2002 MERCURY MERCRUISER 4.3L EFI INBOARD Factory Service & Work Shop Manual
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Number 32 Printed in U.S.A. 90-864261 NOVEMBER 2001 ï›™2001, Mercury Marine 4.3L MPI GASOLINE ENGINE SN 0M322781 and ABOVE SERVICE MANUAL
90-864261 NOVEMBER 2001 Page i Notice Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International 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 Immediate hazards which will result in severe personal injury or death. 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 marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury MerCruiser product, including 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 marine trade of all conceivable procedures and of the possible hazards and/or results of each method. 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. 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. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual.
Page ii 90-864261 NOVEMBER 2001 Precautions 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. 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. Mismatched 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 whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. 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 that 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. Replacement Parts Use of parts other than the recommended service replacement parts, will void the warranty on those parts that are damaged as a result. WARNING Electrical, ignition and fuel system components on Mercury 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.
90-864261 NOVEMBER 2001 Page iii Models Covered in This Manual Sterndrive (MCM) Serial Number 4.3L MPI Alpha and Bravo 0M300000 and Above
Page iv 90-864261 NOVEMBER 2001 THIS PAGE IS INTENTIONALLY BLANK
1 2 3 4 5 6 7 8 Important Information Removal And Installation Engine Mechanical Electrical System Fuel System Cooling System Exhaust System Power Steering 90-864261 NOVEMBER 2001 Page v 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 Mechanical A - 4.3 liter (262 cid) Section 4 - Electrical System A - Starting System B - Ignition System C - Charging System D - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery System Section 6 - Cooling System A - All Models B - Seawater Cooled Models C - Closed Cooled Models Section 7 - Exhaust System A - Manifolds and Elbows Section 8 - Power Steering A - Power Steering Pump
Upon purchasing this manual, you will receive a file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2002 MERCURY MERCRUISER 4.3L EFI INBOARD.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it offers instructions for tasks ranging from an oil change to a transmission swap, empowering both professional mechanics and DIY enthusiasts to effectively diagnose and resolve issues. The manual includes numerous illustrations to assist you in your work, accompanied by easy-to-understand text.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual imparts essential knowledge for maintenance and repair, guiding you through the process step by step, akin to the expertise of factory-trained technicians.
By leveraging the insights within this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Rest assured, in addition to the high-quality service manual, we are committed to providing excellent customer service, ensuring your satisfaction.
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2002 MERCURY MERCRUISER 4.3L EFI INBOARD Factory Service & Work Shop Manual