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MerCruiser Manual

This Clymer Stern Drive manual covers the MerCruiser Stern Drive for the years 1998-2004.

Models Included are:
MerCruiser Alpha One
MerCruiser Bravo One
MerCruiser Bravo Two
MerCruiser Bravo Three
 
Engines Included are:
3.0L (RX, RP)
4.3L (2-barrel carb.)
LJ
4-barrel carb. (LK)
Electronic Fuel Injection (LK)
5.0L (ZA)
5.7L, 350 Mag (MH)
MX 6.2 (OM)
7.4L MPI (XW)
454 Mag MPI (UA)
502 Mag MPI (HJ)
496 Mag
496 Mag HO

The MerCruiser manual by Clymer is the best owners reference book for repair and service information for your MerCruiser stern drive boat. Every MerCruiser service manual is written for the do-it-yourselfer as well as the experienced mechanic. Clymer boat repair manuals are the cheapest way to keep your MerCruiser engine running properly. Every Clymer MerCruiser service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the boat covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the owner through each service, troubleshooting and repair procedure.

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The MerCruiser manual includes the following chapter information:

GENERAL INFORMATION

TOOLS AND TECHNIQUES

TROUBLESHOOTING

LUBRICATION, MAINTENANCE AND TUNE-UP

LAY-UP, WINTERIZING AND FITTING OUT

ADJUSTMENTS
Drive belts | Trim position sender adjustment | Shift cable adjustment | Throttle cable | Ignition timing adjustment | Idle mixture and idle speed adjustment | Trim tab adjustment | Specifications

ENGINE
Removal installation | Engine alignment | Valve adjustment | Placing the No. 1 piston at TDC | Camshaft lobe lift | Cylinder head | Pushrod, rocker arm and rocker arm cover | Oil pan | Oil pump | Harmonic balancer | Timing gear cover | Timing chain and sprocket | Balance shaft | Camshaft and lifter | Piston and connecting rod | Crankshaft and rear main seal | Break-in | Specifications

FUEL SYSTEM
Carburetor | Cool fuel system | Boost pump removal installation (496 Mag and 496 Mag HO) | Throttle body TBI | Fuel rail and injectors | Air pressure sensor | Engine temperature sensor | Air temperature sensor | Fuel pressure sensor | Throttle position sensor | Knock sensor module | Idle air control motor | Manifold temperature sensor | Camshaft position sensor | Crankshaft position sensor | System relay and fuel pump relay | Engine control unit ECU | Manifold | Specifications

EXHAUST AND COOLING SYSTEM
Exhaust elbow | Exhaust flapper valve | Exhaust manifold | Water rail | Heat exchanger | Engine circulating pump | Thermostat and housing | Seawater pump | Coolant reservoir | Specifications

ELECTRICAL AND IGNITION SYSTEMS
Starting system | Ignition system | Warning system | Oil pressure sender | Oil pressure switch | Overheat switch | Engine temperature sensor | Engine temperature sender | Gearcase lubricant monitor | Water pressure sensor | Charging system | Specifications

DRIVE UNIT AND PROPELLER
Alpha drive | Bravo drive | Drive ratio identification | Propeller | Drive unit removal installation | Water pump | Gearcase | Bravo I II III models | Drive shaft housing | Drive shaft unit inspection | Specifications

TRANSOM ASSEMBLY
Gimbal bearing | Shift cable | Trim limit switch and trim sender | Water hose | Bell housing | Gearcase lubricant hose and fitting | Exhaust bellows | Exhaust tube | Universal joint bellows | Speedometer hose and fitting | Gimbal ring, swivel shaft and steering lever | Inner transom plate | Transom assembly | Specifications

TRIM AND TILT SYSTEM
Relieving system pressure | Trim pump | Fluid reservoir | Trim motor | Hydraulic pump and pump adapter | Hydraulic trim cylinder and anchor pins | External hoses | Terminal block | Internal hose | Filling and bleeding the system | Specifications

STEERING SYSTEM
Safety precautions | Mechanical steering system | Power steering | Power steering pump | Specifications

CORROSION CONTROL SYSTEM
Anodes | Ground wires | Mercathode electrode | Specifications

SUPPLEMENT

INDEX

WIRING DIAGRAMS

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The MerCruiser manual by Clymer is the best reference book for repair and service information for your boat.

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Publisher: Clymer Manuals — 2001-2004
Pages: 604 — Hundreds of b&w photos and illustrations

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The MerCruiser service and repair manual applies to the following years:
1998, 1999, 2000, 2001, 2002, 2003, 2004

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Please note that this digital version is accessed online in zmag format. It remains available to the purchaser indefinitely via the internet but it cannot be printed or downloaded to your computer