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Number 25 MARINE ENGINES GM V-6 262 CID (4.3L) Printed in U.S.A.  1999, Mercury

Number 25

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

MARINE ENGINES

GM V-6 262 CID (4.3L)

Printed in U.S.A.

1999, Mercury Marine

90-861328--1

1199

i

MerCruiser #25 GM V-6

262 CID (4.3L)

MerCruiser #25 GM V-6

262 CID (4.3L)

90-861328--1

90-861328--1

Notice

Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the In-

) are used to alert the mechanic to special instructions con-

cerning 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.

ternational HAZARD Symbol

accident prevention measures. ternational HAZARD Symbol DANGER DANGER - Immediate hazards which WILL result in
DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death.

DANGER

DANGER - Immediate hazards which WILL result in severe personal injury or death.

DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury

WARNING

WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or

WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death.

CAUTION Hazards or unsafe practices which could result in minor personal injury or product or

CAUTION

Hazards or unsafe practices which could result in minor personal injury or product or property

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 prod- ucts, 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 recom- mended 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.

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 met- ric 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 automo- tive parts within a short period of time.

Failure to use recommended Quicksilver service replacement parts can result in poor en- gine 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 replace- ment parts.

Replacement Parts

WARNING Electrical, ignition and fuel system components on MerCruiser Engines and Stern- drives are designed

WARNING

Electrical, ignition and fuel system components on MerCruiser Engines and Stern- drives are designed and

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 ig- nition component opening would permit sparks to ignite fuel vapors from fuel sys- tem leaks, if they existed.

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 - Mercarb2 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

Important Information

Removal and Installation

Engine

Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives

Electrical Systems

Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives

Fuel Systems

Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives

Cooling System

Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives

Exhaust System

Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives

Drives

Power Steering System

1

2

3

4

5

6

7

8

9

Table of Contents

IMPORTANT INFORMATION

Section 1A - General Information

Introduction How to Use

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This Manual

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Page

Numbering

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1A-2

1A-2

1A-2

. Water Testing New Engines

Propeller Information

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. Boat and Engine Performance

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1A-5

1A-6

1A-6

How to Read a Parts Manual Directional References

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1A-3

Boat Bottom

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1A-6

 

1A-4

Marine

Fouling

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1A-7

Engine

Rotation

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1A-4

Weight

Distribution

1A-8

Engine

Serial Number

Location

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1A-5

. Elevation and Climate

Water in Boat

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1A-9

1A-9

 

Section 1B - Maintenance

 

. Lubricants / Sealants / Adhesives Maintenance Schedules Maintenance Intervals

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Tools

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1B-2

1B-2

Closed Cooling System

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Checking Coolant Level

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1B-17

1B-17

 

1B-3

Flushing System

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1B-18

1B-3

Lubrication

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1B-20

Gas Sterndrive

. Scheduled Maintenance * Engine and Tune-Up Specifications

. Routine Maintenance *

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1B-3

1B-3

1B-4

Throttle Cable

. Engine Coupler / U-Joint Shaft Splines Sterndrive Drive

Shift Cable

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1B-20

1B-20

 

1B-5

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1B-21

MCM

(Sterndrive)

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1B-5

 

Fluid Capacities

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1B-6

Shaft

Extension Models

1B-22

Sterndrive Engines

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1B-6

Cleaning

Flame

Arrestor

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1B-22

Sterndrives

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1B-6

Top Mounted

Flame Arrestor

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1B-23

20-Hour Break-In Period

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1B-7

. Component Location Serpentine Belt Routing

Serpentine Drive Belt

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1B-23

After Break-in Period

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1B-7

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1B-23

End of First Season

Checkup

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1B-7

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1B-24

Specifications

. Fuel Recommendations

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1B-8

1B-8

S/N

S/N

0L619083

0L619084

and

and

Below

Above

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1B-24

1B-25

Test For Alcohol Content In Gasoline

. Coolant for Closed Cooling System

Power Steering Fluid

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1B-10

1B-10

1B-10

. Replacing and/or Adjusting Tension .

Inspection

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Ignition Timing

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1B-26

1B-26

1B-27

Crankcase Oil

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1B-11

Thunderbolt V Models

1B-27

Overfilled

Crankcase Oil

1B-11

EFI

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1B-28

Checking Engine Oil Level / Filling

 

1B-12

Cold Weather or Extended Storage

 

1B-29

Changing

Oil and

Filter

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1B-12

Precautions

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1B-29

Changing Water Separating Fuel Filter .

1B-13

Power Package Layup

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1B-31

Power Steering System Checking Fluid Level

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1B-15

Draining

Instructions

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1B-33

 

1B-15

Draining

Sterndrive

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1B-38

. Filling and Bleeding

Engine Cold

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1B-15

1B-16

Recommissioning

1B-39

Section 1C - Troubleshooting

. Used Spark Plug Analysis Normal Condition

Precautions

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Chipped Insulator

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Cold Fouling

Overheating

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1C-2

1C-3

1C-3

1C-3

Poor Fuel Economy

. Engine Runs Poorly At High RPM

Engine

Engine

Poorly

Runs

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at Idle

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Acceleration

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1C-14

1C-14

1C-15

1C-16

Wet Fouling (Oil Deposits)

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1C-4

1C-4

1C-4

. Troubleshooting with Vacuum Gauge

Engine Noise

. Important Information

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1C-16

1C-17

1C-17

. High Speed Glazing

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1C-5

Valve Cover Area

1C-17

Scavenger Deposits

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1C-5

Cylinder Area

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1C-18

Pre-Ignition Damage

Reversed Coil Polarity

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1C-5

1C-6

Camshaft Area

Crankshaft Area

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1C-18

1C-19

 

1C-6

Miscellaneous

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1C-20

Splashed Deposits Mechanical Damage

. Poor Boat Performance and/or Poor Maneuverability

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1C-6

1C-7

Oil Pressure

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Miscellaneous

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1C-21

1C-21

1C-22

Improper Full Throttle Engine RPM

 

1C-8

High Oil Pressure

1C-22

RPM

Too

High

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1C-8

Excessive Oil Consumption

1C-23

RPM

Too

Low

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1C-8

Water In Engine

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1C-24

Engine Cranks Over But Will Not Start

 

Important Information

Water

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1C-24

Or

Starts

Hard

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1C-9I

on Top of Pistons

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1C-25

mportant Information

 

1C-9

Water

in Crankcase Oil

1C-25

Thunderbolt V Ignition (No Spark)

1C-10

Engine Overheats

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1C-26

Testing Thunderbolt V Ignition System 1C-10

Mechanical

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1C-26

Fuel

System

Rich

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1C-11

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1C-27

Fuel

System

Lean

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Miscellaneous Engine Will Not Crank Over

. Charging System Inoperative

Instrumentation Malfunction

Radio Noise

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1C-11

1C-11

1C-12

1C-12

Engine Overheats Cooling System

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. Insufficient Water Flow from Belt Driven Seawater Pickup Pump .

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Power Steering

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1C-27

1C-28

1C-29

Noisy Alternator

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1C-13

1C-13

1C-13

Poor, Erratic

Noisy Pump

Fluid Leaks

. or No Assist . .

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1C-29

1C-30

1C-30

REMOVAL AND INSTALLATION

Section 2A - MCM Models

Torque Specifications

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2A-2

. Lubricants / Sealants / Adhesives

Tools

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2A-2

2A-2

Removal

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2A-3

Installation

and

Alignment

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2A-5

. Electrical Connections

Engine Connections

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2A-10

2A-11

. Mercathode Connections

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2A-12

Shift Cable Installation

Power Steering Connections

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2A-12

2A-12

. Throttle Cable Installation and

Fuel Supply Connections

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2A-13

Adjustment

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2A-14

ENGINE

Section 3A - 262 cid (4.3L) Engines

Torque Specifications

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3A-2

Removal

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3A-62

Lubricants / Sealants / Adhesives

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3A-4

Cleaning and Inspection

3A-63

Tools

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3A-4

Installation

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3A-63

Specifications

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3A-6

Flywheel

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3A-64

General

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3A-11

Removal

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