
may leak into boat.
22030
a - Mating Surface (Also, On Exhaust Pipe)
b - O-ring (Renew)
1. After cleaning mating surfaces, install new O-
ring. Be certain it is seated properly in groove of
gimbal housing.
2. Hold exhaust pipe in position. Install thick
washers and bolts (4 each). Torque evenly in a
diagonal pattern to 20-25 lb. ft. (27-34 N·m).
3. Lubricate the inside of large end of exhaust hose
with a soap and water solution. Slide hose over
exhaust pipe and install two hose clamps.
Tighten hose clamps securely.
24841
a - Exhaust Pipe
b - Bolts and Thick Lockwashers (4 each)
c - Hose
d - Hose Clamps (2)
90-806934 1194
Exhaust Manifold 7. Remove nuts and lockwashers (6 cylinder has
24, and 5 cylinder has 20).
Removal
1. Remove heat exchanger assembly as outlined in
Section 6B.
2. Remove intercooler housing as outlined in
Section 7A.
3. Remove wastegate and valve as outlined in
Section 7C, if so equipped.
4. Remove turbocharger as outlined in Section 7C.
5. Disconnect wiring block from water temperature
sender, if located on rear cover.
NOTE: Later engines have a hex head plug in place
of the temperature switch/sender.
6. Loosen hose clamp on rear cover-to-rear
manifold strip elbow hose.
70881

a - Nuts and Lockwashers

Typical

Cleaning and Inspection

1. Clean gasket material from all surfaces and wash
parts in solvent.
70882
2. Inspect all parts carefully. Machined surfaces
must be clean and free of all marks and deep
scratches, or water and exhaust leaks may
result.
3. Check water passages for foreign material.
Passages must be clean for efficient cooling.
4. If more thorough inspection is desired, pipe plugs
may be removed from exhaust manifold and
exhaust elbow.
IMPORTANT: If plugs are removed, coat threads
with Perfect Seal before reinstalling.
5. Check for cracks.
6. To test manifold body for leaks, block off plates,
plugs, or short hoses with plugged ends must be
used. One block off plate must have a threaded
70881
hole for attaching compressed air hose. Use new
gaskets when installing block off plate(s). Apply
a - Exhaust Manifold 40 PSI (276 kPa) of air pressure and submerge
b - Rear Cover manifold in water. Air bubbles will indicate a leak.
c - Hose Clamp
d - Hose, Rear Cover-to-Rear Manifold Strip
e - Water Temperature Switch/Sender (Hex Head Plug On
Later Engines)
Typical

Index
90-806934 1194 INTAKE/EXHAUST SYSTEM – 7B-9
Installation NOTE: Later engines have a hex head plug in place
of the temperature switch/sender.
1. Be certain mating surfaces of cylinder heads are
clean and free of all old gasket material.
Machined surfaces must not have nicks or
gouges, or water and exhaust leaks may result.
2. Install new gaskets on cylinder head/manifold
studs.

70882

70883

a - Cylinder Head/Manifold Studs

b - Gaskets
Typical

3. Slide exhaust manifold on studs. Install

lockwashers and nuts. Torque nuts evenly in a
diagonal pattern to 24 lb. ft. (32 N·m). 70881

4. Install hose clamp on rear cover-to-rear manifold a -

Exhaust Manifold
strip elbow hose. Tighten securely. b -
Rear Cover
c -
Hose Clamp
5. Connect wiring block to water temperature d -
Hose, Rear Cover-to-Rear Manifold Strip
switch/sender, if located on rear cover. e -
Water Temperature Switch/Sender (Hex Head Plug On
Later Engines)
f - Nuts and Lockwashers
Typical

6. Install turbocharger as outlined in SECTION 7C.

7. Install wastegate and valve as outlined in SEC-
TION 7C, if so equipped.
8. Install intercooler housing as outlined in SEC-
TION 7A.
9. Install heat exchanger assembly as outlined in
SECTION 6B.
10. Fill closed cooling system according to
instructions in SECTION 6B, “Filling Closed
Cooling System.”
11. Start engine. Check for leaks.

Index
7B-10 – INTAKE/EXHAUST SYSTEM 90-806934 1194
INTAKE/EXHAUST SYSTEM

7
C
TURBOCHARGER

Index
Table Of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Turbocharger Specifications . . . . . . . . . . . . . . . . . . . . 7C-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-2
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-2
Wastegate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-2
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-3
Turbocharger And Related Components . . . . . . . 7C-3
Boost Pressure Control (Wastegate)
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-4
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-5
Testing Turbocharger Boost Pressure . . . . . . . . . 7C-5
Checking Turbine Bearings (Assembled) . . . . . . 7C-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-6
Removing Exhaust Elbow . . . . . . . . . . . . . . . . 7C-6
Removing Turbocharger Unit . . . . . . . . . . . . . . 7C-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-9
Axial (End) Play – Measuring . . . . . . . . . . . . . 7C-9
Radial (Side) Play – Measuring . . . . . . . . . . . 7C-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-11
Boost Pressure Control (D254 Engines) . . . . . . . . . 7C-16
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-17
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-18
Wastegate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-19

Index
7C –– TURBOCHARGER
7C-0 TURBOCHARGER 90-806934 1194
Identification Torque Specifications
DESCRIPTION Lb. Ft. N⋅m
Turbocharger Mounting Nuts 18 24
Clamping Plate Nuts or
22 30
Screws
Wastegate-to-Exhaust Man-
ifold Mounting Nuts 18 24
(D4.2L/220)
Tighten Securely
Valve-to-Wastegate Screws
(Equally, in a di-
(D4.2L/220)
agonal pattern.)

70076
Sealants
a - Identification Number Location
Loctite 514 92-75505-1
Gasket Sealer 92-72592-1

Turbocharger Specifications
Model D3.0L/150 D3.6L/180 D4.2L/220
KKK
Manufacturer
Kuhnle, Kopp and Kaush
Part KKK K26 2664 GA 10.71 K26 2664 GA 12.71 K26 2964 MNA 8.72
Number Quicksilver 801763701 801763447 816791
Maximum turbine shaft axial (end)
.0059 in. (0.15 mm)
play
Maximum turbine shaft radial
.0165 in. (0.42 mm)
(side) play
14.5 - 18 psi
Maximum Boost 12.5 - 16 psi (82.7 to 110.3 kPa) at 3800 RPM (100 - 124 kPa)
at 3600 RPM
Engine RPM when boost starts 2100 - 2200 1500 - 1800
Wastegate NO YES

Index
90-806934 1194 TURBOCHARGER – 7C-1
Description
Turbocharger
All diesel engines covered in this manual are
equipped with a turbocharger to boost intake
pressure resulting in increased horsepower. In one
casing on the turbocharger housing exhaust gases
are used to spin the turbine up to 100,000 RPM. The
compressor, which is installed on the same shaft but
in a separate casing, draws in filtered air,
compresses it, and delivers it to the engine through
an intake duct and intercooler.
The turbo bearings are lubricated by engine oil.
Coolant from the engine’s closed cooling system
cools the turbocharger housing, while the exhaust
elbow is cooled by seawater flowing through it from
the seawater system.
On D3.0L/150 and D3.6L/180 Engines: Turbo
pressure, or boost, is limited by engine RPM.
On D4.2L/220 Engines: Turbo pressure is limited by
a boost pressure control valve (commonly called a
“wastegate”) is mounted on the combined
exhaust/intake manifold.
Index
7C-2 – TURBOCHARGER
Wastegate
When used in combination with the turbocharger (on
the D4.2L/220 engines only) a higher torque output
even at low engine speeds is obtained and allows the
engine a wider operating speed range.
The function of the wastegate is to limit the boost
pressure generated by the turbocharger within a
controlled tolerance band.
When factory set boost pressure is exceeded, the
valve opens and bypasses a part of the exhaust gas
flow around the turbine. The resulting reduced
mass-flow produces a lower power output. The
compressor output is reduced in proportion and the
boost pressure falls to the predetermined level. This
control process is repeated for each change in
engine load.
This allows the use of a smaller turbocharger turbine
which provides better acceleration and torque, as
boost comes on more rapidly and turbo lag is
reduced.
90-806934 1194
Exploded Views

Turbocharger And Related Components

10
11
8
7 9
9

7
a 3
12 1 4

13 15
2
16

14 6

73941

1 - Turbocharger Torque Specifications

2 - Gasket
3 - Clamp a 18 lb. ft. (24 N·m)
4 - Gasket
5 - Exhaust Elbow, or Riser (Not Shown)
6 - Oil Drain Pipe
7 - Double Banjo Bolt with Sealing Washer
8 - Coolant Vent Hose (Connection shown as dashed line.)
9 - Hose Fittings, At Water Manifold
10- Hose Fitting for Hose to Heat Exchanger
11- Turbocharger-to-Intake Duct Hose
12- Oil Feed Pipe
13- Gasket
14- Turbocharger Support Bracket
15- Spacer
16- O-Ring Seals

- To Heat Exchanger
Index
90-806934 1194 TURBOCHARGER – 7C-3
Boost Pressure Control (Wastegate) Components

Typical MCM (Stern Drive) D4.2L/220 Components Shown - [MIE (Inboard) Similar]

2
9

1 a

5
10
3

4 6

73940

1 - Wastegate Torque Specifications

2 - Wastegate-to-Exhaust Manifold Gasket
3 - Wastegate Exhaust Pipe, MCM Shown (MIE Similar) a 18 lb. ft. (24 N·m)
4 - Gasket (2)
5 - Hex Nut and Lockwasher (4)
6 - Heat Shield Blanket (For Exhaust Pipe)
7 - Boost Pressure Valve
8 - Boost Pressure Line
9 - Banjo Bolt and Sealing Washers (at Exhaust Manifold)
10- Banjo Bolt and Sealing Washers (at Valve))

Index
7C-4 – TURBOCHARGER 90-806934 1194
IMPORTANT: Before suspecting the turbocharger
for engine running problems, the fuel injection
system and engine mechanicals (valves, cam-
shaft, etc.) must be in good working order.
Turbocharger
Testing Turbocharger Boost Pressure
! CAUTION
Safety glasses, gloves and protective clothing
should be worn while testing turbocharger boost
pressure, to protect against pressurized air being
released by a leak or rupture of a hose which could
cause injury.
The following should be observed prior to testing:

Engine should be at normal operating
temperature.

Engine air cleaner should be clean (or replaced
if not clean).
1. Remove plug (screw with sealing washer) from
intercooler housing as shown.
a between turbine blades and housing at two loca-

On D3.0L/150 and D3.6L/180 Engines:
Maximum boost should be between 12.5 - 16 psi
(82.7 - 110.3 kPa) at 3800 RPM.

On D4.2L/220 Engines: Maximum boost should
be between 14.5 - 18 psi (100 - 124 kPa) at 3600
RPM.
Readings LOWER than specified above indicate
possible turbocharger problem(s), or boost pressure
control system problems (D4.2L/220 engines only),
IF no engine problem exists, such as incorrect valve
clearance or a blockage in the exhaust system (refer
to appropriate Sections in this manual, including
“Troubleshooting”). NO boost pressure would
indicate a faulty turbocharger requiring replacement.
Checking Turbine Bearings
(Assembled)
1. Refer to the following section Turbocharger -
“Removal” and remove exhaust elbow as out-
lined for your engine.
2. Rotate the turbine impeller by hand to see that it
turns smoothly. If not, turbine bearings or impel-
ler problems exist.
3. Using a feeler gauge as shown, check clearance
tions opposite one another. The difference in the
two readings is the radial play. Maximum radial
play is .0165 in. (0.42mm).

b
70904

73334

a - Plug (Screw with Sealing Washer)

b - Intercooler Housing
Typical
70984

2. Install a 0-25 psi (0-172.4 kPa) pressure gauge Checking Turbine Blade Clearance
into intercooler where plug was removed in Step 1.
4. Check if turbine blades are rubbing on housing.
3. Start engine and watch pressure gauge. Replace turbocharger if so.

Index
90-806934 1194 TURBOCHARGER – 7C-5
Removal 4. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Engines:
! WARNING Proceed to Step 5.
b. On D4.2L/220 Engines:
Always disconnect battery cables from battery
before working around electrIcal system compo- (1) Loosen spring retaining heat-shield blan-
nents to prevent injury to yourself or damage to ket around wastegate exhaust pipe.
electrical system. (2) Remove fasteners and lockwashers re-
taining wastegate exhaust pipe to ex-
REMOVING EXHAUST ELBOW haust elbow.

1. Disconnect battery cables from battery termi-

nals.
2. Loosen hose clamp and disconnect seawater
hose at turbocharger exhaust elbow or riser.
Drain seawater into a suitable container.

50665
a - Hose Clamp
b - Seawater Hose
Typical 70986

3. Loosen exhaust elbow hose clamps as shown. a - Spring (Blanket Retainer)

b - Blanket, Heat-Shield
c - Hex Nuts With Lockwashers
d - Wastegate Exhaust Pipe
b Typical

5. Suitably mark exhaust elbow, or riser, and

turbocharger housing for alignment during reas-
sembly.

a c

74298

a - Hose Clamps
b - Exhaust Elbow or Riser
c - Exhaust Hose
MCM D4.2L/220 With Riser Shown (All Similar)

Index
7C-6 – TURBOCHARGER 90-806934 1194
6. Loosen exhaust elbow, or riser, clamp. Remove 3. Remove oil feed pipe and banjo bolt from coolant
elbow gasket and clamp. vent pipe at turbocharger as shown. Loosen air
filter and turbocharger-to-intake duct hose
clamps.
c

73632 73941

70989
70987
a - Turbocharger-to-Intake Duct Hose Clamp
a - Clamp
b - Oil Feed Pipe
b - Exhaust Elbow
c - Banjo Bolt (With Sealing Washers), Coolant Vent Line
c - Exhaust Gasket (Not Shown)
d - Air Filter Hose Clamp
Typical Exhaust Elbow Shown
Typical Shown (All Similar)
(Similar With Riser)

4. Remove oil drain pipe on bottom of turbocharger

REMOVING TURBOCHARGER UNIT as shown.

1. Refer to SECTION 6B - Closed Cooling System,

“Draining Coolant” and drain closed cooling sys-
tem.
2. Remove lifting eye bracket as shown to gain ac-
cess to turbocharger mounting nuts.

70988

a - Bracket, Lifting Eye

b - Screws
Typical Shown 70990

a - Oil Drain Pipe

b - Hex Nuts With Lockwashers

Index
90-806934 1194 TURBOCHARGER – 7C-7
5. To gain access to turbocharger mounting nuts, 7. Remove the two support bracket mounting
follow instructions “a” or “b”: screws as shown, and MerCathode controller
bracket if so equipped (not shown in the follow-
a. On D3.0L/150 and D3.6L/180 Engines:
ing). Remove turbocharger unit.
Remove intake duct from side of intercooler
housing. (Refer to SECTION 7A - Intercooler,
for instructions on removal.)
b. On D254 Engines: Remove intake duct from
rear of intercooler housing. (Refer to SEC-
TION 7A - Intercooler, for instructions on re-
moval.) c
IMPORTANT: In the event that turbocharger
mounting nuts are corroded, or otherwise resist
loosening in the following, it may become neces-
sary to completely remove the intercooler hous-
ing to gain a more suitable access to mounting
nuts. Refer to SECTION 7A - Intercooler, for
instructions on removal and installation of the in-
tercooler housing.
6. Remove four mounting nuts retaining turbochar- 70992
ger to exhaust manifold.
a - Support Bracket
b - Screw (2) With Washer
c - MerCathode Controller Bracket Location

Disassembly
1. Make matching marks on the exhaust housing
and bearing housing to aid alignment in reas-
sembly.
2. Remove 6 hex nuts or hex screws and the 3
clamping plates shown.
70991

a - Mounting Nuts (4 Total, Two Hidden In This View)

Typical Shown (All Similar)

70993

a - Matching Marks
b - Hex Nuts or Hex Screws (6 Total - 2 Hidden In This View)
c - Clamping Plates (3 Total - One Hidden In This View)
d - Exhaust Housing
e - Bearing Housing
Typical Turbocharger Shown

Index
7C-8 – TURBOCHARGER 90-806934 1194
NOTE: If the exhaust housing cannot easily be
removed by hand, tap on it carefully all around using
a plastic hammer and carefully remove it in the
following.
IMPORTANT: Be careful not to damage the turbine
impeller when removing exhaust housing.
3. Remove exhaust housing as shown.
Cleaning
IMPORTANT: Never use a caustic cleaning solu-
tion, as it may attack aluminum. Also, never use
a wire brush which could damage impeller or
mating surfaces.
1. BEFORE cleaning inspect the disassembled
parts for burning, abrasion, carbon deposits, gas
and oil leakage.

! CAUTION
Always wear safety glasses when using
compressed air to protect from hose rupturing or
flying debris.

! WARNING
When using compressed air to dry components,
DO NOT spin turbine, or allow turbine to spin,
since no oil is being provided to the bearings and
70994 could result in damage to the bearings.
a - Exhaust Housing
b - Bearing Housing 2. Thoroughly clean all the parts with clean diesel
c - Turbine Impeller fuel, using a soft brush. Dry with compressed air.
Typical Turbocharger Shown

4. Inspect turbine blades. If blades are rubbing Inspection

against housing, the bearings are worn. Replace
turbocharger. IMPORTANT: If turbine shaft bearing axial or
radial play is excessive, replace turbocharger.

AXIAL (END) PLAY – MEASURING

1. With turbocharger held in vise, attach dial indica-
tor as shown following.
2. Move turbine shaft in direction shown. Maximum
axial play (end play) is .0059 in. (0.15mm).

70994

a - Turbine
b - Inspect (Edges of Blades)
70995

Measuring Axial (End) Play

Index
90-806934 1194 TURBOCHARGER – 7C-9
RADIAL (SIDE) PLAY – MEASURING
1. With turbocharger held in vise, attach dial indica-
tor as shown in following.
2. Move turbine shaft in direction shown. Maximum
radial (side) play is .0165 in. (0.42mm).
2. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Engines:
(1) Being certain surfaces are clean of old
gasket material or debris, install a new
gasket on bearing housing oil drain/
spacer flange.
(2) Assemble spacer with bracket attached
as shown. Tighten hex nuts finger tight at
this time.

70996

Measuring Radial (Side) Play

Assembly
IMPORTANT: When installing a new turbochar-
ger, it may be necessary to turn intake, bearing,
and/or exhaust housings to allow mounting
bracket to be bolted to engine.
1. While aligning matching marks, assemble ex-
haust housing and bearing housing together.
Install clamping plates and finger tighten hex
nuts or screws. Do not tighten securely at this
time.
70997

a - Gasket
b - Spacer
c - Support Bracket
d - Hex Nut

70993
a - Matching Marks
b - Exhaust Housing
c - Bearing Housing
d - Clamping Plates (3 Total - One Hidden In This View)
e - Hex Nuts or Hex Screws (6 Total - Two Hidden In This
View)
Typical Turbocharger Shown
Index
7C-10 – TURBOCHARGER 90-806934 1194
 b. On D4.2L/220 Engines:
(1) Being certain surfaces are clean, install a
new O-ring in groove of drain/spacer
flange where it meets bearing housing of
turbocharger.
(2) Assemble spacer with bracket attached
as shown. Tighten hex nuts finger tight at
this time.
Installation
IMPORTANT: When installing turbocharger, it
may be necessary to turn intake and exhaust
housings to line up with intake air duct and ex-
haust manifolds on engine.
1. Using a new gasket, install turbocharger on ex-
haust manifold as shown. Tighten nuts to 18 lb.
ft. (24 N·m).

70991

a - Gasket, Exhaust Manifold-to-Turbocharger

b - Nut (4 Total - Two Hidden In This View)
Typical Turbocharger Shown

2. Install support bracket screws with washers as

shown (and MerCathode controller with bracket
if so equipped - not shown following). Tighten
screws securely.
70998

a - O-ring (Hidden In Assembled View)

b - Spacer (Oil Drain)
c - Support Bracket
d - Hex Nut

3. Position exhaust housing and bearing housing

(with intake housing) as shown.

70992

a - Screws With Washers

b - Support Bracket
Typical
3. Tighten the six hex nuts or hex screws (on D4.2L)
on clamping plates of exhaust housing-to-bear-
70999 ing housing to 22 lb. ft. (30 N·m). (Refer to Step
a - Exhaust Housing 1 in “Assembly” section, for location.)
b - Bearing Housing (With Intake Housing)
Index
90-806934 1194 TURBOCHARGER – 7C-11
4. Follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Engines: Re-
move hex nuts from spacer (previously
installed finger tight). Using a new gasket,
install drain pipe. Tighten hex nuts securely.
5. Follow instructions “a” - “d”:
a. Using new sealing washers on banjo bolt,
install coolant vent line to turbocharger ex-
haust housing as shown. Tighten banjo bolt
securely.
b. Clean sealing surfaces and using a new gas-
ket, install oil feed pipe as shown. Tighten
screws securely.
c. Install turbocharger-to-intake duct hose as
shown. Tighten hose clamp at turbocharger
securely.
d. Fit air filter to turbocharger and tighten clamp
securely.

71000

a - Spacer
b - Hex Nuts
c - Gasket
d - Oil Drain Pipe
b. On D4.2L/220 Engines: Remove hex nuts
from spacer (previously installed finger tight).
Using a new O-ring positioned in spacer
groove, install drain pipe. Tighten hex nuts
with lockwashers securely.

70989

a - Sealing Washers
b - Banjo Bolt
c - Coolant Vent Line
d - Turbocharger Exhaust Housing
e - Gasket
f - Oil Feed Pipe
g - Screw (2)
h - Air Filter
i - Hose Clamp
Typical Shown (All Similar)

70990

a - Spacer
b - Hex Nuts
c - O-ring (Hidden In One View)
d - Oil Drain Pipe

Index
7C-12 – TURBOCHARGER 90-806934 1194
IMPORTANT: If it became necessary to remove (2) Apply Loctite 514 sealer to intake duct
the entire intercooler housing from the intake/ex- flange on intercooler as shown.
haust manifold during disassembly (to gain bet-
ter access to turbocharger mounting nuts) refer
to Section 7A - Intake Manifold/Intercooler, at this
time for proper installation.
6. If previously only the intake duct of intercooler
was removed, follow instructions “a” or “b”:
a. On D3.0L/150 and D3.6L/180 Engines:
(1) Clean sealing flanges of intercooler
housing and intake duct. Do not nick or
gouge the surfaces.
(2) Apply Loctite 514 sealer to intake duct
flange as shown.

70931

a - Intercooler Housing
b - Intake Duct
a - Intake Duct
c - Flange (Apply Sealer Here)
b - Flange (Apply Sealer Here)

(3) Install intake duct on intercooler as

(3) Install intake duct on intercooler as
shown. Torque four allen-head screws
shown. Torque allen-head screws with
with wave washers to 7 lb. ft. (10 N·m).
wave washers to 7 lb. ft. (10 N·m).

NOTE: Intercooler shown removed for visual clarity

only.

70919

a - Intake Duct
b - Intercooler Housing
c - Screws With Wave Washers
D3.6L/180 Shown (D3.0L/150 Similar)

b. On D4.2L/220 Engines: 70929

(1) Clean sealing flanges of intercooler a - Intake Duct

housing and intake duct. Do not nick or b - Intercooler Housing
gouge the surfaces. c - Screw With Wave Washer

Index
90-806934 1194 TURBOCHARGER – 7C-13
7. Install lifting eye bracket as shown. Tighten (2) Install seawater hose to exhaust elbow,
screws securely. or exhaust riser fitting, if so equipped.
Tighten hose clamps securely.
(3) Position exhaust hose on elbow, or riser.
Tighten hose clamps securely.

c
d

70988 c
a - Bracket, Lifting Eye
a
b - Screws With Washers
Typical Shown
50665
8. As shown, tighten turbocharger-to-intake duct
hose clamp securely.

b
73632 73941
d
e

g
74298

70918

a - Hose a - Gasket
b - Hose Clamp b - Exhaust Elbow
c - Turbocharger c - Exhaust Elbow, or Riser, Clamp
d - Intake Duct d - Seawater Hose and Clamp (At Exhaust Elbow or Riser)
e - Exhaust Riser
9. Follow instructions “a” or “b”: f - Exhaust Hose
g - Exhaust Hose Clamp (4)
a. On D3.0L/150 and D3.6L/180 Engines: h - Exhaust Pipe
(1) Using a new gasket, install exhaust el- Typical Installations Shown
bow, or exhaust riser if so equipped, as
shown. Align with exhaust pipe. Tighten
elbow or riser clamp securely.
Index
7C-14 – TURBOCHARGER 90-806934 1194
 b. On D4.2L/220 Engines: (3) Install seawater hose from fluid cooler-to-
exhaust elbow, or riser if so equipped.
(1) Install exhaust elbow, or riser, using new
Tighten hose clamp securely.
gaskets on exhaust elbow and wastegate
exhaust pipe flange as shown, Align (4) Position exhaust hose as shown. Tighten
studs on elbow, or riser, with holes in was- hose clamps securely.
tegate exhaust pipe. Simultaneously,
align with exhaust pipe. Tighten exhaust
elbow clamp securely. a
(2) Install hex nuts and washers, or screws
and washers, on wastegate exhaust
pipe. Tighten fasteners securely and
ce
wrap with heat shield blanket. Fasten
spring to retain blanket.
d

71704
b
e
c

71001
eg

71003

a - Exhaust Riser
b - Exhaust Elbow
70986 c - Seawater Hose (Fluid Cooler-to-Exhaust Elbow)
d - Seawater Hose (Fluid Cooler-to-Exhaust Riser)
a - Gasket, Exhaust Elbow
e - Clamp, Seawater Hose
b - Gasket, Wastegate Exhaust Pipe-to-Elbow, or Riser
f - Exhaust Hose
c - Exhaust Elbow
g - Clamp(s), Exhaust Hose
d - Wastegate Exhaust Pipe
e - Clamp, Exhaust Elbow Early MCM D4.2L/220 Shown, With Inset of Riser
f - Hex Nut Connection (All Connections Similar On MIE
g - Blanket, Heat Shield Models)
h - Spring
Early MCM D4.2L/220 Shown (Similar With Riser,
or On MIE Models)
Index
90-806934 1194 TURBOCHARGER – 7C-15
10. Fill closed cooling system at this time according Exhaust Pipe
to instructions in Section 6B - Closed Cooling
System, “Filling Closed Cooling System.” INSPECTION
11. Connect battery cables to battery by FIRST 1. Loosen spring retaining heat shield blanket
installing positive (+) battery cable end on around wastegate exhaust pipe as shown.
positive (+) battery terminal. Tighten clamp
securely. THEN install negative (–) battery cable
end on negative (–) battery terminal. Tighten
clamp securely.
12. Pre-lubricate turbocharger by turning ignition
switch to the ON position and depressing both
START and STOP buttons TOGETHER, turning
the engine over without starting it. DO NOT en-
gage starter for more than 15 seconds at one
time. Allow at least one minute for starter to cool
before reusing. Crank engine intermittently until
oil pressure registers on oil gauge.
13. Start engine and check for leaks.
14. Test turbocharger boost pressure as previously
outlined.

Boost Pressure Control

(D254 Engines)
! WARNING
71002
Always disconnect battery cables from battery a - Retaining Spring
before working around electrical system compo- b - Blanket, Heat Shield
nents to prevent injury to yourself or damage to c - Wastegate Exhaust Pipe
electrical system. d - Gasket
Typical MCM Assembly Shown (MIE Similar)

2. Visually examine pipe and convolutions for signs

of cracking or leakage. Also, examine gaskets for
signs of leakage. Repair as needed. (Refer to
“Removal” if required.)

Index
7C-16 – TURBOCHARGER 90-806934 1194
REMOVAL 3. Using hex nuts or screws, with lockwashers,
install wastegate exhaust pipe as shown. Tighten
1. Refer to “Removing Exhaust Elbow” as previous-
fasteners securely.
ly outlined and remove exhaust elbow.
2. Remove two remaining hex nuts, or screws, and
lockwashers on wastegate exhaust pipe as
shown.

71004

a - Gasket
b - Wastegate Exhaust Pipe
c - Hex Nuts With Lockwashers
71004
Typical MCM Pipe Shown (MIE Similar)
a - Hex Nut or Screws, With Lockwashers (2)
b - Wastegate Exhaust Pipe
4. Install turbocharger exhaust elbow. (Refer to
c - Wastegate Turbocharger - “Installation” as previously outlined,
and accomplish appropriate instructions regarding
Typical MCM Pipe Shown (MIE Similar)
installation of exhaust elbow or riser.)

3. Remove wastegate exhaust pipe.

INSTALLATION
1. Clean old gasket material from wastegate mating
surfaces and pipe (if to be reused), being careful
not to distort pipe or crack it. Do not allow debris
to enter wastegate opening.
2. Install new gasket on wastegate flange.

Index
90-806934 1194 TURBOCHARGER – 7C-17
Valve 2. Remove allen-head screws and washers retain-
ing valve to wastegate. Remove valve.
REMOVAL
1. Follow instructions “a” - “c”:
a. Remove banjo bolt with sealing washers (2)
from pressure line on bottom of intercooler
housing as shown.
b. Remove banjo bolt with sealing washers (2)
from pressure line on valve as shown.
c. Remove pressure line.

70983

a - Allen-Head Screws With Washers (3 Total - Two Hidden In

This View)
b - Valve
c - Wastegate
Typical

INSTALLATION
1. Position pressure line fitting on valve toward front
of engine and install on wastegate using allen-
head screws and washers. In equal amounts,
tighten screws securely.
2. Install pressure line on valve using banjo bolt with
new sealing washers. Finger tighten.
3. Install banjo bolt with new sealing washers on
pressure line at exhaust manifold. Finger tighten.
4. Tighten both banjo bolts securely. Do not over-
tighten.
5. Pre-lubricate turbocharger and engine. To do
this, move the “STOP” switch toggle lever DOWN
70917
and hold in this position while you turn the key
switch to “START” position. Doing this TOGETH-
a - Banjo Bolts ER turns the engine without starting it. DO NOT
b - Sealing Washers (2 Each) engage starter for more than 15 seconds; allow
c - Pressure Line
at least one minute cool down time before re-en-
d - Intercooler Housing
e - Wastegate
gaging starter for another 15 seconds. Watch
f - Valve that starter does not overheat.
Typical 6. Start engine and check for leaks.
7. Test turbocharger boost pressure as previously
outlined.

Index
7C-18 – TURBOCHARGER 90-806934 1194
Wastegate INSTALLATION

REMOVAL 1. Clean all traces of old gasket material from ex-

haust manifold flange where shown.
1. Remove the following, as previously outlined:

Exhaust elbow

Wastegate exhaust pipe

Wastegate valve
2. Remove the four fasteners with lockwashers re-
taining wastegate to exhaust manifold as shown.

71006

2. Clean old gasket material from wastegate and

using a new gasket install wastegate on exhaust
manifold as shown. Tighten the four fasteners
with lockwashers securely.

71005

a - Hex Nuts, or Screws, With Lockwashers (4)

b - Wastegate
c - Exhaust Manifold
Typical

71005

a - Wastegate
b - Gasket
c - Hex Nuts, or Screws, With Lockwashers (4 Total)
Typical

Index
90-806934 1194 TURBOCHARGER – 7C-19
3. Following instructions previously outlined, install:

Wastegate valve

Wastegate exhaust pipe

Exhaust elbow or riser

4. Pre-lubricate turbocharger and engine. To do

this, move the “STOP” switch toggle lever
DOWN and hold in this position while you turn
the key switch to “START” position. Doing this
TOGETHER turns the engine without starting it.
DO NOT engage starter for more than 15 sec-
onds; allow at least one minute cool down time
before re-engaging starter for another 15 sec-
onds. Watch that starter does not overheat.
5. Start engine and check for leaks.
6. Test turbocharger boost pressure as previously
outlined.

Index
7C-20 – TURBOCHARGER 90-806934 1194
DRIVE SYSTEMS

25280

HURTH DOWN ANGLE TRANSMISSION

Note:Refer to the following Service Bulletins regarding this section. 8
SB 99-5 Proper Oil Fill Level On Velvet Drive Transmissions
SB 98-15 Shift Cable Measurements For Transmissions
SB 96-16 Hurth V-Drive Output Flange Torque
A
SB 96-11 Hurth Transmissions
SB 95-24 Hurth Marine Gear Distributors
SB 95-23 Velvet Drvie Distributors

INDEX
Table of Contents
Page Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-23
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8A-1 Clutch Discs . . . . . . . . . . . . . . . . . . . . . . . . 8A-23
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . 8A-1 Needle Bearings . . . . . . . . . . . . . . . . . . . . . 8A-26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 Gear Assembly . . . . . . . . . . . . . . . . . . . . . . 8A-26
Transmission Fluid Specification . . . . . . . . . . . . 8A-2 Tapered Roller Bearing . . . . . . . . . . . . . . . 8A-27
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 Intermediate Shaft . . . . . . . . . . . . . . . . . . . 8A-28
Operating Specifications . . . . . . . . . . . . . . . . . . . 8A-2 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . 8A-28
Transmission Ratios . . . . . . . . . . . . . . . . . . . . . . 8A-2 Preassembly of Output Half of Housing . 8A-29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 Preassembly of Input Half of Housing . . . 8A-32
Shift Cable Installation and Adjustment . . . . . . . . . 8A-3 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-39
Checking Transmission Input Shaft Seal . . . . . . . . . . . . . . . . . . . . . 8A-39
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-6 Control Block . . . . . . . . . . . . . . . . . . . . . . . . 8A-40
Draining Transmission . . . . . . . . . . . . . . . . . . . . . . . 8A-7 Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-40
Filling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-8 Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-41
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . 8A-9 Output Flange . . . . . . . . . . . . . . . . . . . . . . . 8A-41
Transmission Installation . . . . . . . . . . . . . . . . . . . . . 8A-9 Transmission Fluid Cooler . . . . . . . . . . . . 8A-41
Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . 8A-10 Filling with Transmission Fluid . . . . . . . . . 8A-42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-10 Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-43
Transmission Fluid Cooler . . . . . . . . . . . . 8A-10
Oil Filter and Dipstick . . . . . . . . . . . . . . . . . 8A-10
Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
Control Block . . . . . . . . . . . . . . . . . . . . . . . . 8A-13
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-14
Bearing, Gear and Seal Inspection . . . . . 8A-15
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-16
Tapered Roller Bearing Cups . . . . . . . . . . 8A-17
Tapered Roller Bearings . . . . . . . . . . . . . . 8A-18
Reversing Clutch, Gears and Tapered Roller
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-19
Clutch Discs . . . . . . . . . . . . . . . . . . . . . . . . 8A-21

8A - -HURTH
8A-0 HURTHDOWN
DOWNANGLE
ANGLETRANSMISSION
TRANSMISSION 90-806934 1194
INDEX
Identification Tools/Lubricants/Sealants
The transmission identification plate is located on the
DESCRIPTION PART NUMBER
top rear of the transmission.
Tapered Roller Bearing
91-813950
Inner Race Puller
Tapered Roller Bearing
91-813951
Outer Race Puller
a Pressure Plate Removal
91-813952
Tool Reversing Clutch
Tapered Roller Bearing
91-813953
Inner Race Puller Plate
Mandrel-Input Shaft Seal 91-912955
Mandrel-Output Shaft Seal 91-813956
Preload Tool Input Shaft 91-813957
Preload Tool Intermediate
91-813958
Shaft
Quicksilver Loctite 8831 92-823089-1
72957
Quicksilver Engine Coupler
a - Transmission Identification Plate 91-816391A4
(Stating: Gear Ratio, Serial Number and Model)
Spline Grease
Quicksilver Liquid
92-27511-1
Neoprene
Pressure Gauge (M10x1
Thread)
Loctite 515 (Split-LIne)
Sealer Obtain Locally
HSW 630A – 1,6
Thermometer (3/8 In.
Getr.-Nr. Thread 0-270° F)
iA = 1,56 iB = 1,58 (–18-132° F)
MADE IN WEST-GERMANY 71038

Typical Identification Plate

Torque Specifications
TORQUE
DESCRIPTION
Lb. Ft. N⋅m
Transmission
Housing Halves 36 49
Bolts and Nuts
Control Block to
18 25
Housing Bolts
Output Flange to
63 85
Output Shaft
Mounts 50 68
Transmission to
50 68
Flywheel Housing

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-1

INDEX
Specifications General
The Hurth transmission is a “full power reversing”
Transmission Fluid Specification transmission, allowing a standard (LH rotation) en-
gine to be used for both rotations. Propeller rotation
DESCRIPTION SPECIFICATION is determined by shift cable attachment at the remote
control.
Obtain Locally ATF Dexron ll-D
IMPORTANT: Transmission propeller rotation is
determined by the shift cable installation in the
Capacity remote control.
• RIGHT-HAND PROPELLER ROTATION - Control
MODEL U.S. QTS. (LITRES) cable will have to be installed in remote control so that
630A 8° Down Angle 4.25 (4.0) cable end will move in direction (A) when shift handle is
placed in the forward position.
• LEFT-HAND PROPELLER ROTATION - Control cable
Operating Specifications will have to be installed in remote control so that cable
end will move in direction (B) when shift handle is
DESCRIPTION SPECIFICATION placed in the forward position.
Shifting Pressure 312-377 (2151-2599 kPa) A
Operating
130° 200° F (54° - 93° C)
Temperature B
23242

Transmission Ratios
Transmission
630A
Model
Nominal
Transmission 1.5 2.0 2.5
Ratio
Transmission
Ratio Shifting 72709
1.56 2.04 2.52
Position ”A”
(Forward Gear)
Shifting Lever Propeller
Transmission in Position Rotation Propeller
Ratio Shifting Opposite to Engine Right-Hand
1.58 2.10 2.53 A
Position ”B” Rotation (RH)
(Reverse Gear)
Same as Engine Left-Hand
B
Rotation (LH)

72710

“A” Is Forward Gear for RH Rotation Propeller “B” Is Forward Gear for LH Rotation Propeller

8A-2 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
Shift Cable Installation and IMPORTANT: Check that shift lever is positioned
approximately 10° aft of vertical when in the neu-
Adjustment tral detent position and that the distance (“c”)
between studs in the following is set at 7-1/8 in.
These Hurth transmissions are full reversing trans-
(318mm). If necessary, loosen clamping bolt and
missions. Direction of output/propeller rotation is
position lever so that dimension “c” is as shown
determined by hookup of shift cable at remote
when in the neutral detent position and retighten
control.
bolt.
Shift cable must be hooked up to remote control
before starting installation and adjustment proce-
dures.
For Right Hand Propeller Rotation – shift cable b
hookup at remote control must result in shift cable
end guide moving in direction “A”, when remote
control handle is placed in forward position.
For Left Hand Propeller Rotation – shift cable c
hookup at remote control must result in shift cable
end guide moving in direction “B”, when remote
control handle is placed in forward position.
a

d
73587
a - Shift Lever
b - Lever, in Neutral Detent, Must Be Approximately 10° Aft
of Vertical
23242 c - Dimension Between Studs - 7-1/8 in. (318mm)
d - Clamping Bolt
Typical Hurth Transmission Shown
! WARNING 1. Place remote control shift lever, and transmis-
sion shift lever, in neutral position.
Avoid serious injury or property damage caused
by improper shifting. Anchor stud for shift cable 2. Remove nuts and washers from shift cable at-
must be installed in the correct hole. taching studs.
1. Be certain anchor stud is installed in the lower,
front hole as shown in the illustration following.

b
b

a a

c c

73588
71020

a - Cable Bracket
b - Shift Cable Anchor Stud Location (For Quicksilver
Shift Cables)
Shift Cable Bracket - Anchor Stud Position
Shown for 630A

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-3

INDEX
3. Locate center of remote control and control shift
cable play (backlash), as follows:
a. Check that remote control is in neutral posi-
tion.
b. Push in on control cable end with enough
pressure to remove play, and mark position
“a” on tube.
c. Pull out on control cable end with enough
pressure to remove play, and mark position
“b” on tube.
d. Measure distance between marks “a” and
“b,” and mark position “c,” half-way between
marks “a” and “b.”
b c
a lever, to bottom hole, and recheck for proper
c positioning. If proper positioning is still not
22024
4. Center cable-end play, then adjust cable barrel to
align holes in barrel, and in cable end guide, with
attaching points on transmission.
5. Temporarily install shift cable. Do not secure at
this time.
73587
Typical
8A-4 - HURTH DOWN ANGLE TRANSMISSION
INDEX
IMPORTANT: Transmission is “fully” in gear
when shift lever comes to a stop, in either direc-
tion.
6. Place remote control shift lever in forward gear
position. Check to ensure transmission is fully in
gear, as follows:
a. Hold shift lever in position.
b. Carefully slide shift cable off of anchor points.
c. Attempt to move shift lever further.
7. Place remote control shift lever in the reverse
gear position. Check that transmission is fully in
gear, following same procedure.
8. If transmission shift lever will position properly in
one gear, but not in the other, recheck shift cable
adjustment. If transmission shift lever will not
position properly in both gears, move transmis-
sion shift lever stud (a), from top hole in shift
obtained, remote control does not provide suffi-
cient shift cable travel and must be replaced.
b
c
50228
a - Shift Lever Stud (In Bottom Hole, If Required)
b - Lever, in Neutral Detent, Must Be Approximately 10° Aft
of Vertical
c - Shift Lever Top Hole
9. Reattach locknut and washer to cable end guide
stud. Tighten until snug, then back off one-half
turn.
10. Reattach locknut and washer to cable barrel stud.
Tighten until they bottom out. Tighten securely,
but do not overtighten.
90-806934 1194
NOTE: To change cable approach direction on single
or dual station installations, only the spacers/bush-
ings have to be switched to the opposite stud (the
studs are identical).

e
d

73587

73589
a
f b
d
c
g
b
c

e
b b
g c
f
a
d 71972

c 71210 a - Cable End Guide

b - Spacer (As Required)
a - Cable End Guide c - Elastic Stop Nut and Washer
b - Spacer (As Required) d - Cable Barrel (Position Only Indicated In Lower Drawing)
c - Elastic Stop Nut and Washer e - Bushing(s)
d - Cable Barrel (Position Only Indicated In Lower Drawing) f - Cable Barrel Stud
e - Bushing(s) g - Cable End Guide Stud
f - Cable Barrel Stud
g - Cable End Guide Stud Single Cable - Rear Entry
Single Cable - Forward Entry

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-5

INDEX
 e

73591
73590

g
a
f

e
b
b
d
CABLE
BARREL c d
STUD c
g

f
CABLE
END GUIDE
STUD 50073
a
e
b 71211
a -
Cable End Guide(s)
b -
Spacer
c -
Elastic Stop Nut and Washer
a - Cable End Guides d -
Bushing(s)
b - Locknut and Washer (Tighten Until Bottomed, Then Back Off
e -
Cable Barrel(s) [Position(s) Only Indicated In Lower
One Full Turn)
c - Spacer (Fits over Stud) Drawing]
d - Bushings f - Cable Barrel Stud
e - Cable Barrels[Position(s) Only Indicated In Lower Drawing] g - Cable End Guide Stud
f - Cable Barrel Stud
g - Cable End Guide Stud Dual Cable - Rear Entry
Dual Cable - Forward Entry

8A-6 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
Checking Transmission Draining Transmission
Fluid Level 1. Clean the exterior of transmission before disas-
sembly.
IMPORTANT: Use only specified transmission
fluid (see “Specifications”). 2. Remove oil filter from housing by turning (coun-
terclockwise) and pulling at the same time.
Check transmission fluid before starting engine each
day, as follows:
1. Remove dipstick. Check fluid level as indicated
on dipstick. Fluid level may be somewhat over full
mark, as some of the fluid from transmission fluid
cooler and hoses may have drained back into
transmission. If low, add transmission fluid to
bring level up to full mark on dipstick.

27666

3. Push hose of suction pump through suction pipe

and down to the bottom of the housing. Pump fluid
from housing.

27661

Typical Hurth Transmission Shown

IMPORTANT: To accurately check fluid level, en-

gine must be run at 1500 RPM for two minutes im-
mediately prior to checking level.
2. Start engine and run at 1500 RPM for two minutes
to fill all hydraulic circuits.
IMPORTANT: Be sure to push dipstick all the way
down into dipstick tube when checking fluid lev-
el. 71043

3. Stop engine and quickly check fluid level. Add

automatic transmission fluid, if necessary, to
bring level up to full mark on dipstick. (Refer to
“Filling Transmission,” following.)
4. Reinstall dipstick.
5. If transmission fluid level was extremely low,
carefully check transmission, fluid cooler and
hoses for leaks.

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-7

INDEX
Filling Transmission 3. Start engine and run for two minutes to fill system
with fluid.
IMPORTANT: Use only Automatic Transmission
Fluid (ATF) as recommended in “Specifications.” 4. Stop engine and check fluid level. Fluid should be
between min. and max. lines on dipstick.
1. Fill transmission to proper level, through oil filter
cavity. (Refer to “Capacity.”)
2. Install filter as follows:
a. Coat O-ring on filter cover with transmission
fluid.

27661

27662

a - Filter Cover
b - O-Ring
! CAUTION
Transmission fluid filter and cover must be prop-
erly seated to avoid fluid foaming and/or loss of
fluid, thus resulting in decreased efficiency and/
or damage to transmission.
b. Push down until cover is fully seated (top of
cover flush with housing), then turn T-handle
clockwise until tight.

27666

8A-8 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
Transmission Removal Transmission Installation
1. Disconnect wires from neutral safety switch and 1. Coat splines on input shaft with Quicksilver En-
audio warning temperature switch. gine Coupler Spline Grease.
2. Disconnect fluid cooler hoses. Appropriately la-
bel hose “Port” and “Starboard”.

c c

50686
71044
a - Neutral Safety Switch
b - Audio Warning Temperature Switch a - Input Shaft
c - Fluid Cooler Hoses

3. Remove bolts and locknuts and remove transmis- 2. Install transmission on flywheel housing and se-
sion. cure with hardware shown. Torque fasteners to
50 lb. ft. (68 N·m).
a
a

b
b

72720
72720
a - Bolts (2), One on Each Side
a - Bolts (2), One on Each Side
b - Locknuts (4), Two on Each Side
b - Locknuts (4), Two on Each Side

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-9

INDEX
3. Reconnect fluid cooler hoses. Securely tighten OIL FILTER AND DIPSTICK
hose fittings. 1. Remove oil filter from housing by turning T-handle
counterclockwise and pulling at the same time.
4. Connect wires to neutral safety switch and to
audio warning temperature switch. Coat connec-
tions on neutral safety switch with Quicksilver
Liquid Neoprene.

c c

b
27666

2. Remove cover and filter element from transmis-

50686 sion.

a - Neutral Safety Switch

b - Audio Warning Temperature Switch
c - Fluid Cooler Hoses

Transmission Repair

Disassembly
IMPORTANT: Ensure work area is clean before
disassembly is started. Be sure to use lint free
cloths when cleaning and/or handling parts.

TRANSMISSION FLUID COOLER

27662
See section 6A, “Sea Water System”.

8A-10 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
3. Remove filter element from cover and inspect 5. Remove dipstick by turning counterclockwise and
O-rings for wear. Replace if necessary. pulling at the same time.

a
50975
a - O-Rings

4. Push hose of suction pump through suction pipe

and down to the bottom of the housing. Pump fluid
from housing.

27661

6. Inspect seal for wear and replace if necessary.

71043

27659
a - Seal

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-11

INDEX
BREATHER VALVE OUTPUT FLANGE
1. Remove breather valve. Clean with suitable 1. Remove bolt, washer and O-ring.
cleaner, allow to dry and coat with oil.

a 71049
b

71048
a - Breather Valve b a
MOUNTS
1. Remove mounts from transmission housing. In-
spect mounts for damage and replace if neces-
sary.
c

a
71050
a - Bolt
b - Washer
c - O-Ring

b
72711

a - Transmission Mount
b - Retaining Screws (4 Total on Each Mount - One Hidden in
This View)

8A-12 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
2. Reinstall bolt and remove flange using appropri- CONTROL BLOCK
ate puller. 1. Remove hex head bolts.

27661
a - Hex Head Bolts (6)

2. Remove control block and gasket from housing.

b 71051

27666
b

71052
a - Bolt
b - Flange
c - Puller

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-13

INDEX
 ! CAUTION 2. Remove input side of housing. Be sure to locate
and save locator pins.
Be careful not to allow dirt to enter control block
from front side.
3. Cover openings in control block with a protective
cloth.
a

a
27665 71053
a - Openings a - Locator Pins

3. Remove input shaft assembly.

HOUSING
1. Remove hex head bolts from input side of hous-
ing.

71044

a - Bolts (12) 71054

8A-14 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
4. Remove intermediate shaft assembly. 6. Remove output shaft assembly.

71055
71058
5. Remove baffle plate as follows:
a. Bend tabs up away from screws.
b. Remove screws, then remove baffle plate. BEARING, GEAR AND SEAL INSPECTION
1. Inspect all tapered roller bearings, the piston
a rings on the input shaft and all gears for wear. If
damage has been found on the gearing of the in-
a termediate or output shaft, it is ALWAYS neces-
sary to replace the complete shaft.
When gears on the input shaft have to be re-
placed, the tapered roller bearings and needle
bearings MUST BE replaced as well.
2. Turn gears of input shaft to check correct opera-
tion of the reversing clutch. If it is hard to turn the
gears, the clutch is probably damaged.

71056

a b

b
71057

a - Tab
b - Screws
c - Baffle Plate

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-15

INDEX
SEALS b. Remove screws and hold-down plate.
1. Remove suction pipe seal as follows: c. Remove suction pipe by pulling downward out
of seal.

71060
a - Screws
b - Hold-Down Plate

27666
d. Remove seal from top side.
a - Seal

a. Bend tabs up away from screws.

27660
71059
a - Seal
a - Tabs

8A-16 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
2. Remove input shaft seal using appropriate man-
drel.
a a. Position appropriate puller guide (large diam-
TAPERED ROLLER BEARING CUPS
IMPORTANT: Do not remove tapered roller bear-
ing cups unless replacing tapered roller bear-
ings. Bearing and cup must be replaced as a set.
IMPORTANT: Do not mix up shims under cups on
the input housing side. Shims are required for ad-
justing the bearing preload.
1. Pull tapered roller bearing cups from housing us-
ing special puller as follows:
eter or small diameter) over cup as shown.

27670
a - Seal

3. Remove output shaft seals using appropriate

mandrel.

a
27681

71061

a - Seal
b
72712

a - Small Diameter Puller Guide

b - Large Diameter Puller Guide

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-17

INDEX
 b. Pull bearing cup from housing using tool as TAPERED ROLLER BEARINGS
shown.
! CAUTION
Gears should never be removed from intermedi-
ate shaft or output shaft, as this will affect proper
gear alignment.
1. Remove tapered roller bearings from intermedi-
ate shaft and output shaft by using a universal
puller plate and pressing bearings off.

27681

c. Input Housing Side: Remove and retain

shims. DO NOT MIX UP.

71045

27682

71046

8A-18 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
REVERSING CLUTCH, GEARS AND TAPERED b. Tighten jaws onto bearing by turning on
ROLLER BEARINGS knurled part of tool. Tighten assembly.
1. Remove tapered roller bearing from splined end
of input shaft using special tool as follows:
a. Place tool over tapered roller bearing. Ensure
jaws of tool will be pulling on bottom edge of
rollers and NOT on the cage.

27671

c. Pull tapered roller bearing from shaft using

tool as shown.

27671
b
a - Jaws
b - Bottom Edge of Rollers

27672

a - Hold Tool Stationary

b - Turn Top Nut

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-19

INDEX
2. Remove butting ring from splined end of input 4. Remove needle bearings.
shaft by installing special tool as shown and lightly
tapping upward on tool.

27673

a - Special Tool
b - Butting Ring 27680

3. Remove butting ring and gear assembly. 5. Remove piston rings from shaft.

27675
a - Butting Ring
b - Gear Assembly

27679

8A-20 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
6. Remove tapered roller bearing, butting ring and
gear from piston end of shaft using special tool as
shown. Press all components off at the same
time. Then remove needle bearings.
2. Remove end disc and snap ring as follows:
1. Position snap ring compression tool on clutch as-
sembly so that compression screws are centered
over slots in clutch housing.
a. Tighten all compression screws until a slight
resistance is felt.
b. Tighten compression screws evenly (approxi-
mately 1/2 turn at a time).
c. Tap up lightly on bottom edge of compression
tool until snap ring pops up and out of groove
in clutch housing.

27673 a

CLUTCH DISCS c
NOTE: Discs on both sides of clutch are removed in
the same manner.
IMPORTANT: Reference marks are placed on the
clutch housing and end disc to aid in locating the
snap ring opening.
27674
a - Snap Ring Compression Tool
b - Compression Screws (6)
c - Slots

27675 27675
a - Reference Marks

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-21

INDEX
NOTE: For ease of reassembly, end disc and snap
ring should not be removed from tool unless their con-
dition is questionable.
a
IMPORTANT: Thrust discs have a wave pattern.
These discs must be reinstalled in a specific pat-
tern when reassembled. Make note of notches in
thrust disc tabs, and how they are arranged.

50248
27676
a - End Disc (Snap Ring Compressed)

d. If necessary, remove end disc and snap ring

from tool.
a
c b

b
a
27679

a - Thrust Discs (5 per Side) (See Note)

b - Inner Discs (4 per Side) (See Note)
c - Notches
630A Clutch Arrangement Shown

27676
a - End Disc
b - Snap Ring

8A-22 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
3. Remove discs. Reassembly
CLUTCH DISCS
IMPORTANT: Thrust discs have a wave pattern.
These discs must be reinstalled in a specific man-
ner as explained following.

27680
50248
1. Arrange thrust discs and inner discs as shown.
4. Inspect thrust discs and inner discs for wear. Re-
Ensure notches on thrust disc tabs are aligned as
place if there is any questionable wear.
shown.
5. Remove and inspect disc on opposite side of
clutch in same manner.

a
c b

27679

a - Thrust Discs (5 per Side) (See Note)

b - Inner Discs (4 per Side) (See Note)
c - Notches
630A Clutch Arrangement Shown

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-23

INDEX
2. Install discs in clutch housing. 4. If end disc and snap ring were removed from tool,
reinstall as follows:
a. Loosen all compression screws on tool.

a
27677
a - Compression Screws

b. Place snap ring into groove in end disc and

compress by hand so that compression dogs
27680
will hold in on snap ring.

3. Align snap ring opening with reference marks on

end disc and clutch housing.

c
b
27677
a - End Disc
b - Snap Ring
c - Compression Dogs
b

a
b
27678

a - Snap Ring Opening

b - Reference Marks

8A-24 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
 c. Tighten compression screws evenly to com- 5. Tap lightly around top of tool until end disc bot-
pletely compress snap ring into end disc. toms. Loosen compression screws and remove
tool.

b
27677
a - End Disc
b - Compression Screws

d. Carefully lower end disc and special tool onto

clutch housing and align compression dogs
with slots in housing.
27678

b
a

27675
a - Slots
b - Compression Dogs 27675

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-25

INDEX
6. Double check that snap ring has been properly
seated by prying up lightly on end disc.
GEAR ASSEMBLY
1. Reinstall gear assembly. Twist gear assembly
from side to side to allow splines to engage with
inner discs. Ensure all inner discs are engaged
with splines by observing through slots in clutch
housing.

27679

7. Reinstall discs on opposite side of clutch in same

manner.

NEEDLE BEARINGS
1. Reinstall needle bearings.

27673

2. Reinstall butting ring.

27680

27672

8A-26 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
TAPERED ROLLER BEARING 3. Reinstall piston rings on input shaft. Ensure ends
of rings are coupled as shown. Then position
! WARNING rings so that ends are staggered so no two are
Do not touch bearing once it has been heated. Se- aligned.
vere burns could result. Use special protective
gloves to handle bearing.
1. Heat inner race of tapered roller bearing using a
torch lamp and press bearing onto shaft. When
bearing has cooled (DO NOT cool with water),
carefully tap bearing down to ensure proper
seating against butting ring, using a soft (copper)
punch. Tap on inner race only.

27679

27674
a - Tapered Roller Bearing
b - Butting Ring

2. Install components on opposite side of clutch as-

sembly in same manner.
! CAUTION
Use care in reinstalling piston rings on input
shaft. Piston rings are brittle and may snap if
spread too far open.

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-27

INDEX
INTERMEDIATE SHAFT
! WARNING
Do not touch bearing once it has been heated. Se-
vere burns could result. Use special protective
gloves to handle bearing.
1. Heat inner race of tapered roller bearing using a
torch lamp and press bearing onto shaft. When
bearing has cooled (DO NOT cool with water),
carefully tap bearing to ensure proper seating
against gear, using a soft (copper) punch. Tap on
inner race only.
71045
2. Install tapered roller bearing on opposite end of
shaft in the same manner.
8A-28 - HURTH DOWN ANGLE TRANSMISSION
INDEX
OUTPUT SHAFT
! WARNING
Do not touch bearing once it has been heated. Se-
vere burns could result. Use special protective
gloves to handle bearing.
1. Heat inner race of tapered roller bearing using a
torch lamp and press bearing onto shaft. When
bearing has cooled (DO NOT cool with water),
drive bearing down against gear using a soft (cop-
per) punch. Tap on inner race only.
71046
2. Install tapered roller bearing on opposite end of
shaft in the same manner.
NOTE: Tap bearing on splined end of shaft until it is
seated against shoulder on shaft.
90-806934 1194
PREASSEMBLY OF OUTPUT HALF OF HOUSING ! WARNING
IMPORTANT: If tapered roller bearing cups were Use care in handling housing once it has been
removed, ensure output shaft seal IS NOT in heated. Severe burns could result. Use special
place, as it will be necessary to heat housing prior protective gloves to handle housing.
to installing bearing cups.
2. Heat bearing bores of housing using a torch lamp
IMPORTANT: The tapered roller bearing cup on and install bearing cups using a suitable mandrel.
the input shaft (control block end) is properly po-
sitioned by bottoming out on the face of the con-
trol block assembly. It will be necessary to tempo-
rarily install control block to install this tapered
roller bearing cup.
b
1. Temporarily install control block on outer housing.
Tighten bolts securely. a

27681
a - Bearing Cups
b - Torch Lamp

3. Allow housing to cool (DO NOT cool with water)

and then tap bearing cup with suitable mandrel to
ensure it is properly seated.
4. Remove control block assembly.

27682

27666
a - Input Shaft Bearing Cup
b - Control Block Face

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-29

INDEX
Output Shaft Seal
1. If bearing were not replaced and no shimming
is required, push new seal onto special mandrel.
Ensure seal will be positioned with lip of seal fac-
ing inward. Drive seal uniformly into bore of hous-
ing to the point that it is countersunk .040 in. (1
mm) with reference to housing surface.
2. Reinstall suction pipe. Place one drop of Quicksil-
ver Loctite 8831 or Type A on screw threads.
Then secure suction pipe down with retainer
plate. Tighten screws securely.
3. Bend tabs down over screws.

71060

71061
Shafts and Baffle Plate
a - Seal
1. Coat tapered roller bearings with ATF.
Suction Pipe 2. Install output shaft.
1. Reinstall suction pipe seal in bottom of oil filter
bore. Coat seal with ATF (automatic transmission
fluid).

71058

27660
a - Seal

8A-30 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
3. Install baffle plate. Apply one drop of Quicksilver 5. Install input shaft. Ensure all gears mesh as
Loctite 8831 or Type A to screws. Tighten screws shown.
securely and bend tabs down over screws.

a
b

a
b

71057
a - Tabs
b - Screws
c - Baffle Plate

4. Install intermediate shaft.

71054

71055

71062

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-31

INDEX
PREASSEMBLY OF INPUT HALF OF HOUSING
1. Install breather valve (DO NOT overtighten).
! WARNING
Use care in handling housing once it has been
heated. Severe burns could result. Use special
protective gloves to handle housing.
3. Heat each tapered roller bearing cup bore with a
torch lamp. Insert shims (less those removed)
and bearing cups into appropriate bearing bores.
When housing has cooled (DO NOT cool with wa-
ter), tap bearing cups with a suitable mandrel to
ensure that cups are fully seated.

71048

Bearing Preload Adjustment

IMPORTANT: If new tapered roller bearings have

been installed, the preload must be readjusted. If
bearings were not replaced, proceed to the final
reassembly section. 71063

NOTE: The required preload of bearings of the indi-

vidual shafts is obtained by using shims beneath the b
tapered roller bearing cups in the input half of the
housing.
NOTE: Shims which have been removed during dis-
assembly may be reused.
2. Subtract approximately .008 in. (0.2 mm) of shims
from each bearing cup bore. Remove and set
aside, but do not mix up.

27681

a - Bearing Cups
b - Torch Lamp

8A-32 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
4. Install input half of housing onto output half. En- b. Mount dial indicator on input shaft. Turn input
sure locator pins are in place. Install bolts and shaft several times to seat bearing.
lockwashers and torque to 36 lb. ft. (49 N·m).

71064
27685

c. Zero the dial indicator.

Input Shaft Preload

1. Measure bearing clearance as follows:
a. Install special tool as shown. Tighten
hold-down bolts securely.

27863
27685
a - Special Tool
b - Hold-Down Bolts

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-33

INDEX
IMPORTANT: The following step should be done e. Make note of reading. The bearing clearance
very carefully to obtain the actual bearing clear- measured PLUS the preload required is equal
ance. Avoid bumping the input shaft and turn to the amount of shim thickness to be ADD-
very slowly on the special tool knob. (Shaft will ED.
only be moving a very small amount.)
d. Slowly turn the special tool knob clockwise to
push the shaft upward. (Perform the above
sequence several times to ensure an accu-
rate reading.)

27685

Example:
Bearing Clearance Measured .009 in.
+ Bearing Preload Required .004 in.

= Shims to Be Added .013 in.

27682

8A-34 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
Intermediate Shaft Preload d. Zero dial indicator.

1. Measure bearing clearance as follows:

a. Remove hex plug from housing.

71065 27685

b. Screw special bolt with nut into intermediate
shaft and tighten snugly. Turn nut up until it
touches bolt head.
c. Mount dial indicator on bolt head. Turn output
shaft several times to ensure bearing is
seated.
IMPORTANT: The following step should be done
very carefully, to obtain the actual bearing clear-
ance. Turn nut very slowly as shaft will only be
moving a small amount.
e. Hold bolt with one wrench and slowly turn
down nut to pull shaft upward. (Perform the
above sequence several times to ensure ac-
curate reading.)

71066
a - Special Bolt with Nut b

72869

a - Bolt - Hold Stationary

b - Nut - Turn to Move Shaft

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-35

INDEX
 f. Make note of the reading. The bearing clear-
ance measured PLUS the preload required is
equal to the amount of shim thickness to be
ADDED.
Output Shaft Preload
1. Measure the bearing clearance as follows:
a. Install flange washer and bolt. Tighten snugly.
b. Mount dial indicator on bolt head. Turn output
shaft several times to ensure bearing is
seated.

71069
a - Flange Washer and Bolt
27686

c. Zero dial indicator.

Example:
Bearing Clearance Measured .007 in.
+ Bearing Preload Required .004 in.

= Shims to Be Added .011 in.

g. Remove dial indicator, special bolt and nut,

and reinstall hex plug. Tighten securely.

27685

8A-36 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
IMPORTANT: The following step should be done
very carefully to obtain the actual bearing clear-
ance. Pry up gently and evenly to lift shaft. Shaft
will only move a small amount.
d. Pry up on washer to lift output shaft.
2. When thickness of shims to be ADDED has been
determined, the input half of housing must again
be removed. Remove bolts and lockwashers,
then lift off input half of housing.

71068

e. Make note of the reading. The bearing clear- 71044

ance measured PLUS the preload required is
equal to the amount of shim thickness to be
ADDED.
a - Bolts
3. Remove tapered roller bearing cups from housing
using special puller as follows:
a. Position appropriate puller guide (large or
small diameter) over cup as shown.

27686 27681
a - Small Diameter Puller Guide
Example:
Bearing Clearance Measured .010 in.
+ Bearing Preload Required .004 in.

= Shims to Be Added .014 in.

f. Remove dial indicator. Remove bolt and

flange washer.

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-37

INDEX
 b. Pull bearing cup from housing as shown. ! WARNING
Use care in handling housing once it has been
heated. Severe burns could result. Use special
protective gloves to handle housing.
5. Heat each tapered roller bearing cup bore with a
torch lamp. Install bearing cups into appropriate
bore and tap into place using a suitable mandrel.
When housing has cooled (DO NOT cool with wa-
ter), tap bearing cups to ensure they are fully
seated.
a

27681

4. Add the necessary amount of shims as deter-

mined previously to the appropriate bearing
bores.

27681

b
27682

71063

a - Torch Lamp
b - Bearing Cups

8A-38 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
Final Assembly 4. Install bolts and lockwashers and torque to 36 lb.
ft. (49 N·m).
INPUT SHAFT SEAL
1. Push new seal onto special mandrel. Ensure seal
will be positioned with lip of seal facing inward.
Drive seal uniformly into bore of housing to the
point that it is countersunk .040 in. (1 mm) with ref-
erence to housing surface.

71064

5. Double check to ensure that there is no shaft

clearance on all three shafts. Refer back to pre-
vious steps if necessary, and use dial indicator.
6. Remove intermediate shaft hex plug. Apply a
drop of Quicksilver Loctite type A or 8831 to
threads and reinstall in housing. Tighten securely.
27670

2. Coat lips of seals on input and output shafts with

ATF.
3. Apply a thin layer of Loctite 515 Sealer to ma-
chined surfaces on housing halves. Reinstall in-
put half of housing. Ensure locator pins are prop-
erly positioned.

a
b
71065

71053

a - Locator Pins
b - Machined Surface

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-39

INDEX
CONTROL BLOCK FLUID FILTER
1. Ensure piston rings are in place and the key is in 1. Coat new O-rings with ATF.
keyway. Align key on shaft with keyway in control
block.
2. Install new gasket between control block and
housing.

a
b
50975

a - O-Rings

a
2. Reassemble filter assembly as shown. DO NOT
tighten and compress upper O-ring.

27666
a - Key
b - Piston Rings
3. Carefully push control block onto input shaft.
4. Coat each hex socket head bolt with a drop of a
Quicksilver Loctite type A or 8831. Secure control
block to housing with bolts and lockwashers.
Torque to 18 lb. ft. (25 N·m).

a 72805

a - O-Ring

27661

a - Hex Socket Head Bolts (6)

8A-40 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
DIPSTICK
1. Coat sealing ring on dipstick with ATF.
2. Install dipstick into transmission and tighten by
pressing down and turning clockwise at the same
time.
4. Install O-ring into flange and coat with ATF.
5. Install washer and bolt. Torque to 63 lb. ft. (85
N·m).

b a

71050

27661

OUTPUT FLANGE
1. Coat output shaft splines with a thin coat of Quick-
silver Loctite type A or 8831.
2. Coat lip of output shaft seal with ATF.
3. Install output shaft flange. Be careful not to dam- b a
age output shaft seal.

71049

a - Bolt
b - Washer
c - O-Ring

TRANSMISSION FLUID COOLER

See section 6A, “Seawater System”.

71052
a - Splines
b - Output Shaft Seal

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-41

INDEX
FILLING WITH TRANSMISSION FLUID
IMPORTANT: Use only ATF (Automatic Transmis-
sion Fluid), such as Dexron II-D.
1. Fill transmission to proper level, through fluid filter
cavity. (Refer to “Transmission Fluid Capacity”.)
2. Install filter as follows:
a. Align flat spot on filter with flat surface inside
of housing.
b. Tighten filter by pushing down and turning
clockwise at the same time.

27666

3. Check fluid level. Fluid should be between min.

and max. marks on dipstick.
a

27662

a - Filter Cover
b - O-Ring

27661

27666

a - Flat Spot

8A-42 - HURTH DOWN ANGLE TRANSMISSION 90-806934 1194

INDEX
Functional Test
1. Connect a pressure gauge and thermometer to
fluid pump at locations shown.

b
a

50686

a - Pressure Gauge (M10x1 Thread) - Remove Plug

b - Thermometer (3/8 In. Thread) - Remove Temperature
Sender
2. Perform functional tests as shown in chart follow-
ing. Refer to “Operating Specifications” for cor-
rect readings.
Tests to Be Carried Out:
1. Leakages
2. Noise emission
3. Direction of rotation, LH/RH
4. Fluid temperature
5. Shifting pressure

Engine Speed RPM Shift Lever Position Duration Minutes Tests

800-1000 Neutral 5 1 2
600-800 (Idle) A-B Position Repeatedly 1 2 3
1500-2500 B Position * 1 2 4
600-800 (Idle) A-B Position Repeatedly 1 2 3
Idling Max Speed A Position 1 2 5**
600-800 From A-B Position 1 2
Idling Max Speed B Position 1 2 5**

* Until fluid temperature of 167-176° F(75-80° C) has been reached

**At different speeds

90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-43

INDEX
DRIVE SYSTEMS
8
B

72959

HURTH V-DRIVE TRANSMISSION

Index
Table of Contents
Page Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-23
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1 Clutch Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-23
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1 Needle Bearings . . . . . . . . . . . . . . . . . . . . . . . 8B-25
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . 8B-2 Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 8B-26
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 Tapered Roller Bearing . . . . . . . . . . . . . . . . . . 8B-26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 Intermediate Shaft . . . . . . . . . . . . . . . . . . . . . . 8B-27
Shift Cable Installation and Adjustment . . . . . . . . 8B-3 Reversing Shaft . . . . . . . . . . . . . . . . . . . . . . . . 8B-27
Checking Transmission Fluid Level . . . . . . . . . . . . . . 8B-7 Preassembly of Output Half of Housing . . . . 8B-28
Draining Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7 Preassembly of Input Half of Housing . . . . . 8B-31
Filling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-8 Bearing Preload Adjustment . . . . . . . . . . . . . 8B-31
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9 Reversing Shaft Preload . . . . . . . . . . . . . . . . . 8B-35
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . 8B-9 Output Shaft Preload . . . . . . . . . . . . . . . . . . . . 8B-35
Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-38
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10 Input Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . 8B-38
Transmission Fluid Cooler . . . . . . . . . . . . . . . 8B-10 Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-39
Oil Filter and Dipstick . . . . . . . . . . . . . . . . . . . 8B-10 Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-39
Breather Valve . . . . . . . . . . . . . . . . . . . . . . . . . 8B-11 Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-40
Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-11 Output Flange . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-40
Output Flange . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-12 Transmission Fluid Cooler . . . . . . . . . . . . . . . 8B-40
Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-13 Filling with Transmission Fluid . . . . . . . . . . . . 8B-41
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-13 Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-42
Bearing, Gear and Seal Inspection . . . . . . . . 8B-15
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-15
Tapered Roller Bearing Cups . . . . . . . . . . . . . 8B-17
Tapered Roller Bearings . . . . . . . . . . . . . . . . . 8B-18
Reversing Clutch, Gears and Tapered
Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . 8B-18
Clutch Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-20

Index
8B - HURTH
8B-0 V-DRIVE
- HURTH TRANSMISSION
V-DRIVE TRANSMISSION 90-806934
90-806934 1194
1194
Identification Torque Specifications
The transmission identification plate is located on the
TORQUE
top rear of the transmission. DESCRIPTION
Lb. Ft. N⋅m
Transmission
Housing Halves 36 49
a Bolts and Nuts
Control Block to
18 25
Housing Bolts
Output Flange to
63 85
Output Shaft
Mounts 50 68
Transmission to
50 68
Flywheel Housing

Specifications
DESCRIPTION SPECIFICATION
312-377
Shifting Pressure
(2151-2599 kPa)
130° 200° F
Operating Temperature
(54° - 93° C)

7295
9

HSW 630V – 1,5

Getr.-Nr.
iA
A = 1,56 iB
B = 1,58
MADE IN WEST-GERMANY 71039

Late Style Identification Plate

a - Transmission Identification Plate (Stating: Serial Number
and Gear Ratio)

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-1
Tools/Lubricants/Sealants General
The Hurth transmission is a “full power reversing”
DESCRIPTION PART NUMBER
transmission, allowing a standard (LH rotation) en-
Tapered Roller Bearing gine to be used for both rotations. Propeller rotation
91-813950
Inner Race Puller is determined by shift cable attachment at the remote
Tapered Roller Bearing control.
91-813951
Outer Race Puller IMPORTANT: Transmission propeller rotation is
Pressure Plate Removal determined by the shift cable installation in the
91-813952
Tool Reversing Clutch remote control.
Tapered Roller Bearing • RIGHT-HAND PROPELLER ROTATION - Con-
91-813953
Inner Race Puller Plate trol cable will have to be installed in remote control
Mandrel-Input Shaft Seal 91-912955 so that cable end will move in direction “A” when
Mandrel-Output Shaft Seal 91-813956 shift handle is placed in the forward position.
Preload Tool Input Shaft 91-813957 • LEFT-HAND PROPELLER ROTATION - Control
cable will have to be installed in remote control so
Preload Tool Intermediate that cable end will move in direction “B” when shift
91-813958
Shaft
handle is placed in the forward position.
Quicksilver Loctite 8831 92-823089-1
Quicksilver Engine Coupler
91-816391A4
Spline Grease
Quicksilver Liquid
92-25711-2
Neoprene
Pressure Gauge (M10x1
Thread) 23242
Loctite 515 (Split-LIne)
Sealer Ob i L
Obtain ll
Locally
Thermometer (3/8 In.
Thread 0-270° F)
(–18-132° F)

Capacity
U.S. QTS.
MODEL
(LITRES)
630V V-Drive 5 (4.7)

NOTE: Always use dipstick to determine exact quan-

tity of fluid required.

Index
8B-2 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
Shift Cable Installation and IMPORTANT: Check that shift lever is positioned
approximately 10° aft of vertical when in the neu-
Adjustment
tral detent position and that the distance (“c”)
These Hurth transmissions are full reversing trans- between studs in the following is set at 7-1/8 in.
missions. Direction of output/propeller rotation is (318mm). If necessary, loosen clamping bolt and
determined by hookup of shift cable at remote position lever so that dimension “c” is as shown
control. when in the neutral detent position and retighten
bolt.
Shift cable must be hooked up to remote control
before starting installation and adjustment proce-
dures.
For Right Hand Propeller Rotation – shift cable b
hookup at remote control must result in shift cable
end guide moving in direction “A”, when remote
control handle is placed in forward position.
For Left Hand Propeller Rotation – shift cable
hookup at remote control must result in shift cable c
end guide moving in direction “B”, when remote
control handle is placed in forward position.

d
73587
a - Shift Lever
b - Lever, in Neutral Detent, Must Be Approximately 10° Aft
23242 of Vertical
c - Dimension Between Studs - 7-1/8 in. (318mm)
d - Clamping Bolt
Typical Hurth Transmission Shown
! WARNING
Avoid serious injury or property damage caused 1. Place remote control shift lever, and transmis-
by improper shifting. Anchor stud for shift cable sion shift lever, in neutral position.
must be installed in the correct hole. 2. Remove nuts and washers from shift cable at-
1. Be certain anchor stud is installed in the lower, taching studs.
front hole as shown in the illustration following.

b
b

a a

c c

73588
71020

a - Cable Bracket
b - Shift Cable Anchor Stud Location (For Quicksilver Shift Cables)
Shift Cable Bracket - Anchor Stud Position
Shown for 630V Transmission

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-3
3. Locate center of remote control and control shift 6. Place remote control shift lever in forward gear
cable play (backlash), as follows: position. Check to ensure transmission is fully in
gear, as follows:
a. Check that remote control is in neutral posi-
tion. a. Hold shift lever in position.
b. Push in on control cable end with enough b. Carefully slide shift cable off of anchor points.
pressure to remove play, and mark position
c. Attempt to move shift lever further.
“a” on tube.
7. Place remote control shift lever in the reverse
c. Pull out on control cable end with enough
gear position. Check that transmission is fully in
pressure to remove play, and mark position
gear, following same procedure.
“b” on tube.
8. If transmission shift lever will position properly in
d. Measure distance between marks “a” and
one gear, but not in the other, recheck shift cable
“b,” and mark position “c,” half-way between
adjustment. If transmission shift lever will not
marks “a” and “b.”
position properly in both gears, move transmis-
sion shift lever stud (a), from top hole in shift
b c lever, to bottom hole, and recheck for proper
positioning. If proper positioning is still not
obtained, remote control does not provide suffi-
a cient shift cable travel and must be replaced.
c b

22024

4. Center cable-end play, then adjust cable barrel to

align holes in barrel, and in cable end guide, with
attaching points on transmission. c

5. Temporarily install shift cable. Do not secure at

this time. a

50228
a
a - Shift Lever Stud (In Bottom Hole, If Required)
b - Lever, in Neutral Detent, Must Be Approximately 10° Aft
of Vertical
c - Shift Lever Top Hole

9. Reattach locknut and washer to cable end guide

stud. Tighten until snug, then back off one-half
turn.

73587

Typical
IMPORTANT: Transmission is “fully” in gear
when shift lever comes to a stop, in either direc-
tion.

Index
8B-4 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
10. Reattach locknut and washer to cable barrel stud.
Tighten until they bottom out. Tighten securely,
but do not overtighten.
NOTE: To change cable approach direction on
single or dual station installations, only the spacers/
bushings have to be switched to the opposite stud
(the studs are identical). e

73587

a
b

73589 c
g
f
d

b
c
e
e b
c
f
b
g
d 71972

a
a - Cable End Guide
b - Spacer (As Required)
c - Elastic Stop Nut and Washer
d - Cable Barrel (Position Only Indicated In Lower Drawing)
c 71210 e - Bushing(s)
f - Cable Barrel Stud
a - Cable End Guide g - Cable End Guide Stud
b - Spacer (As Required) Single Cable - Rear Entry
c - Elastic Stop Nut and Washer
d - Cable Barrel (Position Only Indicated In Lower Drawing)
e - Bushing(s)
f - Cable Barrel Stud
g - Cable End Guide Stud

Single Cable - Forward Entry

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-5
 e

73591
73590

g
a
f

e
b
b
d
CABLE
BARREL c d
STUD c
g

f
CABLE
END GUIDE
STUD 50073
a
e
b 71211
a -
Cable End Guide(s)
b -
Spacer
c -
Elastic Stop Nut and Washer
a - Cable End Guides d -
Bushing(s)
b - Locknut and Washer (Tighten Until Bottomed, Then Back e -
Cable Barrel(s) [Position(s) Only Indicated In Lower
Off Drawing]
One Full Turn) f - Cable Barrel Stud
c - Spacer (Fits over Stud) g - Cable End Guide Stud
d - Bushings
e - Cable Barrels[Position(s) Only Indicated In Lower Drawing] Dual Cable - Rear Entry
f - Cable Barrel Stud
g - Cable End Guide Stud
Dual Cable - Forward Entry

Index
8B-6 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
Checking Transmission Draining Transmission
Fluid Level 1. Clean the exterior of transmission before disas-
sembly.
IMPORTANT: Use only specified transmission
fluid (see “Lubricants/Sealants”). 2. Remove oil filter from housing by turning (coun-
terclockwise) and pulling at the same time.
Check transmission fluid before starting engine each
day, as follows:
1. Remove dipstick. Check fluid level as indicated
on dipstick. Fluid level may be somewhat over full
mark, as some of the fluid from transmission fluid
cooler and hoses may have drained back into
transmission. If low, add transmission fluid to
bring level up to full mark on dipstick.

27666

3. Remove drain plug from transmission and allow

fluid to drain. Reinstall drain plug and tighten se-
curely.

27661

Typical Hurth Transmission Shown

IMPORTANT: To accurately check fluid level, en- a

gine must be run at 1500 RPM for two minutes im-
mediately prior to checking level.
2. Start engine and run at 1500 RPM for two minutes
to fill all hydraulic circuits.
73013
IMPORTANT: Be sure to push dipstick all the way
down into dipstick tube when checking fluid lev- a - Drain Plug
el.
3. Stop engine and quickly check fluid level. Add
automatic transmission fluid, if necessary, to
bring level up to full mark on dipstick. (Refer to
“Filling Transmission,” following.)
4. Reinstall dipstick.
5. If transmission fluid level was extremely low,
carefully check transmission, fluid cooler and
hoses for leaks.
Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-7
Filling Transmission b. Push down until cover is fully seated (top of
cover flush with housing), then, Turn T-handle
IMPORTANT: Use only Automatic Transmission clockwise until tight.
Fluid (ATF) as recommended in “Tool/Lubricants/
Sealants.”
1. Fill transmission to proper level, through oil filter
cavity. (Refer to “Capacity.”)
2. Install filter as follows:
a. Coat O-ring on filter cover with transmission
fluid.

27666
b

3. Start engine and run for two minutes to fill system

with fluid.
4. Stop engine and check fluid level. Fluid should be
between min. and max. lines on dipstick.

27662

a - Filter Cover
b - O-Ring

! CAUTION
Transmission fluid filter and cover must be prop-
erly seated to avoid fluid foaming and/or loss of
fluid, thus resulting in decreased efficiency and/
or damage to transmission.

27661

Typical Hurth Transmission Shown

Index
8B-8 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
Transmission Removal Transmission Installation
1. Disconnect wires from neutral safety switch and 1. Coat splines on input shaft with Quicksilver En-
audio warning temperature switch. gine Coupler Spline Grease.
2. Disconnect fluid cooler hoses. Appropriately la-
bel hose “Port” and “Starboard”.

c c

b
a

71044

50686 a - Input Shaft

a - Pressure Gauge (M10x1 Thread) - Remove Plug
b - Thermometer (3/8 In. Thread) - Remove Temperature
Sender
c - Fluid Cooler Hoses
3. Remove bolts and locknuts and remove transmis-
sion.
2. Install transmission on flywheel housing and se-
cure with hardware shown. Torque fasteners to
50 lb. ft. (68 N•m).
a

b
72720

a - Bolts (2), One On Each Side

72720 b - Locknuts (4), Two On Each Side

a - Bolts (2), One On Each Side

b - Locknuts (4), Two On Each Side

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-9
3. Connect wires to neutral safety switch and to au- 2. Remove cover and filter element from transmis-
dio warning temperature switch. Coat connec- sion.
tions on neutral safety switch with Quicksilver Liq-
uid Neoprene.

c c

27662
50686 3. Remove filter element from cover and inspect
O-rings for wear. Replace if necessary.
a - Neutral Safety Switch
b - Audio Warning Temperature Switch
c - Fluid Cooler Hoses

Transmission Repair
Disassembly
IMPORTANT: Ensure work area is clean before
disassembly is started. Be sure to use lint free a
cloths when cleaning and/or handling parts. 50975
a - O-Rings
TRANSMISSION FLUID COOLER
4. Remove drain plug from transmission and allow
See section 6A, “Sea Water System”. fluid to drain. Reinstall drain plug and tighten se-
curely.
OIL FILTER AND DIPSTICK
1. Remove oil filter from housing by turning (coun-
terclockwise) and pulling at the same time.

73013

a - Drain Plug

27666
Index
8B-10 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
5. Remove dipstick by turning (counterclockwise) BREATHER VALVE
and pulling at the same time.
1. Remove breather valve. Clean with suitable
cleaner, allow to dry and coat with oil.

71048
a - Breather Valve

MOUNTS
27661 1. Remove mounts from transmission housing. In-
spect mounts for damage and replace if neces-
6. Inspect seal for wear and replace if necessary.
sary.

b
27659 72711
a - Seal
a - Transmission Mount
b - Retaining Screws (4 Total on Each Mount - One Hidden In
This View)

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-11
OUTPUT FLANGE 2. Turn four remaining bolts out until they just con-
tact flange puller plate. Then continue to turn bolts
1. Remove four bolts as shown and loosen but DO
out evenly (to push on puller plate) to remove
NOT remove four remaining bolts. Install flange
flange.
puller plate on output flange and secure with bolts
and nuts.

b
c
a

a
b

73014

d
b

73016

73015

a - Bolts - Remove
b - Bolts - Loosen (DO NOT Remove)
c - Flange Puller Plate
d - Bolts and Nuts

73017

a - Hex Wrench
b - Flange
c - Flange Puller Plate

Index
8B-12 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
CONTROL BLOCK ! CAUTION
1. Remove hex head bolts.
Be careful not to allow dirt to enter control block
from front side.
3. Cover openings in control block with a protective
cloth.

27661
a - Hex Socket Head Bolts (6)
27665

2. Remove control block and gasket from housing. a - Openings

HOUSING
1. Remove hex head bolts from input side of hous-
ing.

27666

73018

a - Hex Bolts (16)

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-13
2. Remove input side of housing. Be sure to locate 4. Remove intermediate shaft assembly.
and save locator pins.

73021

5. Remove reversing shaft assembly.

73019

a - Locator Pins

3. Remove input shaft assembly.

73022
73020

Index
8B-14 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
6. Remove output shaft assembly. SEALS
1. Remove suction pipe seal as follows:

73023
27666
a - Seal
BEARING, GEAR AND SEAL INSPECTION
1. Inspect all tapered roller bearings, the piston
rings on the input shaft and all gears for wear. If a. Bend tabs up away from screws.
damage has been found on the gearing of the in-
termediate or output shaft, it is ALWAYS neces-
sary to replace the complete shaft.
When gears on the input shaft have to be re-
placed, the tapered roller bearings and needle
bearings MUST BE replaced as well.
2. Turn gears of input shaft to check correct opera-
tion of the reversing clutch. If it is hard to turn the
gears, the clutch is probably damaged.

73024
a - Tabs

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-15
 b. Remove screws and hold down plate. 2. Remove input shaft seal using appropriate man-
drel.
c. Remove suction pipe by pulling downward out
of seal.

27670
a - Seal
a
3. Remove output shaft seals using appropriate
mandrel.
73025

a - Screws
b - Hold Down Plate

d. Remove seal from top side. a

73026

a
a

27660
a - Seal

73027

a - Seals
Index
8B-16 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
TAPERED ROLLER BEARING CUPS b. Pull bearing cup from housing using tool as
shown.
IMPORTANT: Do not remove tapered roller bear-
ing cups unless replacing tapered roller bear-
ings. Bearing and cup must be replaced as a set.
IMPORTANT: Do not mix up shims under cups on
the input housing side. Shims are required for ad-
justing the bearing preload.
1. Pull tapered roller bearing cups from housing us-
ing special puller as follows:
a. Position appropriate puller guide (large diam-
eter or small diameter) over cup as shown.

a
27681

c. Input Housing Side: Remove and retain

shims. DO NOT MIX UP.

27681

27682

72712

a - Small Diameter Puller Guide

b - Large Diameter Puller Guide

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-17
TAPERED ROLLER BEARINGS
IMPORTANT: Bearings and gear on output shaft
are not replaceable. Replace output shaft, gear
and bearings as a complete assembly only.
REVERSING CLUTCH, GEARS AND TAPERED
ROLLER BEARINGS
1. Remove tapered roller bearing from splined end
of input shaft using special tool as follows:
a. Place tool over tapered roller bearing. Ensure
jaws of tool will be pulling on bottom edge of
rollers and NOT on the cage.

73028

! CAUTION a

Gears should never be removed from intermedi-

ate shaft or output shaft, as this will affect proper b
gear alignment.
1. Remove tapered roller bearings from intermedi-
ate shaft and output shaft by using a universal
puller plate and pressing bearings off.

Intermediate
Shaft

27671
a - Jaws
b - Bottom Edge of Rollers

73029

Reversing
Shaft

73030

Index
8B-18 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
 b. Tighten jaws onto bearing by turning on 2. Remove butting ring from splined end of input
knurled part of tool. Tighten assembly. shaft by installing special tool as shown and lightly
tapping upward on tool.

27673

a - Special Tool
b - Butting Ring
27671
3. Remove butting ring and gear assembly.
c. Pull tapered roller bearing from shaft using
tool as shown.

b a

27675
a - Butting Ring
b - Gear Assembly

27672

a - Hold Tool Stationary

b - Turn Top Nut

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-19
4. Remove needle bearings. 6. Remove tapered roller bearing, butting ring and
gear from piston end of shaft using special tool as
shown. Press all components off at the same
time. Then, remove needle bearings.

27673

27680
CLUTCH DISCS

5. Remove piston rings from shaft.
NOTE: Discs on both sides of clutch are removed in
the same manner.
IMPORTANT: Reference marks are placed on the
clutch housing and end disc to aid in locating the
snap ring opening.

27679

27675
a - Reference Marks

Index
8B-20 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
1. Position snap ring compression tool on clutch as- NOTE: For ease of reassembly, end disc and snap
sembly so that compression screws are centered ring should not be removed from tool unless their con-
over slots in clutch housing. dition is questionable.
2. Remove end disc and snap ring as follows:
a. Tighten all compression screws until a slight a
resistance is felt.
b. Tighten compression screws evenly (approxi-
mately 1/2 turn at a time).
c. Tap up lightly on bottom edge of compression
tool until snap ring pops up and out of groove
in clutch housing.

27676
a
a - End Disc (Snap Ring Compressed)

d. If necessary, remove end disc and snap ring

from tool.
c

27674
a - Snap Ring Compression Tool
b - Compression Screws (6) b
c - Slots a

27676

a - End Disc
b - Snap Ring

27675

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-21
IMPORTANT: Thrust discs have a wave pattern. 3. Remove discs.
These discs must be reinstalled in a specific pat-
tern, when reassembled. Make note of notches in
thrust disc tabs, and how they are arranged.

50248

27680

4. Inspect thrust discs and inner discs for wear. Re-

a place if there is any questionable wear.
c b
5. Remove and inspect discs on opposite side of
clutch in same manner.

27679

a - Thrust Discs (5 per Side)

b - Inner Discs (4 per Side)
c - Notches
630V Clutch Arrangement

Index
8B-22 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
Reassembly 2. Install discs in clutch housing.

CLUTCH DISCS
IMPORTANT: Thrust discs have a wave pattern.
These discs must be reinstalled in a specific man-
ner as explained following.

50248
1. Arrange thrust discs and inner discs as shown.
Ensure notches on thrust disc tabs are aligned as
shown.
27680
3. Align snap ring opening with reference marks on
end disc and clutch housing.

a
c b

27679

a - Thrust Discs (5 per Side)

b - Inner Discs (4 per Side)
c - Notches
b

630V Clutch Arrangement

a
b
27678
a - Snap Ring Opening
b - Reference Marks
Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-23
4. If end disc and snap ring were removed from tool, c. Tighten compression screws evenly to com-
reinstall as follows: pletely compress snap ring into end disc.
a. Loosen all compression screws on tool.

a
27677 b
a - Compression Screws
27677
b. Place snap ring into groove in end disc and
compress by hand so that compression dogs a - End Disc
b - Compression Screws
will hold in on snap ring.

d. Carefully lower end disc and special tool onto

clutch housing and align compression dogs
with slots in housing.

b
c a
b
27677
a - End Disc
b - Snap Ring
c - Compression Dogs

27675

a - Slots
b - Compression Dogs

Index
8B-24 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
5. Tap lightly around top of tool until end disc bot- 6. Double check that snap ring has been properly
toms. Loosen compression screws and remove seated by prying up lightly on end disc.
tool.

27679

7. Reinstall discs on opposite side of clutch in same

manner.

NEEDLE BEARINGS
27678
1. Reinstall needle bearings.

27675

27680

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-25
GEAR ASSEMBLY
1. Reinstall gear assembly. Twist gear assembly
from side to side to allow splines to engage with
inner discs. Ensure all inner discs are engaged
with splines by observing through slots in clutch
housing.
27673
2. Reinstall butting ring.
27672
Index
8B-26 - HURTH V-DRIVE TRANSMISSION
TAPERED ROLLER BEARING
! WARNING
Do not touch bearing once it has been heated. Severe
burns could result. Use special protective gloves to
handle bearing.
1. Heat inner race of tapered roller bearing using a
torch lamp and press bearing onto shaft. When
bearing has cooled down (DO NOT cool with wa-
ter), tap bearing carefully down to ensure proper
seating against butting ring, using a soft (copper)
punch. Tap on inner race only.
27674
a - Tapered Roller Bearing
b - Butting Ring
2. Install components on opposite side of clutch as-
sembly in same manner.
90-806934 1194
 ! CAUTION
Use care in reinstalling piston rings on input
shaft. Piston rings are brittle and may snap if
spread too far open.
3. Reinstall piston rings on input shaft. Ensure ends
of rings are coupled as shown. Then position
rings so that ends are staggered so no two are
aligned.
2. Install tapered roller bearing on opposite end of
shaft in the same manner.
REVERSING SHAFT
! WARNING
Do not touch bearing once it has been heated. Severe
burns could result. Use special protective gloves to
handle bearing.
1. Heat inner race of tapered roller bearing using a
torch lamp and press bearing onto shaft. When
bearing has cooled (DO NOT cool with water),
drive bearing down against gear using a soft (cop-
per) punch. Tap on inner race only.

73030

2. Install tapered roller bearing on opposite end of

shaft in the same manner.
NOTE: Bearing on splined end of shaft is tapped until
27679
seated against shoulder on shaft.

INTERMEDIATE SHAFT
! WARNING
Do not touch bearing once it has been heated. Severe
burns could result. Use special protective gloves to
handle bearing.
1. Heat inner race of tapered roller bearing using a
torch lamp and press bearing onto shaft. When
bearing has cooled down (DO NOT cool with wa-
ter), tap bearing carefully down to ensure proper
seating against gear, using a soft (copper) punch.
Tap on inner race only.

73029
Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-27
PREASSEMBLY OF OUTPUT HALF OF ! WARNING
HOUSING
Use care in handling housing, once it is heated with
IMPORTANT: If tapered roller bearing cups were torch lamp. Severe burns could result. Use special
removed, ensure output shaft seal IS NOT in protective gloves when handling housing.
place, as it will be necessary to heat housing prior
to installing bearing cups. 2. Heat bearing bores of housing using a torch lamp
IMPORTANT: The tapered roller bearing cup on and install bearing cups using a suitable mandrel.
the input shaft (control block end) is properly po-
sitioned by bottoming out on the face of the con-
trol block assembly. It will be necessary to tempo-
rarily install control block to install this tapered
roller bearing cup. b
1. Temporarily install control block on outer housing.
a
Tighten bolts securely.

27681
a - Bearing Cups
b - Torch Lamp

3. Allow housing to cool (DO NOT cool with water)

and then tap bearing cup with suitable mandrel to
ensure it is properly seated.
4. Remove control block assembly.

27682

27666
a - Input Shaft Bearing Cup
b - Control Block Face

Index
8B-28 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
Output Shaft Seal Suction Pipe
1. Reinstall suction pipe seal in bottom of oil filter
1. If bearing were not replaced and no shimming bore. Coat seal with ATF.
is required, push new seal onto special mandrel.
Ensure seal will be positioned with lip of seal fac-
ing inward. Drive seal uniformly into bore of hous-
ing to the point that it is countersunk .040 in. (1
mm) with reference to housing surface.

27660
73027
a - Seal
a - Seal
2. Reinstall suction pipe. Place one drop of Loctite
8831 or Type A on screw threads. Then secure
suction pipe down with retainer plate. Tighten
screws securely.
3. Bend tabs down over screws.

Index 73025

90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-29

Shafts 4. Install intermediate shaft.
1. Coat tapered roller bearings with ATF.
2. Install output shaft.

73021

5. Install input shaft. Ensure all gears mesh as

shown.

73023

3. Install reversing shaft.

73020

73022

73031

Index
8B-30 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
PREASSEMBLY OF INPUT HALF OF HOUSING ! WARNING
Use care in handling housing once it has been heated
with a torch lamp. Severe burns could result. Use spe-
1. Install breather valve (do not over-tighten). cial protective gloves when handling housing.

2. Heat each tapered roller bearing cup bore with a

torch lamp. Insert shims (less those removed)
and bearing cups into appropriate bearing bores.
When housing has cooled (DO NOT cool with wa-
ter), tap bearing cups with a suitable mandrel to
ensure that cups are fully seated.
a
a

71048

a - Breather Valve

27681
a - Torch Lamp
BEARING PRELOAD ADJUSTMENT

IMPORTANT: If new tapered roller bearings have a

been installed, the preload must be readjusted. If
bearings were not replaced, proceed to the “Final
Assembly.”

NOTE: The required preload of bearings of the indi-

vidual shafts is obtained by using shims beneath the
tapered roller bearing cups in the input half of the
housing.

NOTE: Shims which have been removed during dis-

assembly may be reused.

1. Subtract approximately .008 in. (.2 mm) of shims

from each bearing cup bore. Remove and set 73032
aside, but do not mix up.
a - Bearing Cups

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-31
3. Install input half of housing onto output half. En- b. Mount dial indicator on input shaft. Turn input
sure locator pins are in place. Install bolts and shaft several times to seat bearing.
lockwashers and torque to 36 lb. ft. (49 N·m).

73033
a - Bolts and Lockwashers
27685

Input Shaft Preload c. Zero the dial indicator.

1. Measure bearing clearance as follows:

a. Install special tool as shown. Tighten hold
down bolts securely.

27863
27685
a - Special Tool
b - Hold Down Bolts

Index
8B-32 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
IMPORTANT: The following step should be done e. Make note of reading. The bearing clearance
very carefully to obtain the actual bearing clear- measured PLUS the preload required is equal
ance. Avoid bumping the input shaft and turn to the amount of shim thickness to be ADD-
very slowly on the special tool knob. (Shaft will ED.
only be moving a very small amount.)
d. Slowly turn the special tool knob clockwise to
push the shaft upward. (Perform the above
sequence several times to ensure on accu-
rate reading.)

27685

Example:
Bearing Clearances Measured .009 in.
+ Bearing Preload Required .004 in.

= Shims to Be Added .013 in.

27682

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-33
Intermediate Shaft Preload
1. Measure bearing clearance as follows:
a. Remove hex plug from housing.
73034
b. Screw special bolt with nut into intermediate
shaft and tighten snugly. Turn nut up until it
touches bolt head.
c. Mount dial indicator on bolt head. Turn output
shaft several times to ensure bearing is
seated.
73035
a - Special Bolt with Nut
Index
8B-34 - HURTH V-DRIVE TRANSMISSION
d. Zero dial indicator.
27685
IMPORTANT: The following step should be done
very carefully, to obtain the actual bearing clear-
ance. Turn nut very slowly as shaft will only be
moving a small amount.
e. Hold bolt with one wrench and slowly turn
down nut to pull shaft upward. (Perform the
above sequence several times to ensure ac-
curate reading.)
a
73036
a - Bolt - Hold Stationary
b - Nut - Turn to Move Shaft
90-806934 1194
 f. Make note of the reading. The bearing clear- OUTPUT SHAFT PRELOAD
ance measured PLUS the preload required is
1. Measure the bearing clearance as follows:
equal to the amount of shim thickness to be
ADDED. a. Install flange with bolts and washers. Tighten
snugly.
b. Mount dial indicator on flange. Turn output
shaft several times to ensure bearing is
seated.

73038
27686
a - Flange
Example:
c. Zero dial indicator.
Bearing Clearance Measured .007 in.
+ Bearing Preload Required .004 in.

= Shims to Be Added .011 in.

g. Remove dial indicator, special bolt and nut,

and reinstall hex plug. Tighten securely.

REVERSING SHAFT PRELOAD

The reversing shaft preload is adjusted exactly the
same as the intermediate shaft. Refer to that proce-
dure for adjusting reversing shaft.

a
b

27685

73037

a - Reversing Shaft Location

b - Intermediate Shaft Location
Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-35
IMPORTANT: The following step should be done
very carefully to obtain the actual bearing clear-
ance. Pry up gently and evenly to lift shaft. Shaft
will only move a small amount.
d. Pry up on flange to lift output shaft.
2. When thickness of shims to be ADDED has been
determined, the input half of housing must again
be removed. Remove bolts and lockwashers,
then lift off input half of housing.

73039 73018

a - Hex Bolts (16)

e. Make note of the reading. The bearing clear-

ance measured PLUS the preload required is 3. Remove tapered roller bearing cups from housing
equal to the amount of shim thickness to be using special puller as follows:
ADDED. a. Position appropriate puller guide (large or
small diameter) over cup as shown.

27681
a - Small Diameter Puller Guide
27686

Example:
Bearing Clearance Measured .010 in.
+ Bearing Preload Required .004 in.

= Shims to Be Added .014 in.

Index
8B-36 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
 b. Pull bearing cup from housing as shown. ! WARNING
Use care in handling housing once it has been heated.
Severe burns could result. Use special protective
gloves to handle housing.
5. Heat each tapered roller bearing cup bore with a
torch lamp. Install bearing cups into appropriate
bore and tap into place using a suitable mandrel.
When housing has cooled (DO NOT cool with wa-
ter), tap bearing cups to ensure they are fully
seated.
a

27681

4. Add the necessary amount of shims as deter-

mined previously to the appropriate bearing
bores.

27681

27682

73032
a - Torch Lamp
b - Bearing Cups

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-37
Final Assembly
INPUT SHAFT SEAL
1. Push new seal onto special mandrel. Ensure seal
will be positioned with lip of seal facing inward.
Drive seal uniformly into bore of housing to the
point that it is countersunk .040 in. (1 mm) with ref-
erence to housing surface.
2. Coat lips of seals on input and output shafts with
ATF.
3. Apply a thin layer of Loctite 515 Sealer to ma-
chined surfaces on housing halves. Reinstall in-
put half of housing. Ensure locator pins are prop-
erly positioned.
b
a

73019

a - Locator Pins
b - Machined Surface

4. Install bolts and lockwashers and torque to 36 lb.

ft. (49 N·m).

27670

IMPORTANT: Transmissions with 2.0 or 2.5 Gear

Ratios - The input shaft seal should not be in-
stalled until after the input shaft is installed and
housing halves have been joined. (The input
shaft must be tilted in order to install the other
shafts and this could damage the seal.)
a
73033

73040

a - Input Shaft
b - Seal
Index
8B-38 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
5. Double check to ensure that there is no shaft 4. Coat each hex socket head bolt with a drop of
clearance on all three shafts. Refer back to pre- Quicksilver Loctite 8831 or Type A. Secure con-
vious steps if necessary, and use dial indicator. trol block to housing with bolts and lockwashers.
Torque to 18 lb. ft. (25 N·m).
6. Remove intermediate shaft hex plug. Apply a
drop of Quicksilver Loctite 8831 or Type A to
threads and reinstall in housing. Tighten securely.

73041
27661

a - Hex Socket Head Bolts (6)

CONTROL BLOCK
1. Ensure piston rings are in place and the key is in FLUID FILTER
keyway. Align key on shaft with keyway in control
block. 1. Coat new O-rings with ATF.
2. Install new gasket between control block and
housing.

b
a

50975

a - O-Rings
a

27666

a - Key
b - Piston Rings

3. Carefully push control block onto input shaft.

Index
90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-39
2. Reassemble filter assembly as shown. DO NOT OUTPUT FLANGE
tighten and compress upper O-ring.
1. Install locator pins into output shaft.

72805
73017
a - O-Ring
a - Locator Pins (4)

DIPSTICK 2. Install flange on output shaft. Apply Loctite 8831

or Type A to threads of bolts and torque to 14 lb.
1. Coat sealing ring on dipstick with ATF. ft. (18 N·m).
2. Install dipstick into transmission and tighten by a
pressing down and turning clockwise at the same
time.

73013

a - Flange
b - Bolts (8)
73042

TRANSMISSION FLUID COOLER

See section 6A, “Sea Water System”.

Index
8B-40 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
FILLING WITH TRANSMISSION FLUID
IMPORTANT: Use only ATF (Automatic Transmis-
sion Fluid), such as Dexron II-D.
1. Fill transmission to proper level, through fluid filter
cavity. (Refer to “Capacity.”)
2. Install filter as follows:
a. Bring flat spot on filter into agreement with flat
surface inside of housing.
b. Tighten filter by pushing down and turning
clockwise at the same time.

27666
a

b 3. Check fluid level. Fluid should be between min.

and max. marks on dipstick.

27662

a - Filter Cover
b - O-Ring

27661

27666

a - Flat
IndexSpot

90-806934 1194 HURTH V-DRIVE TRANSMISSION - 8B-41

Functional Test
1. Connect a pressure gauge and thermometer to fluid pump at locations shown.

b
a

50686

a - Pressure Gauge (M10x1 Thread) - Remove Plug

b - Thermometer (3/8 In. Thread) - Remove Temperature
Sender

2. Perform functional tests as shown in chart following. Refer to “Specifications” for correct readings.

Tests to Be Carried Out:

1. Leakages
2. Noise emission
3. Direction of rotation, LH/RH
4. Fluid temperature
5. Shifting pressure

Engine Speed RPM Shift Lever Position Duration Minutes Tests

800-1000 Neutral 5 1 2
600-800 (Idle) A-B Position Repeatedly 1 2 3
1500-2500 B Position * 1 2 4
600-800 (Idle) A-B Position Repeatedly 1 2 3
Idling Max Speed A Position 1 2 5**
600-800 From A-B Position 1 2
Idling Max Speed B Position 1 2 5**

* Until fluid temperature of 167-176° F(75-80° C) has been reached

**At different speeds

Index
8B-42 - HURTH V-DRIVE TRANSMISSION 90-806934 1194
DRIVE SYSTEMS

8
C

PROPELLER SHAFT MODELS

Index
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 8C-1
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . 8C-1
Propeller Shaft (MIE Model) . . . . . . . . . . . . . . . 8C-1
Checks Made with Boat In Water . . . . . . . . 8C-1
Checks Made with Boat Out of Water
and Shaft Installed . . . . . . . . . . . . . . . . . . . . 8C-2
Checks Made with Propeller Shaft
Removed from Boat . . . . . . . . . . . . . . . . . . . . 8C-3
Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-3

Index
8C- –PROPELLER
8C-0 PROPELLERSHAFT
SHAFTMODELS
MODELS 90-806934 1194
Torque Specifications
TORQUE
DESCRIPTION
Lb. Ft. N⋅m
Propeller Shaft Coupling to Coupling Housing 50 68
(MIE Model)
Coupling Set Screws (If so equipped) Securely (See NOTE. )
NOTE: Safety wire set screws if so equipped

Tools/Lubricants/Sealants
DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubricant 92-86154A1
Quicksilver Engine Coupler Spline Grease 92-8166391A4
Quicksilver Loctite 8831 92-823089--1
Loctite 290 Obtain Locally

Propeller Shaft (MIE Model)

NOTICE
The following information can be used as a guide for determining vibration problems on boats pow-
ered by inboard engines (MIE Engines). For installation, alignment and repairs to shafts,struts,shaft
logs and rudders, refer to boat manufacturer’s service manual. If boat is equipped with V-Drive or a
remote mounted V-Drive refer to boat manufacturer’s service manual. For MIE engine installation and
alignment, refer to SECTION 2, of this handbook.

Checks Made with Boat In Water

1. Disconnect propeller shaft coupling from trans-
mission coupling.
2. Check fit of coupling to propeller shaft following
instructions “a” or “b”:
a. Straight Bore Type:
(1) Loosen set screws.
(2) Try to move coupling by hand. The bore of
the coupling should be a semi press fit to
shaft.
(3) Check shaft for wear. If worn replacement
of shaft may be necessary. If shaft is not
worn try another coupling.
b. Tapered Bore Type
(1) Check nut on shaft for tightness.
(2) If nut was loose, remove coupling and
check for damage to taper on shaft or in
coupling.
(3) Replace worn parts.
(4) Always make sure key is not sticking out
of coupling.
(5) Install coupling on shaft without the key.
(6) Mark the shaft (behind the coupling);
then, remove the coupling.
(7) Now install the key and coupling. Make
sure coupling still lines up with the mark.
This ensures that the key is not oversize
and holding the tapers apart.

Index
90-806934 1194 PROPELLER SHAFT MODELS – 8C-1
3. Check output coupling flange of transmission. 7. Tighten set screws securely. Safety wire set-
screws, if so equipped.

Checks Made with Boat Out of Water

and Shaft Installed
Possible causes for vibration may be propeller shaft,
propeller to shaft fit or propeller. All three can be
checked by using the rudder, a strong metal straight
edge and a C-clamp.
1. Check installation of propeller to shaft.
a. Remove propeller.
b. Check for chipped or cracked keyway in pro-
peller on shaft without key.
c. Install propeller on shaft without key.
d. Mark the shaft (behind the propeller), then re-
move propeller.
e. Install the key and propeller. Make sure pro-
Checking Coupling Outside Diameter - Rotate peller still lines up with mark. This ensures
One Complete Turn that key is not oversize and holding the tapers
apart. Retighten propeller nut.
f. Be sure key is not sticking out of propeller.
2. Check for propeller shaft being bent behind the
strut.

b
Checking Coupling Face - Rotate One Complete
Turn a
a - Metal Straight Edge (Held to Rudder with C-Clamp) -
Typical Drive System Shown Position Corner of Straight Edge at Center of Shaft. Rotate
Shaft One Complete Turn. If Shaft “Wobbles,” Replace
Shaft.
4. If there is movement in Step 3, replace output b - Rudder
coupling.
5. Replace damaged parts and realign engine as
outlined.
6. Torque propeller shaft coupling and transmission
coupling (output flange) to 50 lb. ft. (68 N·m).
Index
8C-2 - PROPELLER SHAFT MODELS 90-806934 1194
3. Check the diameter of all propeller blades. If not Checks Made with Propeller Shaft
the same, repair propeller.
Removed from Boat
1. Check propeller shaft for straightness. Check at
three or four places. If dial indicator deflects over
.004 in. (0.1 mm), replace shaft.
a
b
c

c a
a - V-Blocks
a - Metal Straight Edge (Held to Rudder with C-Clamp) b - Dial Indicator
b - Rudder c - Shaft - Rotate One Complete Turn
c - Rotate Propeller One Complete Turn
2. Check that bore of coupling is 90 degrees from
4. Check that all propeller blades are the same pitch coupling flange. Replace coupling if needle
and that propeller is properly seated on shaft. Re- moves.
pair or replace if necessary.

a
a
b

b c

a - Metal Straight Edge (Held to Rudder with C-Clamp)

b - Rudder a - V-Blocks
c - Rotate Propeller One Complete Turn. Check at Three b - Dial Indicator
Different Points on Blades c - Coupling Flange - Rotate One Complete Turn
d - Shaft Against Block to Prevent Fore and Aft Movement

Strut
Refer to boat manufacturer’s service manual for
alignment and replacement. Normally, the shaft
should be centered in the cutlass bearing. Shims
(placed between the strut and hull) are used to align
the strut to the shaft.

Index
90-806934 1194 PROPELLER SHAFT MODELS – 8C-3
POWER STEERING SYSTEM

9
71034
A
PUMPS AND RELATED COMPONENTS
Note:Refer to the following Service Bulletins regarding this section.

SB 96-8 Brass Power Steering Hose Coupling

SB 95-8 MerCruiser Steering Recommendations

INDEX
Table of Contents
Page
NOTICE
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Lubricants / Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1 For more information on power steering
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1 system and components refer to Service
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Power Steering Pumps . . . . . . . . . . . . . . . . . . . . . 9A-2 Manual Number 11 - Bravo Stern Drive
D3.0L/150 and D3.6L/180 Engines . . . . . . . . 9A-2 Unit, “Steering Systems”.
D4.2L/220 Engines . . . . . . . . . . . . . . . . . . . . . . 9A-3
Related Components . . . . . . . . . . . . . . . . . . . . . . . 9A-4
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-4
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9A-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-6
Maintaining Power Steering Pump Fluid Level . . . . 9A-8
Filling and Bleeding Power Steering System . . . . . . 9A-8

9A –- PUMPS AND RELATED COMPONENTS

9A-0 90-806934 1194
INDEX
Torque Specifications Description
TORQUE
DESCRIPTION The power steering system utilizes an engine-driven
Lb. Ft. N⋅m hydraulic pump that supplies fluid flow and pressure
Front bracket by means of hoses to a control valve that, in turn, con-
24 32 trols fluid flow and pressure to-and-from a booster
Rear Brace
cylinder. A reservoir mounted on the side of the en-
Mounting Nut and gine supplies fluid to the pump
15 21
Screw
All Fasteners Not IMPORTANT: Power Steering Pump is a non-re-
Tighten Securely
Listed pairable unit and is intended to be removed and
replaced by a new unit.

Lubricants / Sealants
DESCRIPTION PART NUMBER
Quicksilver Power Trim and
92-90100
Steering Fluid
Automatic Transmission Fluid -
Obtain Locally
Dexron, Dexron II, Dexron II -D

IMPORTANT: Power Steering Pumps are consid-

ered non-repairable units and are intended to be
removed and replaced by new units.

90-806934 1194 PUMPS AND RELATED COMPONENTS - 9A-1

INDEX
Exploded Views

Power Steering Pumps

D3.0L/150 AND D3.6L/180 ENGINES

b 14

10 15 b
7 1

6
14
13
a
12

4 5 15 b

3 16
a 11
17
16
14

71034
1 - Pump Torque Specifications
2 - Pulley
3 - Tensioning Bolt a 24 lb. ft. (32 N·m)
4 - Pinion For Tensioning Nut
5 - Tensioning Nut b 15 lb. ft. (21 N·m)
6 - O-Ring
7 - Adaptor
8 - Fluid Pressure Hose
9 - Fluid Reservoir Hose
10- Hose Clamp
11- Front Bracket
12- Rear Brace
13- Bracket
14- Mounting Bolt
15- Mounting Nut
16- Spacer
17- Tightening Brace

9A-2 - PUMPS AND RELATED COMPONENTS 90-806934 1194

INDEX
Power Steering Pumps (continued)

D4.2L/220 ENGINES

9
8 6

a 4 5
4 a

a 3

71035
1 - Pump Torque Specifications
2 - Pulley
3 - Tensioning Screw a 15 lb. ft. (21 N·m)
4 - Mounting Screw
5 - Bushing
6 - Fluid Pressure Hose
7 - Fluid Reservoir Hose
8 - Hose Clamp
9 - Bracket

90-806934 1194 PUMPS AND RELATED COMPONENTS - 9A-3

INDEX
Related Components
ALL ENGINES

a
8 7
3
A
1
2
4
2
6

71034

1 - Fluid Reservoir Tank Lubricant/Sealant Application Points

2 - Hose Clamp (2)
3 - Clamping Screw A Quicksilver Power Trim and Steering . .
4 - Support
5 - Supply Hose Fluid - 92-90100, or Automatic Transmis
6 - Pressure Hose sion Fluid - Dexron, Dexron II, Dexron II -D
7 - Return Hose (From Transom) - Obtain Locally
8 - Return Hose (From Cooler)
9 - Power Steering Fluid Cooler
Torque Specifications
a 20 - 25 lb. ft. (27 - 34 N·m)

9A-4 - PUMPS AND RELATED COMPONENTS 90-806934 1194

INDEX
Power Steering Pump 3. Lower pump down to gain access to hose con-
nections. Remove hoses and adaptor as shown.
Using clean, suitable plugs, quickly plug hoses to
Removal limit loss of fluid.
NOTE: If possible lift pump above power steering res-
! CAUTION ervoir and then remove hoses to minimize fluid loss.
Disconnect Battery cables at battery to prevent
a
engine rotation and injury while working on
pump.
b

1. Remove vacuum pump belt (see SECTION 1B

“Maintenance.”)
2. Remove and retain bolts or screws, lockwashers,
hardware and nuts as shown.

26441
a - Hoses
b - Adaptor
D3.0L/150, D3.6L/180
4. Drain power steering fluid from pump into a suit-
able container. DO NOT reuse fluid.
5. Following instructions “a” or “b”.
a. On D4.2L/220 Pumps: Proceed to Step 5.
b b. On D3.0L/150, D3.6L/180 Pumps:
26441 (1) Remove and retain front bracket and
a - Mounting Bolt and Nut
screws.
b - Tensioning Bolt with Pinion and Nut (2) Remove and retain rear brace and
D3.0L/150, D3.6L/180 screws.

a b

a
b

c
70113 a
74482
a - Mounting Screws (2-One Hidden In This View with a Bush-
ing)
b - Tension Screw a - Front Bracket
D4.2L/220 b - Rear Brace
c - Screws (5 Total - 2 Hidden in This View)

90-806934 1194 PUMPS AND RELATED COMPONENTS - 9A-5

INDEX
6. Using a suitable puller remove pulley from pump (2) Install front bracket and rear brace as
shaft. Retain pulley for installation on new pump. shown. Torque screws to 24 lb. ft. (32
N·m).

71035
D4.2L/220 (All Similar)
7. Drain fluid from power steering reservoir into a
suitable container. DO NOT reuse fluid. Dispose
of fluid properly. 74483

a - O-Ring
Installation b - Adaptor
c - Front Bracket
1. Using a suitable screw, pull (install) pulley onto d - Rear Brace
shaft until pulley face is flush as shown with shaft e - Screws (5 Total - 3 Front, 2 Rear)
end (screw head will bottom out). 3. Install reservoir hose and pressure hose to pump
as shown. Do not tighten presently.

a
c
d

74481

2. Follow instructions “a” or “b”:

a. D4.2L/220 Pumps: Proceed to Step 3.
26441
b. D3.0L/150, D3.6L/180 Pumps:
a - Reservoir Hose
(1) Install new O-ring onto adaptor and install b - Hose Clamp
adaptor into new pump. Tighten securely. c - Pressure Hose
d - Fitting
D3.0L/150, D3.6L/180 (D4.2L/220 similar)

9A-6 - PUMPS AND RELATED COMPONENTS 90-806934 1194

INDEX
4. Place hoses appropriately between oil filter and
pump mounting bracket, lift pump into place and
attach with fasteners and hardware retained pre-
viously, as shown.
b
6. Position drive belt in pulley groove and tension
belt following instructions “a” or “b”:
a. On D3.0L/150, D3.6L 180 Pumps: Turn ten-
sioning bolt with pinion to adjust belt. Torque
mounting nut and tensioning nut 15 lb. ft. (21
N·m).
b. On D4.2L/220 Pumps: Move or pry power
steering pump to tension belt. Torque mount-
ing screws and tensioning screw to 15 lb. ft.
(21 N·m).

NOTE: On All Models: Check belt tension by de-

a pressing upper strand of belt at center point between
pulleys. Belt must not deflect more than 3/16 in.
(5mm).
d

26441

a - Mounting Nut a
b - Mounting Bolt
c - Tensioning Nut
d - Tensioning Bolt with Pinion
D3.0L/150, D3.6L/180

c
23724

a
a - Belt Center Point Between Pulleys, - Deflection of 3/16 in.
(5mm) or Less

NOTE: On D4.2L/220 models, power steering drive

a pulley is behind crankshaft front pulley.

7. If not already accomplished, drain fluid from pow-

b 70113
a - Mounting Screws with Washers (2-One Hidden, Shown in
Inset with Bushing)
b - Tensioning Screw with Washer
c - Bushing
(D4.2L/220 similar)
5. Tighten reservoir hose clamp securely. Tighten
pressure hose fitting securely. DO NOT overtigh-
ten.
er steering reservoir into a suitable container. Do
not reuse old fluid. Dispose of properly.
8. Fill power steering reservoir with new fluid. Refer
to “Power Steering Fluid” Chart at front of section.
9. Connect battery cables at battery by FIRST
installing Positive (+) battery cable to Positive (+)
battery terminal and tighten clamp. THEN, install
NEgative (–) battery cable to NEgative (–) battery
terminal and tighten clamp.
10. Bleed air from power steering system following
instruction in “Filling and Air Bleeding Power
Steering System.”

90-806934 1194 PUMPS AND RELATED COMPONENTS - 9A-7

INDEX
Maintaining Power Steering
Pump Fluid Level
IMPORTANT: Use only Quicksilver Power Trim
and Steering Fluid, or Dexron II automatic trans-
mission fluid (ATF), in power steering system.
! CAUTION
DO NOT RUN POWER STEERING DRY, or pump
will be damaged.
Position drive unit so that it is straight back.
Remove fill cap from power steering pump reservoir,
and check fluid level. Fill to “MAX” line - DO NOT over
fill.
Min.
Max.
23162
Filling and Bleeding Power
Steering System
IMPORTANT: Poser Steering Systems MUST BE
filled exactly as explained, in the following, to be
sure that all air is bled from the system. All air
must be removed, or fluid in the pump may foam
during operation and be discharged from pump
reservoir. Foamy fluid also may cause POWER
Steering Systems to become spongy, which may
result in poor boat control.
1. Position drive unit straight back. Remove cap
from power steering reservoir and check fluid lev-
el with the attached dipstick.
Min.
Max.
23162
2. Add Quicksilver Power Trim and Steering Fluid or
Dexron ATF to bring fluid up to the correct level.
9A-8 - PUMPS AND RELATED COMPONENTS
INDEX
3. With the engine NOT running, turn the steering
wheel at a moderate rate, back-and-forth, to end
of travel for a few seconds to allow any air to
bubble from pump reservoir. Do this a minimum
of 5 complete cycles. Recheck fluid level and add
if necessary.
4. Install reservoir cap.
! CAUTION
DO NOT operate engine without water being sup-
plied to seawater pickup holes in gear housing
(on MCM Stern Drive Models) and to seawater in-
let for seawater pump (ALL Models). Overheating
damage to seawater pump impeller and engine
may occur.
5. Position boat in the water or see that water is sup-
plied to seawater pickup holes in gear housing
(using a suitable flush device( and to seawater in-
let for seawater pump (using suitable adaptor),
connected to hose, or hoses attached to water
tap..
NOTE: If using test tank or boat is in the water, ensure
that stern drive gear housing water intake holes and
seawater pickup are below water level.
6. Partially open water tap(s) (approximately 1/2
maximum) to hose(s) and allow water to enter
cooling system. DO NOT use full tap water pres-
sure.
7. Start engine and run AT IDLE. During this time,
turn steering wheel back-and-forth to end of travel
in each direction several times.
8. Position drive unit so that it is straight back and
then stop the engine. Remove the reservoir cap.
Allow any foam in the reservoir to disperse, then
check fluid level and add fluid if needed. DO NOT
OVERFILL. Install and tighten the cap securely.
9. If fluid was foamy in Step 6., repeat Steps 7 and
8, until the fluid does not foam and the level re-
mains constant.
NOTICE
For more information on power steering system
and components refer to appropriate
MerCruiser Stern Drive Service Manual.
90-806934 1194
POWER STEERING SYSTEM

9
71034
A
PUMPS AND RELATED COMPONENTS
Table of Contents
Page
NOTICE
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 10A-1
Lubricants / Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 10A-1 For more information on power steering
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-1 system and components refer to Service
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-2
Power Steering Pumps . . . . . . . . . . . . . . . . . . . . . 10A-2 Manual Number 11 - Bravo Stern Drive
D3.0L/150 and D3.6L/180 Engines . . . . . . . 10A-2 Unit, “Steering Systems”.
D4.2L/220 Engines . . . . . . . . . . . . . . . . . . . . . 10A-3
Related Components . . . . . . . . . . . . . . . . . . . . . . 10A-4
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-4
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10A-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A-6
Maintaining Power Steering Pump Fluid Level . . . 10A-8
Filling and Bleeding Power Steering System . . . . . 10A-8

10A -- PUMPS
10A-0 PUMPS AND
AND RELATED
RELATED COMPONENTS
COMPONENTS 90-806934 1194
Torque Specifications Description
TORQUE The power steering system utilizes an engine-driven
DESCRIPTION hydraulic pump that supplies fluid flow and pressure
Lb. Ft. N⋅m by means of hoses to a control valve that, in turn, con-
Front bracket trols fluid flow and pressure to-and-from a booster
24 32 cylinder. A reservoir mounted on the side of the en-
Rear Brace
gine supplies fluid to the pump
Mounting Nut and
15 21 IMPORTANT: Power Steering Pump is a non-re-
Screw
pairable unit and is intended to be removed and
All Fasteners Not
Tighten Securely replaced by a new unit.
Listed

Lubricants / Sealants
DESCRIPTION PART NUMBER
Quicksilver Power 92-90100
Trim and Steering
Fluid
Automatic Trans- Obtain Locally
mission Fluid - Dex-
ron, Dexron II, Dex-
ron II -D

IMPORTANT: Power Steering Pumps are consid-

ered non-repairable units and are intended to be
removed and replaced by new units.

90-806934 1194 PUMPS AND RELATED COMPONENTS - 10A-1

Exploded Views

Power Steering Pumps

D3.0L/150 AND D3.6L/180 ENGINES

b 14

10 15 b
7 1

6
14
13
a
12

4 5 15 b

3 16
a 11
17
16
14

71034
1 - Pump Torque Specifications
2 - Pulley
3 - Tensioning Bolt a 24 lb. ft. (32 N·m)
4 - Pinion For Tensioning Nut
5 - Tensioning Nut b 15 lb. ft. (21 N·m)
6 - O-Ring
7 - Adaptor
8 - Fluid Pressure Hose
9 - Fluid Reservoir Hose
10- Hose Clamp
11- Front Bracket
12- Rear Brace
13- Bracket
14- Mounting Bolt
15- Mounting Nut
16- Spacer
17- Tightening Brace

10A-2 - PUMPS AND RELATED COMPONENTS 90-806934 1194

Power Steering Pumps (continued)

D4.2L/220 ENGINES

9
8 6

a 4 5
4 a

a 3

71035
1 - Pump Torque Specifications
2 - Pulley
3 - Tensioning Screw a 15 lb. ft. (21 N·m)
4 - Mounting Screw
5 - Bushing
6 - Fluid Pressure Hose
7 - Fluid Reservoir Hose
8 - Hose Clamp
9 - Bracket

90-806934 1194 PUMPS AND RELATED COMPONENTS - 10A-3

Related Components
ALL ENGINES

a
8 7
3
A
1
2
4
2
6

71034

1 - Fluid Reservoir Tank Lubricant/Sealant Application Points

2 - Hose Clamp (2)
3 - Clamping Screw A Quicksilver Power Trim and Steering
4 - Support
5 - Supply Hose Fluid - 92-90100, or Automatic Transmission Fluid -
6 - Pressure Hose Dexron, Dexron II, Dexron II -D - Obtain Locally
7 - Return Hose (From Transom)
8 - Return Hose (From Cooler) Torque Specifications
9 - Power Steering Fluid Cooler
a 20 - 25 lb. ft. (27 - 34 N·m)

10A-4 - PUMPS AND RELATED COMPONENTS 90-806934 1194

Power Steering Pump D3.0L/150, D3.6L/180

Removal
a
! CAUTION
Disconnect Battery cables at battery to prevent
engine rotation and injury while working on
pump.
1. Remove vacuum pump belt (see Section 1B
“Maintenance.”)
2. Remove and retain bolts or screws, lockwashers, b 70113
hardware and nuts as shown.

a - Mounting Screws (2-One Hidden In This View with a Bush-

ing)
b - Tension Screw
D4.2L/220
3. Lower pump down to gain access to hose con-
nections. Remove hoses and adaptor as shown.
Using clean, suitable plugs, quickly plug hoses to
limit loss of fluid.
NOTE: If possible lift pump above power steering res-
ervoir and then remove hoses to minimize fluid loss.
b
a
26441
a - Mounting Bolt and Nut b
b - Tensioning Bolt with Pinion and Nut

26441
a - Hoses

90-806934 1194 PUMPS AND RELATED COMPONENTS - 10A-5

b - Adaptor Installation
D3.0L/150, D3.6L/180
1. Using a suitable screw, pull (install) pulley onto
4. Drain power steering fluid from pump into a suit- shaft until pulley face is flush as shown with shaft
able container. DO NOT reuse fluid. end (screw head will bottom out).
5. Following instructions “a” or “b”.
a. On D4.2L/220 Pumps: Proceed to Step 5.
b. On D3.0L/150, D3.6L/180 Pumps:
1. Remove and retain front bracket and
screws.
2. Remove and retain rear brace and
screws.

74481

2. Follow instructions “a” or “b”:

a. D4.2L/220 Pumps: Proceed to Step 3.
b. D3.0L/150, D3.6L/180 Pumps:
1. Install new O-ring onto adaptor and install
adaptor into new pump. Tighten securely.
2. Install front bracket and rear brace as
c shown. Torque screws to 24 lb. ft. (32
a N·m).
74482

a - Front Bracket
b - Rear Brace
c - Screws (5 Total - 2 Hidden in This View)
6. Using a suitable puller remove pulley from pump
shaft. Retain pulley for installation on new pump.

74483

a - O-Ring
b - Adaptor
71035 c - Front Bracket
D4.2L/220 (All Similar) d - Rear Brace
e - Screws (5 Total - 3 Front, 2 Rear)
7. Drain fluid from power steering reservoir into a
suitable container. DO NOT reuse fluid. Dispose
of fluid properly.

10A-6 - PUMPS AND RELATED COMPONENTS 90-806934 1194

3. Install reservoir hose and pressure hose to pump
as shown. Do not tighten presently.

a
c
d

26441 b
a - Reservoir Hose 70113
b - Hose Clamp
c - Pressure Hose
d - Fitting
D3.0L/150, D3.6L/180 (D4.2L/220 similar)
a - Mounting Screws with Washers (2-One Hidden, Shown in
Inset with Bushing)
4. Place hoses appropriately between oil filter and b - Tensioning Screw with Washer
c - Bushing
pump mounting bracket, lift pump into place and
attach with fasteners and hardware retained pre- (D4.2L/220 similar)
viously, as shown.
5. Tighten reservoir hose clamp securely. Tighten
pressure hose fitting securely (DO NOT overtigh-
b ten).
6. Position drive belt in pulley groove and tension
belt following instructions “a” or “b”:
a. On D3.0L/150, D3.6L 180 Pumps: Turn ten-
sioning bolt with pinion to adjust belt. Torque
mounting nut and tensioning nut 15 lb. ft. (21
N·m).
a
b. On D4.2L/220 Pumps: Move or pry power
steering pump to tension belt. Torque mount-
ing screws and tensioning screw to 15 lb. ft.
d (21 N·m).

26441

a - Mounting Nut
b - Mounting Bolt
c - Tensioning Nut
d - Tensioning Bolt with Pinion
D3.0L/150, D3.6L/180

90-806934 1194 PUMPS AND RELATED COMPONENTS - 10A-7

NOTE: On All Models: Check belt tension by de-
pressing upper strand of belt at center point between
pulleys. Belt must not deflect more than 3/16 in.
(5mm).
a
23724
a - Belt Center Point Between Pulleys, [Deflection of 3/16 in.
(5mm) or Less]
NOTE: On D4.2L/220 models, power steering drive
pulley is behind crankshaft front pulley.
7. If not already accomplished, drain fluid from pow-
er steering reservoir into a suitable container. Do
not reuse old fluid. Dispose of properly.
8. Fill power steering reservoir with new fluid. Refer
to “Power Steering Fluid” Chart at front of section.
9. Connect battery cables at battery by FIRST
installing Positive (+) battery cable to Positive (+)
battery terminal and tighten clamp. THEN, install
NEgative (–) battery cable to NEgative (–) battery
terminal and tighten clamp.
10. Bleed air from power steering system following
instruction in “Filling and Air Bleeding Power
Steering System.”
10A-8 - PUMPS AND RELATED COMPONENTS
Maintaining Power Steering
Pump Fluid Level
IMPORTANT: Use only Quicksilver Power Trim
and Steering Fluid, or Dexron II automatic trans-
mission fluid (ATF), in power steering system.
! CAUTION
DO NOT RUN POWER STEERING DRY, or pump
will be damaged.
Position drive unit so that it is straight back.
Remove fill cap from power steering pump reservoir,
and check fluid level. Fill to “MAX” line - DO NOT over
fill.
Min.
Max.
23162
Filling and Bleeding Power
Steering System
IMPORTANT: Poser Steering Systems MUST BE
filled exactly as explained, in the following, to be
sure that all air is bled from the system. All air
must be removed, or fluid in the pump may foam
during operation and be discharged from pump
reservoir. Foamy fluid also may cause POWER
Steering Systems to become spongy, which may
result in poor boat control.
1. Position drive unit straight back. Remove cap
from power steering reservoir and check fluid lev-
el with the attached dipstick.
Min.
Max.
23162
2. Add Quicksilver Power Trim and Steering Fluid or
Dexron ATF to bring fluid up to the correct level.
90-806934 1194
3. With the engine NOT running, turn the steering
wheel at a moderate rate, back-and-forth, to end
of travel for a few seconds to allow any air to
bubble from pump reservoir. Do this a minimum
of 5 complete cycles. Recheck fluid level and add
if necessary.
4. Install reservoir cap.
! CAUTION
DO NOT operate engine without water being sup-
plied to seawater pickup holes in gear housing
(on MCM Stern Drive Models) and to seawater in-
let for seawater pump (ALL Models). Overheating
damage to seawater pump impeller and engine
may occur.
5. Position boat in the water or see that water is sup-
plied to seawater pickup holes in gear housing
(using a suitable flush device( and to seawater in-
let for seawater pump (using suitable adaptor),
connected to hose, or hoses attached to water
tap..
90-806934 1194
NOTE: If using test tank or boat is in the water, ensure
that stern drive gear housing water intake holes and
seawater pickup are below water level.
6. Partially open water tap(s) (approximately 1/2
maximum) to hose(s) and allow water to enter
cooling system. DO NOT use full tap water pres-
sure.
7. Start engine and run AT IDLE. During this time,
turn steering wheel back-and-forth to end of travel
in each direction several times.
8. Position drive unit so that it is straight back and
then stop the engine. Remove the reservoir cap.
Allow any foam in the reservoir to disperse, then
check fluid level and add fluid if needed. DO NOT
OVERFILL. Install and tighten the cap securely.
9. If fluid was foamy in Step 6., repeat Steps 7 and
8, until the fluid does not foam and the level re-
mains constant.
NOTICE
For more information on power steering system
and components refer to appropriate
MerCruiser Stern Drive Service Manual.
PUMPS AND RELATED COMPONENTS - 10A-9