Mercury Mercruiser 4.3L MPI Gasoline Engine Service Manual

Number 32 Printed in U.S.A. 90-864261 NOVEMBER 2001 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

Page vi 90-864261 NOVEMBER 2001 IMPORTANT INFORMATION Section 1A - General Information Introduction 1A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual 1A-2 . . . . . . . . . . . . . . . . . Page Numbering 1A-2 . . . . . . . . . . . . . . . . . . . . Engine Serial Number Locations 1A-3 . . . . . . . . . . Mercury/Quicksilver Lubricants, Sealants And Adhesives 1A-4 . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION Section 1B - Maintenance Torque Specifications 1B-2 . . . . . . . . . . . . . . . . Special Tools 1B-2 . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 1B-3 . . . . . Engine And Tune-Up Specifications 1B-4 . . . . MCM (Sterndrive) Models 1B-4 . . . . . . . . . . Fluid Specifications 1B-5 . . . . . . . . . . . . . . . . . . Engines 1B-5 . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrives 1B-5 . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedules 1B-6 . . . . . . . . . . . . . . Maintenance Intervals 1B-6 . . . . . . . . . . . . . Routine Maintenance 1B-7 . . . . . . . . . . . . . Scheduled Maintenance 1B-8 . . . . . . . . . . Crankcase Oil 1B-10 . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase Oil 1B-11 . . . . . . . . . . . Checking 1B-11 . . . . . . . . . . . . . . . . . . . . . . . . Filling 1B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Oil and Filter 1B-13 . . . . . . . . . . . . Flushing The Power Package - MCM 1B-15 . . Sterndrive Water Pickups 1B-15 . . . . . . . . . . Alternative Water Pickups 1B-17 . . . . . . . . . . Sterndrive Unit Oil 1B-19 . . . . . . . . . . . . . . . . . . . Checking 1B-19 . . . . . . . . . . . . . . . . . . . . . . . . Filling 1B-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing 1B-20 . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Fluid 1B-22 . . . . . . . . . . . . . . Checking 1B-22 . . . . . . . . . . . . . . . . . . . . . . . . Filling 1B-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing 1B-22 . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Fluid 1B-23 . . . . . . . . . . . Checking 1B-23 . . . . . . . . . . . . . . . . . . . . . . . . Filling and Bleeding 1B-24 . . . . . . . . . . . . . . . Water Inlets 1B-26 . . . . . . . . . . . . . . . . . . . . . . . . Seawater Strainer 1B-26 . . . . . . . . . . . . . . . . Closed Cooling System 1B-27 . . . . . . . . . . . . . . Checking Coolant Level 1B-27 . . . . . . . . . . . Cleaning and Inspection 1B-27 . . . . . . . . . . . Changing Coolant 1B-27 . . . . . . . . . . . . . . . . Anodes 1B-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft 1B-31 . . . . . . . . . . . . . . . . . . . . . . Power Package Surfaces 1B-32 . . . . . . . . . . . . . Painting Your Power Package 1B-32 . . . . . . Battery 1B-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruments 1B-33 . . . . . . . . . . . . . . . . . . . . . . . . . Gimbal Ring / Steering Connection 1B-33 . . . . Changing Water Separating Fuel Filter 1B-34 . Steering System 1B-35 . . . . . . . . . . . . . . . . . . . . Remote Control 1B-35 . . . . . . . . . . . . . . . . . . . . . Sterndrive Components 1B-35 . . . . . . . . . . . . . . Lubrication 1B-35 . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable 1B-35 . . . . . . . . . . . . . . . . . . . . Shift Cable 1B-36 . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Components 1B-36 . . . . . . . . . . . Continuity Circuit 1B-41 . . . . . . . . . . . . . . . . . . . . MerCathode 1B-43 . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts 1B-43 . . . . . . . . . . . . . . . . . . . . . . Electrical System 1B-43 . . . . . . . . . . . . . . . . . . . . Cleaning Flame Arrestor 1B-44 . . . . . . . . . . . . . Serpentine Drive Belt 1B-45 . . . . . . . . . . . . . . . . Sterndrive Models 1B-45 . . . . . . . . . . . . . . . . Inspection 1B-45 . . . . . . . . . . . . . . . . . . . . . . . Replacing Belt and/or Adjusting Tension 1B-46 . . . . . . . . . . . . . . . . Exhaust System 1B-47 . . . . . . . . . . . . . . . . . . . . . Seawater Pump 1B-47 . . . . . . . . . . . . . . . . . . . . . Cold Weather And Extended Storage 1B-48 . . Preparing Your Power Package For Storage 1B-48 . . . . . . . . . . . . . . . . . . . . . Draining Instructions 1B-50 . . . . . . . . . . . . . . . . . Identification 1B-51 . . . . . . . . . . . . . . . . . . . . . Boat In The Water 1B-52 . . . . . . . . . . . . . . . . Boat Out Of The Water 1B-56 . . . . . . . . . . . . All Models 1B-59 . . . . . . . . . . . . . . . . . . . . . . .

90-864261 NOVEMBER 2001 Page vii IMPORTANT INFORMATION Section 1C - Troubleshooting Used Spark Plug Analysis 1C-2 . . . . . . . . . . . . Normal Condition 1C-2 . . . . . . . . . . . . . . . . . Chipped Insulator 1C-3 . . . . . . . . . . . . . . . . . Wet Fouling (Oil Deposits) 1C-3 . . . . . . . . . Cold Fouling 1C-4 . . . . . . . . . . . . . . . . . . . . . Overheating 1C-4 . . . . . . . . . . . . . . . . . . . . . . High Speed Glazing 1C-5 . . . . . . . . . . . . . . . Scavenger Deposits 1C-5 . . . . . . . . . . . . . . . Pre-Ignition Damage 1C-6 . . . . . . . . . . . . . . Reversed Coil Polarity 1C-6 . . . . . . . . . . . . . Splashed Deposits 1C-7 . . . . . . . . . . . . . . . . Mechanical Damage 1C-7 . . . . . . . . . . . . . . Poor Boat Performance And/Or Poor Maneuverability 1C-8 . . . . . . . . . . . . . . . . Improper Full Throttle Engine RPM 1C-10 . . . . Engine Cranks Over But Will Not Start Or Starts Hard 1C-11 . . . . . . . . . . . . . . . . . . . . . . Important Information 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-15 . . . . . . . . . . . Engine Runs Poorly At High RPM 1C-16 . . . . . Engine Acceleration Is Poor 1C-17 . . . . . . . . . . Troubleshooting with Vacuum Gauge 1C-17 . . Engine Noise 1C-18 . . . . . . . . . . . . . . . . . . . . . . . Important Information 1C-18 . . . . . . . . . . . . . Oil Pressure 1C-24 . . . . . . . . . . . . . . . . . . . . . . . . Excessive Oil Consumption 1C-27 . . . . . . . . . . . Water In The Engine 1C-28 . . . . . . . . . . . . . . . . . Important Information 1C-28 . . . . . . . . . . . . . Engine Overheats (Mechanical) 1C-30 . . . . . . . Power Steering 1C-33 . . . . . . . . . . . . . . . . . . . . . Drain System Will Not Drain Or Drains Slowly 1C-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION Section 2A - MCM Models Torque Specifications 2A-2 . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 2A-3 . . . . . Special Tools 2A-4 . . . . . . . . . . . . . . . . . . . . . . . Removal 2A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation 2A-8 . . . . . . . . . . . . . . . . . . . Electrical Connections 2A-13 . . . . . . . . . . . . . . . EFI Electrical System Precautions 2A-13 . . Installing Continuity Wire 2A-14 . . . . . . . . . . Instrumentation Connections 2A-14 . . . . . . . Trim Position Sender Connections 2A-15 . . MerCathode Connections 2A-16 . . . . . . . . . . Audio Warning Alarm Connections 2A-17 . . Power Trim Pump Connections 2A-17 . . . . . Fluid Connections 2A-18 . . . . . . . . . . . . . . . . . . . Fuel 2A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Lube Monitor Hose 2A-19 . . . . . . . . . . Power Steering Hoses 2A-20 . . . . . . . . . . . . . Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups 2A-21 . . . . Alpha or Bravo Models Using Alternative Water Pickups 2A-21 . . . Coolant Recovery Bottle 2A-24 . . . . . . . . . . . Shift Cable Installation 2A-25 . . . . . . . . . . . . . . . Alpha Models - Drive Unit Not Installed 2A-25 . . . . . . . . . . . Bravo Models 2A-30 . . . . . . . . . . . . . . . . . . . . Throttle Cable Installation and Adjustment 2A-35 . . . . . . . . . . . . . . . . . . Battery Connection 2A-37 . . . . . . . . . . . . . . . Engine Cover Installation 2A-37 . . . . . . . . . .

Page viii 90-864261 NOVEMBER 2001 ENGINE MECHANICAL Section 3A - 4.3 liter (262 cid) Identification 3A-3 . . . . . . . . . . . . . . . . . . . . . . . . General Specifications 3A-4 . . . . . . . . . . . . . . . 4.3 liter (262 cid) 3A-4 . . . . . . . . . . . . . . . . . Engine Specifications - 4.3 liter (262 cid) 3A-5 Cylinder Head 3A-5 . . . . . . . . . . . . . . . . . . . . Cylinder Bore 3A-5 . . . . . . . . . . . . . . . . . . . . Oil Pump 3A-5 . . . . . . . . . . . . . . . . . . . . . . . . Piston Bore Clearance 3A-5 . . . . . . . . . . . . Piston Rings 3A-6 . . . . . . . . . . . . . . . . . . . . . Piston Pin 3A-6 . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 3A-7 . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod 3A-8 . . . . . . . . . . . . . . . . . . Valve 3A-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve (continued) 3A-9 . . . . . . . . . . . . . . . . . Camshaft 3A-10 . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain 3A-10 . . . . . . . . . . . . . . . . . . . . . Flywheel 3A-10 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 3A-11 . . . . . . . . . . . . . . . . Special Tools 3A-15 . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 3A-16 . . . . . Precautions 3A-18 . . . . . . . . . . . . . . . . . . . . . . . . General Information 3A-19 . . . . . . . . . . . . . . . . . Repair Procedures 3A-19 . . . . . . . . . . . . . . . . Special Notice 3A-19 . . . . . . . . . . . . . . . . . . . . Engine Rotation 3A-19 . . . . . . . . . . . . . . . . . . Crankcase Oil Dipstick Measurements 3A-20 Engine Mounts 3A-21 . . . . . . . . . . . . . . . . . . . . . . Exploded Views 3A-21 . . . . . . . . . . . . . . . . . . Valve Cover 3A-22 . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-22 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-22 . . . . . . . . . . . Installation 3A-23 . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm / Valve Pushrod 3A-24 . . . . . . . . . . Removal 3A-24 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-25 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-25 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-26 . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal / Valve Spring - Cylinder Head Installed 3A-28 . . . . . . . . . . . . . . Exploded View 3A-28 . . . . . . . . . . . . . . . . . . . Removal 3A-29 . . . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-30 . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold Assembly 3A-33 . . . . . . . . . . . . Exploded View 3A-33 . . . . . . . . . . . . . . . . . . . Removal 3A-34 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-35 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-35 . . . . . . . . . . . . . . . . . . . . . . . Upper And Lower Intake Manifolds 3A-36 . . Installation 3A-36 . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Lifters 3A-39 . . . . . . . . . . . . . . . Exploded View 3A-39 . . . . . . . . . . . . . . . . . . . Special Information 3A-39 . . . . . . . . . . . . . . . Removal 3A-40 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-41 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-41 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-42 . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Camshaft Bearings 3A-43 . . . . . Measuring Camshaft Lobe Lift 3A-43 . . . . . . Removal 3A-45 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-49 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-50 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-51 . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 3A-58 . . . . . . . . . . . . . . . . . . . . . . Removal 3A-58 . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 3A-59 . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-60 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-61 . . . . . . . . . . . . . . . . . . . . . . . Repair 3A-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly 3A-69 . . . . . . . . . . . . . . . . . . . . . Installation 3A-73 . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 3A-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-75 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-76 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-76 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-76 . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 3A-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View 3A-78 . . . . . . . . . . . . . . . . . . . Removal 3A-79 . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 3A-79 . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-80 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-81 . . . . . . . . . . . . . . . . . . . . . . . Reassembly 3A-82 . . . . . . . . . . . . . . . . . . . . . Installation 3A-84 . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Balancer 3A-85 . . . . . . . . . . . . . . . . . Removal 3A-85 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-85 . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-85 . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-86 . . . . . . . . . . . . . . . . . . . . . . . Front Cover Oil Seal 3A-88 . . . . . . . . . . . . . . . . . Oil Seal Replacement Without Removing Front Cover 3A-88 . . . . Front Cover 3A-89 . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-89 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-90 . . . . . . . . . . . Installation 3A-90 . . . . . . . . . . . . . . . . . . . . . . .

Mercury Mercruiser 4.3L MPI Gasoline Engine Service Manual

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