MerCruiser Service Manual #41 - Engines: Turn Key Start (TKS) Carburetors

Service Manual #41 90-866202 Turn Key Start Carburetor’s Supplement to #25, 26, & 31 Turn Key Start (TKS) Carburetors Supplement to #25, 26, & 31

Page i Models Covered Model Serial Number 3.0L Alpha 0W302000 4.3L Alpha 0W300013 5.0L Alpha and Bravo 0W300010 5.7L Bravo 0W300755 Notice to Users of This Manual 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 DANGER - indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. ! WARNING WARNING - indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. ! CAUTION CAUTION - indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices. This 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. We reserve the right to make changes to this manual without prior notification. © 2004, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. 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 Marine Power Products, including the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.

Page ii 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. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual. Precautions It should be kept in mind, while working on the product, that the electrical and ignition systems 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 reuse, care should be taken to select a replacement that matches the original. 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 Marine Power Products 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.

Page iii Cleanliness and Care of Product A Mercury Marine Power Product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible.

Page iv

Page v Manual Outline 1 - Important Information A - General Information B - Maintenance C - Troubleshooting 2 - Engine A - Oil Pressure Switch 3 - Electrical Systems A - Wiring Diagrams 4 - Fuel System A - TKS Carburetor B - Diagnostics 5 - Cooling Systems A - Cooling System Important Information 1 Engine 2 Electrical Systems 3 Fuel System 4 Cooling Systems 5

General Information 90-866202 DECEMBER 2004 Page 1A-1 1 A Important Information Section 1A - General Information Table of Contents Important Information.......................................1A-2 General Information..................................1A-2 How To Use This Manual.........................1A-2 Page Identification....................................1A-2 Directional References.............................1A-3

General Information Page 1A-2 90-866202 DECEMBER 2004 Important Information General Information NOTICE For information and procedures not listed, refer to the appropriate Mercury MerCruiser Service Manual. NOTICE Refer to appropriate Mercury MerCruiser Service Manual for engine assembly and repair. The following sections of supplemental information have been prepared to assist in the identification and servicing of Mercury MerCruiser Turn Key Start (TKS) systems. This supplement is intended to be used in conjunction with the appropriate Mercury MerCruiser Service Manual for your engine, and not in place of the manual. The scope of this supplement is to highlight new or different specifications, components, and procedural information as they pertain to Turn Key Start (TKS) Systems How To Use This Manual This manual is divided into sections, which represent major components and systems. Some sections are further divided into parts that more fully describe the component. Refer to the Service Manual Outline following Models Covered in this manual for section titles. Page Identification The service manual number and section title appear at the top of the page. Two number groups appear at the bottom of each page. Following is an example and a description. Page 1A-3 90-8600074-1 NOVEMBER 2004 a b c d e f g 9516 a - Section number b - Section part c - Page number d - Manual number e - Revision number (if applicable) f - Month printed g - Year printed

General Information 90-866202 DECEMBER 2004 Page 1A-3 Directional References The front of the boat is the bow; the rear is the stern. Starboard side is the right side; the port side is the left side. In this service manual supplement, all directional references are given as they appear when viewing boat from the stern, looking toward the bow. 9515 a b c d a - Fore or bow (front) b - Aft or stern (rear) c - Starboard (right) d - Port (left)

Maintenance 90-866202 DECEMBER 2004 Page 1B-1 1 B Important Information Section 1B - Maintenance Table of Contents Maintenance....................................................1B-2 Torque Specifications...............................1B-2 Special Tools............................................1B-2

MerCruiser Service Manual #41 - Engines: Turn Key Start (TKS) Carburetors

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