2002 Mercury Mercruiser 4.3L GM V6 (262 CID) OEM Service & Repair Manual

Number 25 Printed in U.S.A. 90-861328--1 1199 1999, Mercury Marine GM V-6 262 CID (4.3L) MARINE ENGINES SERVICE MANUAL

90-861328--1 NOVEMBER 1999 Page i Notice Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention 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 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 personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

Page ii 90-861328--1 NOVEMBER 1999 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Engine Mechanical Components Many of the engine mechanical components are designed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications which are required to provide 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 replacement parts can result in poor engine performance and/or durability, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replacement parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replacement parts. Replacement Parts WARNING Electrical, ignition and fuel system components on MerCruiser Engines and Stern- drives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed.

1 2 3 4 5 6 7 8 9 Important Information Removal and Installation Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives Power Steering System 90-861328--1 NOVEMBER 1999 Page iii Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models Section 3 - Engine A - 262 CID / 4.3L Engines Section 4 - Electrical Systems A - Starting System B - Ignition System C - Charging System D - Instrumentation E - Wiring Diagrams Section 5 - Fuel Systems A - Fuel Delivery System For Carbureted Engines B - Mercarb 2 Barrel Carburetor C - Weber 4 Barrel Carburetor D - SAV1 Emission Fuel System With Weber Carburetor E - Fuel Delivery System For Electronic Fuel Injection F - Fuel Injection Descriptions And System Operation G - Fuel Injection Disassembly And Reassembly H - Fuel Injection System Troubleshooting I - Diagnostics Section 6 - Cooling System A - Seawater Cooled Models B - Closed Cooled Models Section 7 - Exhaust System A - General B - Manifolds, Elbows and Risers C - Collectors Section 8 - Drives A - Drive Shaft Models Section 9 - Power Steering System A - Pump and Related Components

Page iv 90-861328--1 NOVEMBER 1999 Table of Contents IMPORTANT INFORMATION Section 1A - General Information Introduction 1A-2 . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual 1A-2 . . . . . . . . . . . . . Page Numbering 1A-2 . . . . . . . . . . . . . . . . . How to Read a Parts Manual 1A-3 . . . . . . . . . Directional References 1A-4 . . . . . . . . . . . . . . . Engine Rotation 1A-4 . . . . . . . . . . . . . . . . . . . . . Engine Serial Number Location 1A-5 . . . . . . . Propeller Information 1A-5 . . . . . . . . . . . . . . . . Water Testing New Engines 1A-6 . . . . . . . . . . Boat and Engine Performance 1A-6 . . . . . . . . Boat Bottom 1A-6 . . . . . . . . . . . . . . . . . . . . . Marine Fouling 1A-7 . . . . . . . . . . . . . . . . . . . Weight Distribution 1A-8 . . . . . . . . . . . . . . . . Water in Boat 1A-9 . . . . . . . . . . . . . . . . . . . . Elevation and Climate 1A-9 . . . . . . . . . . . . . Section 1B - Maintenance Tools 1B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 1B-2 . . . . . Maintenance Schedules 1B-3 . . . . . . . . . . . . . . Maintenance Intervals 1B-3 . . . . . . . . . . . . . Gas Sterndrive 1B-3 . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance * 1B-3 . . . . . . . . . . . . Scheduled Maintenance * 1B-4 . . . . . . . . . . Engine and Tune-Up Specifications 1B-5 . . . . MCM (Sterndrive) 1B-5 . . . . . . . . . . . . . . . . . Fluid Capacities 1B-6 . . . . . . . . . . . . . . . . . . . . . Sterndrive Engines 1B-6 . . . . . . . . . . . . . . . Sterndrives 1B-6 . . . . . . . . . . . . . . . . . . . . . . 20-Hour Break-In Period 1B-7 . . . . . . . . . . . . . After Break-in Period 1B-7 . . . . . . . . . . . . . . . . End of First Season Checkup 1B-7 . . . . . . . . . Specifications 1B-8 . . . . . . . . . . . . . . . . . . . . . . . Fuel Recommendations 1B-8 . . . . . . . . . . . Test For Alcohol Content In Gasoline 1B-10 Power Steering Fluid 1B-10 . . . . . . . . . . . . . . . . Coolant for Closed Cooling System 1B-10 . . . . Crankcase Oil 1B-11 . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase Oil 1B-11 . . . . . . . . . . . Checking Engine Oil Level / Filling 1B-12 . . Changing Oil and Filter 1B-12 . . . . . . . . . . . . . . . Changing Water Separating Fuel Filter 1B-13 . Power Steering System 1B-15 . . . . . . . . . . . . . . Checking Fluid Level 1B-15 . . . . . . . . . . . . . . Engine Cold 1B-15 . . . . . . . . . . . . . . . . . . . . . Filling and Bleeding 1B-16 . . . . . . . . . . . . . . . Closed Cooling System 1B-17 . . . . . . . . . . . . . . Checking Coolant Level 1B-17 . . . . . . . . . . . Flushing System 1B-18 . . . . . . . . . . . . . . . . . Lubrication 1B-20 . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable 1B-20 . . . . . . . . . . . . . . . . . . . . Shift Cable 1B-20 . . . . . . . . . . . . . . . . . . . . . . . Engine Coupler / U-Joint Shaft Splines 1B-21 . . . . . . . . . . . . . Sterndrive Drive Shaft Extension Models 1B-22 . . . . . . . . . . . Cleaning Flame Arrestor 1B-22 . . . . . . . . . . . . . Top Mounted Flame Arrestor 1B-23 . . . . . . . Serpentine Drive Belt 1B-23 . . . . . . . . . . . . . . . . Component Location 1B-23 . . . . . . . . . . . . . . Serpentine Belt Routing 1B-24 . . . . . . . . . . . . . . S/N 0L619083 and Below 1B-24 . . . . . . . . . . S/N 0L619084 and Above 1B-25 . . . . . . . . . Inspection 1B-26 . . . . . . . . . . . . . . . . . . . . . . . Replacing and/or Adjusting Tension 1B-26 . Ignition Timing 1B-27 . . . . . . . . . . . . . . . . . . . . . . Thunderbolt V Models 1B-27 . . . . . . . . . . . . . EFI 1B-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather or Extended Storage 1B-29 . . . . Precautions 1B-29 . . . . . . . . . . . . . . . . . . . . . . Power Package Layup 1B-31 . . . . . . . . . . . . Draining Instructions 1B-33 . . . . . . . . . . . . . . Draining Sterndrive 1B-38 . . . . . . . . . . . . . . . Recommissioning 1B-39 . . . . . . . . . . . . . . . . .

90-861328--1 NOVEMBER 1999 Page v Section 1C - Troubleshooting Precautions 1C-2 . . . . . . . . . . . . . . . . . . . . . . . . Used Spark Plug Analysis 1C-3 . . . . . . . . . . . . Normal Condition 1C-3 . . . . . . . . . . . . . . . . . Chipped Insulator 1C-3 . . . . . . . . . . . . . . . . . Wet Fouling (Oil Deposits) 1C-4 . . . . . . . . . Cold Fouling 1C-4 . . . . . . . . . . . . . . . . . . . . . Overheating 1C-4 . . . . . . . . . . . . . . . . . . . . . High Speed Glazing 1C-5 . . . . . . . . . . . . . . . Scavenger Deposits 1C-5 . . . . . . . . . . . . . . Pre-Ignition Damage 1C-5 . . . . . . . . . . . . . . Reversed Coil Polarity 1C-6 . . . . . . . . . . . . . Splashed Deposits 1C-6 . . . . . . . . . . . . . . . . Mechanical Damage 1C-6 . . . . . . . . . . . . . . Poor Boat Performance and/or Poor Maneuverability 1C-7 . . . . . . . . . . . . . . . . Improper Full Throttle Engine RPM 1C-8 . . . . RPM Too High 1C-8 . . . . . . . . . . . . . . . . . . . RPM Too Low 1C-8 . . . . . . . . . . . . . . . . . . . . Engine Cranks Over But Will Not Start Or Starts Hard 1C-9I . . . . . . . . . . . . . . . . . . . . . . mportant Information 1C-9 . . . . . . . . . . . . . . . . . Thunderbolt V Ignition (No Spark) 1C-10 . . . Testing Thunderbolt V Ignition System 1C-10 Fuel System Rich 1C-11 . . . . . . . . . . . . . . . . . Fuel System Lean 1C-11 . . . . . . . . . . . . . . . . Miscellaneous 1C-11 . . . . . . . . . . . . . . . . . . . . Engine Will Not Crank Over 1C-12 . . . . . . . . . . . Charging System Inoperative 1C-12 . . . . . . . . . Noisy Alternator 1C-13 . . . . . . . . . . . . . . . . . . . . . Instrumentation Malfunction 1C-13 . . . . . . . . . . Radio Noise 1C-13 . . . . . . . . . . . . . . . . . . . . . . . . Poor Fuel Economy 1C-14 . . . . . . . . . . . . . . . . . Engine Runs Poorly at Idle 1C-14 . . . . . . . . . . . Engine Runs Poorly At High RPM 1C-15 . . . . . Engine Acceleration Is Poor 1C-16 . . . . . . . . . . Troubleshooting with Vacuum Gauge 1C-16 . . Engine Noise 1C-17 . . . . . . . . . . . . . . . . . . . . . . . Important Information 1C-17 . . . . . . . . . . . . . Valve Cover Area 1C-17 . . . . . . . . . . . . . . . . . Cylinder Area 1C-18 . . . . . . . . . . . . . . . . . . . . Camshaft Area 1C-18 . . . . . . . . . . . . . . . . . . . Crankshaft Area 1C-19 . . . . . . . . . . . . . . . . . . Miscellaneous 1C-20 . . . . . . . . . . . . . . . . . . . . Oil Pressure 1C-21 . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous 1C-21 . . . . . . . . . . . . . . . . . . . . Low Oil Pressure 1C-22 . . . . . . . . . . . . . . . . . High Oil Pressure 1C-22 . . . . . . . . . . . . . . . . . Excessive Oil Consumption 1C-23 . . . . . . . . . . . Water In Engine 1C-24 . . . . . . . . . . . . . . . . . . . . . Important Information 1C-24 . . . . . . . . . . . . . Water on Top of Pistons 1C-25 . . . . . . . . . . . Water in Crankcase Oil 1C-25 . . . . . . . . . . . . Engine Overheats 1C-26 . . . . . . . . . . . . . . . . . . . Mechanical 1C-26 . . . . . . . . . . . . . . . . . . . . . . Engine Overheats 1C-27 . . . . . . . . . . . . . . . . . . . Cooling System 1C-27 . . . . . . . . . . . . . . . . . . Insufficient Water Flow from Belt Driven Seawater Pickup Pump 1C-28 . Power Steering 1C-29 . . . . . . . . . . . . . . . . . . . . . Poor, Erratic or No Assist 1C-29 . . . . . . . . . . Noisy Pump 1C-30 . . . . . . . . . . . . . . . . . . . . . . Fluid Leaks 1C-30 . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION Section 2A - MCM Models Torque Specifications 2A-2 . . . . . . . . . . . . . . . . Tools 2A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 2A-2 . . . . . Removal 2A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and Alignment 2A-5 . . . . . . . . . . . . Engine Connections 2A-10 . . . . . . . . . . . . . . Electrical Connections 2A-11 . . . . . . . . . . . . . Mercathode Connections 2A-12 . . . . . . . . . . Shift Cable Installation 2A-12 . . . . . . . . . . . . Power Steering Connections 2A-12 . . . . . . . Fuel Supply Connections 2A-13 . . . . . . . . . . Throttle Cable Installation and Adjustment 2A-14 . . . . . . . . . . . . . . . . . . . . . .

Page vi 90-861328--1 NOVEMBER 1999 ENGINE Section 3A - 262 cid (4.3L) Engines Torque Specifications 3A-2 . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 3A-4 . . . . . Tools 3A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 3A-6 . . . . . . . . . . . . . . . . . . . . . . . General 3A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Failures 3A-14 . . . . . . . . . . . . . . . . . . . . Piston Failures 3A-16 . . . . . . . . . . . . . . . . . . . . . . Pre-Ignition 3A-16 . . . . . . . . . . . . . . . . . . . . . . Detonation 3A-17 . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts 3A-19 . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Cover 3A-20 . . . . . . . . . . . . . . . . . . . Removal 3A-20 . . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-20 . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold 3A-21 . . . . . . . . . . . . . . . . . . . . . Removal 3A-21 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-23 . . . . . . . . . . . Installation 3A-23 . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm / Push Rod 3A-27 . . . . . . . . . . . . . . Removal 3A-27 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-28 . . . . . . . . . . . Installation 3A-28 . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Roller Valve Lifters 3A-29 . . . . . . . . . Locating Noisy Lifters 3A-30 . . . . . . . . . . . . . Removal 3A-31 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-34 . . . . . . . . . . . Installation 3A-34 . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal / Valve Spring 3A-36 . . . . Removal - Head Installed 3A-36 . . . . . . . . . . Valve Assembly (Exploded View) 3A-38 . . . Installation - Head Installed 3A-39 . . . . . . . . Cylinder Head 3A-40 . . . . . . . . . . . . . . . . . . . . . . Removal 3A-40 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-42 . . . . . . . . . . . Installation 3A-43 . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Conditioning 3A-47 . Disassembly 3A-47 . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-47 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-48 . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Bore Repair 3A-49 . . . . . . . . . . Valve Springs - Checking Tension 3A-50 . . . Valve Seat Repair 3A-50 . . . . . . . . . . . . . . . . Valve Grinding 3A-51 . . . . . . . . . . . . . . . . . . . Reassembly 3A-52 . . . . . . . . . . . . . . . . . . . . . Dipstick Specifications 3A-55 . . . . . . . . . . . . . . . Oil Pan 3A-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-56 . . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-56 . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 3A-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-57 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 3A-58 . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-58 . . . . . . . . . . . Reassembly 3A-58 . . . . . . . . . . . . . . . . . . . . . Installation 3A-59 . . . . . . . . . . . . . . . . . . . . . . . Torsional Damper 3A-59 . . . . . . . . . . . . . . . . . . . Removal 3A-59 . . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-60 . . . . . . . . . . . . . . . . . . . . . . . Crankcase Front Cover Oil Seal 3A-61 . . . . . . . Crankcase Front Cover 3A-62 . . . . . . . . . . . . . . Removal 3A-62 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-63 . . . . . . . . . . . Installation 3A-63 . . . . . . . . . . . . . . . . . . . . . . . Flywheel 3A-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-64 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-64 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-65 . . . . . . . . . . . . . . . . . . . . . . . Rear Main Oil Seal 3A-66 . . . . . . . . . . . . . . . . . . Removal 3A-66 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-67 . . . . . . . . . . . Installation 3A-67 . . . . . . . . . . . . . . . . . . . . . . . Rear Main Oil Seal Retainer 3A-68 . . . . . . . . . . Removal 3A-68 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-68 . . . . . . . . . . . Installation 3A-68 . . . . . . . . . . . . . . . . . . . . . . . Main Bearings 3A-69 . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-69 . . . . . . . . . . . . . . . . . . . . . . . Replacement 3A-71 . . . . . . . . . . . . . . . . . . . . . Connecting Rod Bearings 3A-74 . . . . . . . . . . . . Inspection and Replacement 3A-74 . . . . . . . Connecting Rod / Piston Assembly 3A-76 . . . . Removal 3A-76 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 3A-77 . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-78 . . . . . . . . . . . Reassembly 3A-80 . . . . . . . . . . . . . . . . . . . . . Installation 3A-82 . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 3A-84 . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-84 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-86 . . . . . . . . . . . Installation 3A-87 . . . . . . . . . . . . . . . . . . . . . . . Timing Chain and Sprocket 3A-88 . . . . . . . . . . . Exploded View 3A-88 . . . . . . . . . . . . . . . . . . . Removal 3A-88 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-89 . . . . . . . . . . . Installation - Timing Chain 3A-89 . . . . . . . . . Crankshaft Sprocket 3A-89 . . . . . . . . . . . . . . . . . Removal 3A-89 . . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-89 . . . . . . . . . . . . . . . . . . . . . . . Checking Timing Chain Deflection 3A-90 . . Balance Shaft / Gears 3A-91 . . . . . . . . . . . . . . . Removal 3A-91 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-94 . . . . . . . . . . . Installation 3A-94 . . . . . . . . . . . . . . . . . . . . . . . Camshaft 3A-96 . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring Lobe Lift 3A-96 . . . . . . . . . . . . . . . Removal 3A-97 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-98 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-98 . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearings 3A-99 . . . . . . . . . . . . . . . . . . Removal 3A-99 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-100 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-100 . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block 3A-101 . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-101 . . . . . . . . . . . Oil Filter By-Pass Valve 3A-105 . . . . . . . . . . . . . . Inspection and/or Replacement 3A-105 . . . . . Remote Oil Filter 3A-106 . . . . . . . . . . . . . . . . . . . . Inspection and/or Replacement 3A-106 . . . . .

90-861328--1 NOVEMBER 1999 Page vii Section 4A - Starting Systems Identification 4A-2 . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning 4A-2 . . . . . . . . . . General Precautions 4A-2 . . . . . . . . . . . . . . . . . Starting System Components 4A-3 . . . . . . . . . Positive Current Flow 4A-4 . . . . . . . . . . . . . . . . Battery 4A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Cable Recommendations 4A-4 . . . Maintenance 4A-6 . . . . . . . . . . . . . . . . . . . . . Testing 4A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . Storage 4A-7 . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide 4A-8 . . . . . . . . . . . . . . . . . . How Temperature Affects Battery Power 4A-8 . . . . . . . . . . . . . . . . . . . Standard Starter Slave Solenoid 4A-9 . . . . . . Identification 4A-9 . . . . . . . . . . . . . . . . . . . . . Standard Type Slave Solenoid 4A-9 . . . . . Testing / Replacement 4A-9 . . . . . . . . . . . . . Installation 4A-10 . . . . . . . . . . . . . . . . . . . . . . . Permanent Magnet - Gear Reduction (PG260F1) Starter Motor 4A-10 . . . . . . . . . . . . . Starter Specifications 4A-10 . . . . . . . . . . . . . Torque Specifications 4A-10 . . . . . . . . . . . . . Lubricants / Sealants 4A-10 . . . . . . . . . . . . . . Description 4A-11 . . . . . . . . . . . . . . . . . . . . . . PG260F1 Exploded View 4A-12 . . . . . . . . . . . . . Solenoid Switch 4A-13 . . . . . . . . . . . . . . . . . . . . . Periodic Inspection 4A-13 . . . . . . . . . . . . . . . . . . Motor 4A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 4A-13 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 4A-13 . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 4A-16 . . . . . . . . . . . Reassembly 4A-17 . . . . . . . . . . . . . . . . . . . . . Checking Pinion Clearance 4A-21 . . . . . . . . Installation 4A-22 . . . . . . . . . . . . . . . . . . . . . . . Delco PG260 Starter 4A-23 . . . . . . . . . . . . . . . . . PG260 Specifications 4A-23 . . . . . . . . . . . . . Torque Specification 4A-23 . . . . . . . . . . . . . . Lubricants / Sealants 4A-23 . . . . . . . . . . . . . . Description 4A-23 . . . . . . . . . . . . . . . . . . . . . . PG260 Exploded View 4A-24 . . . . . . . . . . . . . . . Solenoid Switch 4A-25 . . . . . . . . . . . . . . . . . . . . . Periodic Inspection 4A-25 . . . . . . . . . . . . . . . . . . Motor 4A-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 4A-26 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 4A-26 . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 4A-30 . . . . . . . . . . . Armature Tests 4A-31 . . . . . . . . . . . . . . . . . . . Armature Bearing (Commutator End) 4A-32 Gear Bearing 4A-32 . . . . . . . . . . . . . . . . . . . . Shaft Assembly Bearing 4A-33 . . . . . . . . . . . Drive End Housing Bearing 4A-33 . . . . . . . . Brushes and Brush Holder 4A-34 . . . . . . . . . Section 4B - Thunderbolt V Ignition System Replacement Parts Warning 4B-2 . . . . . . . . . . General Precautions 4B-2 . . . . . . . . . . . . . . . . . EFI System Maintenance Precautions 4B-3 . Thunderbolt V Ignition System 4B-4 . . . . . . . . Identification 4B-4 . . . . . . . . . . . . . . . . . . . . . Timing and Idle Adjustment Procedures 4B-5 Setting Base Ignition Timing 4B-5 . . . . . . . . Adjusting Idle Mixture 4B-5 . . . . . . . . . . . . . Spark Plugs 4B-6 . . . . . . . . . . . . . . . . . . . . . . . . Specifications 4B-6 . . . . . . . . . . . . . . . . . . . . Removal 4B-6 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 4B-6 . . . . . . . . . . . . . . . . . . . . . . . Replacing 4B-7 . . . . . . . . . . . . . . . . . . . . . . . Description 4B-7 . . . . . . . . . . . . . . . . . . . . . . . . . Idle Speed Spark Control 4B-7 . . . . . . . . . . Acceleration Spark Advance 4B-8 . . . . . . . Mean-Best-Timing (MBT) Spark Advance 4B-8 . . . . . . . . . . . . . . . . . . Over-Speed Control 4B-8 . . . . . . . . . . . . . . . Knock Retard Spark Control 4B-8 . . . . . . . Spark Plug Wires 4B-9 . . . . . . . . . . . . . . . . . . . . Adjusting Engine Idle Speed 4B-9 . . . . . . . Circuit Description 4B-10 . . . . . . . . . . . . . . . . . . . Ignition Control Module 4B-10 . . . . . . . . . . . . Knock Control Module 4B-10 . . . . . . . . . . . . . Ignition Control System Timing Lead 4B-10 Thunderbolt V Spark Control Graph 4B-11 . . . Distributor Advance Curves 4B-12 . . . . . . . . . . . Distributor 4B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 4B-12 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 4B-13 . . . . . . . . . . . . . . . . . . . . . Reassembly 4B-13 . . . . . . . . . . . . . . . . . . . . . Installation - Engine Not Disturbed 4B-14 . . Installation - Engine Disturbed 4B-14 . . . . . . Distributor Cap 4B-15 . . . . . . . . . . . . . . . . . . . . . . Removal 4B-15 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 4B-15 . . . . . . . . . . . . . . . . . . . . . . . Rotor/Sensor Wheel 4B-16 . . . . . . . . . . . . . . . . . Removal 4B-16 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 4B-16 . . . . . . . . . . . . . . . . . . . . . . . Installation 4B-17 . . . . . . . . . . . . . . . . . . . . . . . Sensor 4B-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 4B-17 . . . . . . . . . . . . . . . . . . . . . . . . Inspection 4B-18 . . . . . . . . . . . . . . . . . . . . . . . Installation 4B-18 . . . . . . . . . . . . . . . . . . . . . . .

Page viii 90-861328--1 NOVEMBER 1999 Section 4C - Charging System General Precautions 4C-2 . . . . . . . . . . . . . . . . . EFI Electrical System Precautions 4C-2 . . . . . Replacement Parts Warning 4C-2 . . . . . . . . . . Multiple EFI Engine Battery Precautions 4C-3 Situation 4C-3 . . . . . . . . . . . . . . . . . . . . . . . . . Recommendations 4C-3 . . . . . . . . . . . . . . . . Identification 4C-4 . . . . . . . . . . . . . . . . . . . . . . . . Specifications 4C-4 . . . . . . . . . . . . . . . . . . . . . . . Mando 4C-4 . . . . . . . . . . . . . . . . . . . . . . . . . . DelcoRemy 4C-5 . . . . . . . . . . . . . . . . . . . . . . Tools 4C-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 4C-5 . . . . . Torque Specifications 4C-5 . . . . . . . . . . . . . . . . Description 4C-6 . . . . . . . . . . . . . . . . . . . . . . . . . Testing 4C-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System 4C-7 . . . . . . . . . . . . . . . . . Charging System Resistance 4C-8 . . . . . . . Circuitry 4C-10 . . . . . . . . . . . . . . . . . . . . . . . . . Component 4C-11 . . . . . . . . . . . . . . . . . . . . . . Exploded View 4C-16 . . . . . . . . . . . . . . . . . . . . . . Alternator Repair 4C-17 . . . . . . . . . . . . . . . . . . . . Removal 4C-17 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 4C-17 . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 4C-22 . . . . . . . . . . . Reassembly 4C-22 . . . . . . . . . . . . . . . . . . . . . Installation 4C-26 . . . . . . . . . . . . . . . . . . . . . . . . . Pulley Removal 4C-27 . . . . . . . . . . . . . . . . . . Battery Isolator Diagram 4C-28 . . . . . . . . . . . Section 4D - Instrumentation Tools 4D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 4D-2 . . . . . Identification 4D-2 . . . . . . . . . . . . . . . . . . . . . . . . Special Information 4D-3 . . . . . . . . . . . . . . . . . . Lighting Options 4D-3 . . . . . . . . . . . . . . . . . . Gauges 4D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil, Fuel and Temperature 4D-5 . . . . . . . . . Battery Gauge 4D-6 . . . . . . . . . . . . . . . . . . . Cruiselog Meter 4D-7 . . . . . . . . . . . . . . . . . . Vacuum Gauge 4D-7 . . . . . . . . . . . . . . . . . . . Speedometer 4D-7 . . . . . . . . . . . . . . . . . . . . Tachometer 4D-8 . . . . . . . . . . . . . . . . . . . . . . Gauge Replacement 4D-8 . . . . . . . . . . . . . . Senders 4D-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure 4D-9 . . . . . . . . . . . . . . . . . . . . . Water Temperature 4D-10 . . . . . . . . . . . . . . . Fuel Tank Sender 4D-13 . . . . . . . . . . . . . . . . . Switches 4D-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Key Switch 4D-16 . . . . . . . . . . . . . . . Lanyard Stop Switches 4D-17 . . . . . . . . . . . . Testing 4D-17 . . . . . . . . . . . . . . . . . . . . . . . . . . Start/Stop Switch 4D-19 . . . . . . . . . . . . . . . . . Audio Warning System 4D-20 . . . . . . . . . . . . . . . Buzzer 4D-20 . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch 4D-21 . . . . . . . . . . . . . . . Water Temperature Switch 4D-21 . . . . . . . . . Section 4E - Wiring Diagrams Wiring Colors for Mercury MerCruiser 4E-2 . . MCM Gasoline Engine Wiring Diagrams 4E-4 Starting and Charging Harness 4E-4 . . . . . Fuel and Ignition System Harnesses 4E-16 Quicksilver Instrumentation 4E-22 . . . . . . . . Dual Station Wiring 4E-24 . . . . . . . . . . . . . . . FUEL SYSTEM Section 5A - Fuel Delivery System For Carbureted Engines Identification 5A-2 . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning 5A-2 . . . . . . . . . . Specifications 5A-2 . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 5A-2 . . . . . . . . . . . . . . . . Tools 5A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 5A-3 . . . . . Precautions 5A-3 . . . . . . . . . . . . . . . . . . . . . . . . Fuel Supply Connections 5A-3 . . . . . . . . . . Fuel Delivery System 5A-4 . . . . . . . . . . . . . . . . Recommendations 5A-4 . . . . . . . . . . . . . . . . Fuel System Components 5A-6 . . . . . . . . . . . . Water Separating Fuel Filter 5A-7 . . . . . . . . . . Replacement 5A-8 . . . . . . . . . . . . . . . . . . . . . Vent Hose Routing 5A-8 . . . . . . . . . . . . . . . . . . Carbureted Models 5A-8 . . . . . . . . . . . . . . .

90-861328--1 NOVEMBER 1999 Page ix Section 5B - Mercarb 2 Barrel Carburetor Identification 5B-2 . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning 5B-3 . . . . . . . . . . Precautions 5B-3 . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 5B-3 . . . . . . . . . . . . . . . . Specifications 5B-4 . . . . . . . . . . . . . . . . . . . . . . . Tools 5B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View 5B-6 . . . . . . . . . . . . . . . . . . . . . . Important Service Information 5B-8 . . . . . . . . . High Altitude Re-Jetting 5B-8 . . . . . . . . . . . 8 Point Carburetor Check List 5B-9 . . . . . . Flooding At Idle RPM 5B-9 . . . . . . . . . . . . . Needle / Seat Change 5B-9 . . . . . . . . . . . . . Adjustable Accelerator Pump Lever 5B-10 . Description 5B-10 . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 5B-11 . . . . . . . . . . . . . . . . . . . . . . . . Flame Arrestor 5B-11 . . . . . . . . . . . . . . . . . . . Fuel Inlet Filter 5B-13 . . . . . . . . . . . . . . . . . . . Choke Inspection 5B-14 . . . . . . . . . . . . . . . . . Adjustments 5B-14 . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Rod 5B-14 . . . . . . . . . . . . . . . . . . Choke Setting 5B-16 . . . . . . . . . . . . . . . . . . . . Choke Unloader 5B-17 . . . . . . . . . . . . . . . . . . Initial Idle Speed and Mixture 5B-17 . . . . . . . Final Idle Speed and Mixture 5B-18 . . . . . . . Replacing Carburetor 5B-18 . . . . . . . . . . . . . . . . Repair 5B-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 5B-19 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 5B-20 . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 5B-28 . . . . . . . . . . . Reassembly 5B-30 . . . . . . . . . . . . . . . . . . . . . Installation 5B-40 . . . . . . . . . . . . . . . . . . . . . . . Section 5C - Weber 4 Barrel Carburetor Identification 5C-2 . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Metering Rod And Jet Identification 5C-2 . . . . . . . . . . . . . Torque Specifications 5C-4 . . . . . . . . . . . . . . . . Specifications 5C-4 . . . . . . . . . . . . . . . . . . . . . . . Tools 5C-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning 5C-5 . . . . . . . . . . Precautions 5C-6 . . . . . . . . . . . . . . . . . . . . . . . . Fuel Delivery System 5C-6 . . . . . . . . . . . . . . . . Fuel Supply Connections 5C-6 . . . . . . . . . . 8 Point Carburetor Check List 5C-7 . . . . . . . . . Exploded View 5C-8 . . . . . . . . . . . . . . . . . . . . . . Description 5C-10 . . . . . . . . . . . . . . . . . . . . . . . . . Important Service Information 5C-11 . . . . . . . . . Adjustable Accelerator Pump Lever 5C-11 . Hard Starting 5C-11 . . . . . . . . . . . . . . . . . . . . . Maintenance 5C-12 . . . . . . . . . . . . . . . . . . . . . . . . Flame Arrestor 5C-12 . . . . . . . . . . . . . . . . . . . Fuel Inlet Filter 5C-13 . . . . . . . . . . . . . . . . . . . Adjustments 5C-14 . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Pump 5C-14 . . . . . . . . . . . . . . . . Float Drop 5C-16 . . . . . . . . . . . . . . . . . . . . . . . Float Level 5C-17 . . . . . . . . . . . . . . . . . . . . . . . Electric Choke 5C-18 . . . . . . . . . . . . . . . . . . . Idle Speed and Mixture 5C-18 . . . . . . . . . . . . Replacing Carburetor 5C-19 . . . . . . . . . . . . . . . . Repair 5C-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 5C-19 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 5C-21 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 5C-32 . . . . . . . . . . . . . . Reassembly 5C-33 . . . . . . . . . . . . . . . . . . . . . . . . Installation 5C-44 . . . . . . . . . . . . . . . . . . . . . . . Section 5D - Sav1 Emission Fuel System With Weber 4 Barrel Carburetor Identification 5D-2 . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning 5D-2 . . . . . . . . . . Torque Specifications 5D-2 . . . . . . . . . . . . . . . . Special Tools 5D-2 . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications 5D-3 . . . . . . . . . . . . . . . . Carburetor Specifications 5D-3 . . . . . . . . . . . . . Carburetor Adjustment Specifications 5D-4 . . Description 5D-4 . . . . . . . . . . . . . . . . . . . . . . . . . Special Notes 5D-5 . . . . . . . . . . . . . . . . . . . . . . . Carburetor Top Cover 5D-5 . . . . . . . . . . . . . Sealed Idle Mixture Screws 5D-5 . . . . . . . . Piston Bore of Emissions Model 5D-6 . . . . Precautions 5D-6 . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 5D-7 . . . . . . . . . . . . . . . . . . . . . . . . Flame Arrestor 5D-7 . . . . . . . . . . . . . . . . . . . Fuel Filter 5D-7 . . . . . . . . . . . . . . . . . . . . . . . Positive Crankcase Ventilation (PCV) 5D-8 Troubleshooting 5D-8 . . . . . . . . . . . . . . . . . . . . . Checking Ported Vacuum Switch and Carburetor Vacuum Circuit for Correct Operation 5D-9 . . . . . . . . . . . . . Service Procedures 5D-11 . . . . . . . . . . . . . . . . . . Checking Positive Crankcase Ventilation (PCV) Valve 5D-11 . . . . . . . . . . . Removing Seals From Idle Mixture Screws 5D-11 . . . . . . . . . . . . . . Installing New Seals 5D-12 . . . . . . . . . . . . . . Carburetor Installation 5D-12 . . . . . . . . . . . . . Ported Vacuum Switch Installation 5D-13 . . Emissions System Connections 5D-13 . . . . Propane Assisted Idle Set Procedure 5D-15 Test Equipment 5D-18 . . . . . . . . . . . . . . . . . . . . . Emissions Testing 5D-19 . . . . . . . . . . . . . . . . . . .

2002 Mercury Mercruiser 4.3L GM V6 (262 CID) OEM Service & Repair Manual

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