Mercruiser GM 454 502 7.4 8.2 Engines Complete Workshop Service Repair Manual

Number 16 Printed in U.S.A. 90-823224--2 796 1996, Mercury Marine MARINE ENGINES SERVICE MANUAL GM V-8 454 CID (7.4L) / 502 CID (8.2L) Book 1 of 2 Sections 1 thru 4

90-823224--2 796 i Notice Throughout this publication, “Dangers,” “Warnings” and “Cautions” are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incor- rectly 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 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 personnel 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 Mercury Marine, and that they have been trained in the recommended servicing procedures for these products which include the use of mechanic’s 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 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 service procedure selected. All information, illustrations and specifications con- tained in this manual are based on the latest product information available at time of publication. It should be kept in mind, while working on the 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 inter- nal damage when the engine is started. It is important to note that, during any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. Numbers on the heads of the metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or mal- function, or possible personal injury. Therefore, fasteners removed should be saved for re-use in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that meets the same specifications as the original.

90-823224--2 796 ii 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 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 cor- rode 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 open- ing would permit sparks to ignite fuel va- pors from fuel system leaks, if they existed.

90-823224--2 796 iii V-8 Models Covered in This Manual Gen V Engines Model Serial Number Stern Drive Engines MCM 7.4L Bravo OD830779 to OF800699 MCM 7.4L Bravo Three OD838819 to OF800699 MCM 7.4LX MPI OF595275 to OF801999 MCM 454 Magnum (Carburetor) OD837587 to OF801999 MCM 454 Magnum EFI, EFI/MP and MPI OF111570 to OF802349 MCM 502 Magnum (Carburetor) OD831432 to OF114528 MCM 502 Magnum EFI, EFI/MP, MPI OD840650 to OF802599 Inboard Engines MIE 7.4L (Carburetor) OD840300 to OF820141 MIE 7.4L EFI/MP and MPI OF490697 to OF820103 MIE 8.2L (Carburetor) OD857200 to OF819619 Ski Engines MIE 454 Magnum EFI, EFI/MP and MPI Tournament Ski OF215800 to OF820099 Gen VI Engines Model Serial Number Stern Drive Engines MCM Bravo 7.4L (Carburetor) OF800700 and above MCM 7.4LX EFI OF820000 and above MCM 7.4LX MPI OF802000 and above MCM 454 Magnum (Carburetor) OF801700 and Above MCM 454 MPI OF802350 and above MCM 502 MPI OF802600 and above Inboard Engines MIE 7.4L (Carburetor) OF820142 and above MIE 7.4L EFI OF874815 and above MIE 7.4L MPI OF820104 and above MIE 8.2L MPI OF775694 and OF775695 MIE 8.2L MPI OF819620 and above

90-823224--2 796 iv

Important Information Removal and Installation Engine Electrical System Fuel System Cooling System Exhaust System Drives 8 1 2 3 4 5 6 7 9 Power Steering 90-823224--2 796 v Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models - Bravo and Blackhawk Drives B - MCM Models - Bravo and Blackhawk with Driveshaft Extension C - MIE Models - Velvet Drive Transmissions D - MIE Models - Hurth Transmissions Section 3 - Engine A - 454 CID / 7.4L / 502 CID / 8.2L Section 4 - Electrical Systems A - Starting System B - Ignition System C - Charging System D - Instrumentation E - Electrical Kits F - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery Systems and Fuel Pumps B - Weber 4 Barrel Carburetor C - Electronic Fuel Injection (Throttle Body and Multi-Port Injection) Section 6 - Cooling System A - Seawater Cooled Models B - Closed Cooled Models Section 7 - Exhaust System A - General B - Manifold and Elbows C - Risers D - Collectors Section 8 - Drives A - Velvet Drive In-Line Transmission B - Velvet Drive V-Drive Transmission C - Hurth Down Angle Transmission D - Hurth V-Drive Transmission E - Drive Shaft Models/Propeller Shaft Section 9 - Power Steering A - Pump

A 1 IMPORTANT INFORMATION GENERAL INFORMATION

1A-0 - GENERAL INFORMATION 90-823224--2 796 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 Locations 1A-4 . . . . . . . . . . . Propeller Information 1A-4 . . . . . . . . . . . . . . . . . . . . . Water Testing New Engines 1A-4 . . . . . . . . . . . . . . . Boat and Engine Performance 1A-5 . . . . . . . . . . . . . Boat Bottom 1A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . Marine Fouling 1A-6 . . . . . . . . . . . . . . . . . . . . . . . . Weight Distribution 1A-6 . . . . . . . . . . . . . . . . . . . . Water in Boat 1A-7 . . . . . . . . . . . . . . . . . . . . . . . . . Elevation and Climate 1A-7 . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION - 1A-1 90-823224--2 796 Introduction This comprehensive overhaul and repair manual is designed as a service guide for the models previous- ly listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines. Before attempting repairs or tune-up, it is suggested that the procedure first be read through to gain knowl- edge of the methods and tools used and the cautions and warnings required for safety. How to Use This Manual This manual is divided into sections which represent major components and systems. Some sections are further divided into parts which more fully describe the component. Sections and section parts are listed on the “Service Manual Outline” page following “V-8 Models Covered in This Manual” page. Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. 72426

1A-2 - GENERAL INFORMATION 90-823224--2 796 How To Read Parts Manual 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. PART NO. REF. NO. DESCRIPTION QUAN. a A. Part Number: For part ordering - Note N.S.S. for Reference Number 2, Plug, expansion - that means Not Sold Sepa- rately 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 thru 14, are at the left side of the column. Description of Part for Ref. Nos. 2 thru 7 are indented under “Cylinder Block Assembly”. If Ref. No. 1 (Cylinder Block Assembly) was ordered, all indented parts (Ref. Nos 2thru 7) would come with the part. Ref. Nos. 8 thru 14 would not come with Ref. No. 1 and would have to be ordered separately. If 2 Cylinder Blocks were listed, both cylinder blocks would come with the indented parts. In some cases, an indented part will have anoth er 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. Rota tion, 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. M0033-D8 b c d e CYLINDER BLOCK AND CAMSHAFT

Mercruiser GM 454 502 7.4 8.2 Engines Complete Workshop Service Repair Manual

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