Mercury Mercruiser Stern Drive (mcm) Alpha And Bravo 262 C.i. 4.3l Mpi Cd #32

US $9.97

MONTREAL CANADA, Canada
Jan 30th

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Mercury Mercruiser Service Manual , Stern Drive (MCM) Alpha and bravo Engines 4.3L MPI Full Service Repair Manual #32 , 500 plus pages !! 4.3L MPI GASOLINE ENGINE SN 0M322781 and ABOVE please note: this is a mailed computer cd-rom and not printed material at this low price !!! This manual is Crystal Clear OEM and not a scanned manual, so no worries about the quality sample snap below details scroll all the way to the bottom to see!! just print off what you need on your own computer !!! 510 pages and 137 MB of very well detailed easy to read troubleshooting, rebuilding, servicing, maintenance and repair information complete with many charts, diagrams, schematics, specifications and pictures. email me if you need this asap: Content as follows: 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 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 Anodes . . 1B-28 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . 1B-31 Lubricants / Sealants / Adhesives . . . . . 1B-3 Power Package Surfaces . . . . . . . . . . . . . 1B-32 Engine And Tune-Up Specifications . . . . 1B-4 Painting Your Power Package . . . . . . 1B-32 MCM (Sterndrive) Models . . . . . . . . . . 1B-4 Battery . . . 1B-33 Fluid Specifications . . . . . . . . . . . . . . . . . . 1B-5 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . 1B-33 Engines . . . . . . . . . . . . 1B-5 Gimbal Ring / Steering Connection . . . . 1B-33 Sterndrives . . . . . . . . . . . . . . . . . . . . . . 1B-5 Changing Water Separating Fuel Filter . 1B-34 Maintenance Schedules . . . . . . . . . . . . . . 1B-6 Steering System . . . . . . . . . . . . . . . . . . . . 1B-35 Maintenance Intervals . . . . . . . . . . . . . 1B-6 Remote Control. . . . . . . . . . . . . . . . . . . . . 1B-35 Routine Maintenance . . . . . . . . . . . . . 1B-7 Sterndrive Components . . . . . . . . . . . . . . 1B-35 Scheduled Maintenance . . . . . . . . . . 1B-8 Lubrication . . . . . . . . . . . . 1B-35 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . 1B-10 Throttle Cable . . . . . . . . . . . . . . . . . . . . 1B-35 Overfilled Crankcase Oil. . . . . . . . . . . 1B-11 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . 1B-36 Checking . . . . . . . . . . . 1B-11 Sterndrive Components . . . . . . . . . . . 1B-36 Filling . 1B-12 Continuity Circuit . . . . . . . . . . . . . . . . . . . . 1B-41 Changing Oil and Filter . . . . . . . . . . . . 1B-13 MerCathode . 1B-43 Flushing The Power Package - MCM . . 1B-15 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . 1B-43 Sterndrive Water Pickups . . . . . . . . . . 1B-15 Electrical System . . . . . . . . . . . . . . . . . . . . 1B-43 Alternative Water Pickups . . . . . . . . . . 1B-17 Cleaning Flame Arrestor . . . . . . . . . . . . . 1B-44 Sterndrive Unit Oil. . . . . . . . . . . . . . . . . . . 1B-19 Serpentine Drive Belt . . . . . . . . . . . . . . . . 1B-45 Checking . . . . . . . . . . . 1B-19 Sterndrive Models . . . . . . . . . . . . . . . . 1B-45 Filling . 1B-19 Inspection . . . . . . . . . . 1B-45 Changing . . . . . . . . . . . 1B-20 Replacing Belt and/or Power Trim Pump Fluid . . . . . . . . . . . . . . 1B-22 Adjusting Tension . . . . . . . . . . . . . . . . 1B-46 Checking . . . . . . . . . . . 1B-22 Exhaust System . . . . . . . . . . . . . . . . . . . . . 1B-47 Filling . 1B-22 Seawater Pump . . . . . . . . . . . . . . . . . . . . . 1B-47 Changing . . . . . . . . . . . 1B-22 Cold Weather And Extended Storage . . 1B-48 Power Steering Pump Fluid . . . . . . . . . . . 1B-23 Preparing Your Power Package Checking . . . . . . . . . . . 1B-23 For Storage . . . . . . . . . . . . . . . . . . . . . 1B-48 Filling and Bleeding . . . . . . . . . . . . . . . 1B-24 Draining Instructions . . . . . . . . . . . . . . . . . 1B-50 Water Inlets . . . . . . . . . . . . . . . . . . . . . . . . 1B-26 Identification . . . . . . . . . . . . . . . . . . . . . 1B-51 Seawater Strainer . . . . . . . . . . . . . . . . 1B-26 Boat In The Water . . . . . . . . . . . . . . . . 1B-52 Closed Cooling System . . . . . . . . . . . . . . 1B-27 Boat Out Of The Water . . . . . . . . . . . . 1B-56 Checking Coolant Level . . . . . . . . . . . 1B-27 All Models . . . . . . . . . . 1B-59 Cleaning and Inspection . . . . . . . . . . . 1B-27 Changing Coolant . . . . . . . . . . . . . . . . 1B-27 IMPORTANT INFORMATION Section 1C - Troubleshooting Used Spark Plug Analysis . . . . . . . . . . . . 1C-2 Charging System Inoperative . . . . . . . . . 1C-12 Normal Condition . . . . . . . . . . . . . . . . . 1C-2 Noisy Alternator . . . . . . . . . . . . . . . . . . . . . 1C-13 Chipped Insulator . . . . . . . . . . . . . . . . . 1C-3 Instrumentation Malfunction . . . . . . . . . . 1C-13 Wet Fouling (Oil Deposits) . . . . . . . . . 1C-3 Radio Noise . 1C-13 Cold Fouling . . . . . . . . . . . . . . . . . . . . . 1C-4 Poor Fuel Economy . . . . . . . . . . . . . . . . . 1C-14 Overheating . . . . . . . . . . . . . . . . . . . . . . 1C-4 Engine Runs Poorly at Idle . . . . . . . . . . . 1C-15 High Speed Glazing . . . . . . . . . . . . . . . 1C-5 Engine Runs Poorly At High RPM . . . . . 1C-16 Scavenger Deposits . . . . . . . . . . . . . . . 1C-5 Engine Acceleration Is Poor . . . . . . . . . . 1C-17 Pre-Ignition Damage . . . . . . . . . . . . . . 1C-6 Troubleshooting with Vacuum Gauge . . 1C-17 Reversed Coil Polarity . . . . . . . . . . . . . 1C-6 Engine Noise 1C-18 Splashed Deposits . . . . . . . . . . . . . . . . 1C-7 Important Information . . . . . . . . . . . . . 1C-18 Mechanical Damage . . . . . . . . . . . . . . 1C-7 Oil Pressure . 1C-24 Poor Boat Performance And/Or Excessive Oil Consumption . . . . . . . . . . . 1C-27 Poor Maneuverability . . . . . . . . . . . . . . . . 1C-8 Water In The Engine . . . . . . . . . . . . . . . . . 1C-28 Improper Full Throttle Engine RPM . . . . 1C-10 Important Information . . . . . . . . . . . . . 1C-28 Engine Cranks Over But Will Not Start Engine Overheats (Mechanical) . . . . . . . 1C-30 Or Starts Hard . . . . . . . . . . . . . . . . . . . . . . 1C-11 Power Steering . . . . . . . . . . . . . . . . . . . . . 1C-33 Important Information . . . . . . . . . . . . . 1C-11 Drain System Will Not Drain Or Drains Engine Will Not Crank Over. . . . . . . . . . . 1C-12 Slowly . . 1C-35 REMOVAL AND INSTALLATION Section 2A - MCM Models Torque Specifications . . . . . . . . . . . . . . . . 2A-2 Fluid Connections . . . . . . . . . . . . . . . . . . . 2A-18 Lubricants / Sealants / Adhesives . . . . . 2A-3 Fuel . . . 2A-18 Special Tools 2A-4 Gear Lube Monitor Hose . . . . . . . . . . 2A-19 Removal . 2A-5 Power Steering Hoses . . . . . . . . . . . . . 2A-20 Engine Installation . . . . . . . . . . . . . . . . . . . 2A-8 Bravo Models and Electrical Connections . . . . . . . . . . . . . . . 2A-13 Alpha Seawater Cooled Models EFI Electrical System Precautions . . 2A-13 Using Sterndrive Water Pickups . . . . 2A-21 Installing Continuity Wire . . . . . . . . . . 2A-14 Alpha or Bravo Models Instrumentation Connections . . . . . . . 2A-14 Using Alternative Water Pickups . . . 2A-21 Trim Position Sender Connections . . 2A-15 Coolant Recovery Bottle . . . . . . . . . . . 2A-24 MerCathode Connections . . . . . . . . . . 2A-16 Shift Cable Installation . . . . . . . . . . . . . . . 2A-25 Audio Warning Alarm Connections . . 2A-17 Alpha Models - Power Trim Pump Connections . . . . . 2A-17 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 ENGINE MECHANICAL Section 3A - 4.3 liter (262 cid) Identification . . . . . . . . . . . 3A-3 Hydraulic Valve Lifters . . . . . . . . . . . . . . . 3A-39 General Specifications . . . . . . . . . . . . . . . 3A-4 Exploded View . . . . . . . . . . . . . . . . . . . 3A-39 4.3 liter (262 cid) . . . . . . . . . . . . . . . . . 3A-4 Special Information . . . . . . . . . . . . . . . 3A-39 Engine Specifications - 4.3 liter (262 cid) 3A-5 Removal . . . . . . . . . . . . 3A-40 Cylinder Head . . . . . . . . . . . . . . . . . . . . 3A-5 Cleaning . . . . . . . . . . . . 3A-41 Cylinder Bore . . . . . . . . . . . . . . . . . . . . 3A-5 Inspection . . . . . . . . . . 3A-41 Oil Pump . . . . . . . . . . . 3A-5 Installation . . . . . . . . . . 3A-42 Piston Bore Clearance . . . . . . . . . . . . 3A-5 Camshaft and Camshaft Bearings . . . . . 3A-43 Piston Rings . . . . . . . . . . . . . . . . . . . . . 3A-6 Measuring Camshaft Lobe Lift . . . . . . 3A-43 Piston Pin . . . . . . . . . . 3A-6 Removal . . . . . . . . . . . . 3A-45 Crankshaft 3A-7 Cleaning . . . . . . . . . . . . 3A-49 Connecting Rod . . . . . . . . . . . . . . . . . . 3A-8 Inspection . . . . . . . . . . 3A-50 Valve . . 3A-8 Installation . . . . . . . . . . 3A-51 Valve (continued) . . . . . . . . . . . . . . . . . 3A-9 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 3A-58 Camshaft . 3A-10 Removal . . . . . . . . . . . . 3A-58 Timing Chain . . . . . . . . . . . . . . . . . . . . . 3A-10 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-59 Flywheel . . . . . . . . . . . . 3A-10 Cleaning . . . . . . . . . . . . 3A-60 Torque Specifications . . . . . . . . . . . . . . . . 3A-11 Inspection . . . . . . . . . . 3A-61 Special Tools 3A-15 Repair . 3A-66 Lubricants / Sealants / Adhesives . . . . . 3A-16 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-69 Precautions . 3A-18 Installation . . . . . . . . . . 3A-73 General Information . . . . . . . . . . . . . . . . . 3A-19 Oil Pan . . 3A-75 Repair Procedures . . . . . . . . . . . . . . . . 3A-19 Removal . . . . . . . . . . . . 3A-75 Special Notice . . . . . . . . . . . . . . . . . . . . 3A-19 Cleaning . . . . . . . . . . . . 3A-76 Engine Rotation . . . . . . . . . . . . . . . . . . 3A-19 Inspection . . . . . . . . . . 3A-76 Crankcase Oil Dipstick Measurements 3A-20 Installation . . . . . . . . . . 3A-76 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . 3A-21 Oil Pump . 3A-78 Exploded Views . . . . . . . . . . . . . . . . . . 3A-21 Exploded View . . . . . . . . . . . . . . . . . . . 3A-78 Valve Cover . 3A-22 Removal . . . . . . . . . . . . 3A-79 Removal . . . . . . . . . . . . 3A-22 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-79 Cleaning and Inspection . . . . . . . . . . . 3A-22 Cleaning . . . . . . . . . . . . 3A-80 Installation . . . . . . . . . . 3A-23 Inspection . . . . . . . . . . 3A-81 Rocker Arm / Valve Pushrod . . . . . . . . . . 3A-24 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-82 Removal . . . . . . . . . . . . 3A-24 Installation . . . . . . . . . . 3A-84 Cleaning . . . . . . . . . . . . 3A-25 Crankshaft Balancer . . . . . . . . . . . . . . . . . 3A-85 Inspection . . . . . . . . . . 3A-25 Removal . . . . . . . . . . . . 3A-85 Installation . . . . . . . . . . 3A-26 Cleaning . . . . . . . . . . . . 3A-85 Valve Stem Oil Seal / Valve Spring - Inspection . 3A-85 Cylinder Head Installed . . . . . . . . . . . . . . 3A-28 Installation . . . . . . . . . . 3A-86 Exploded View . . . . . . . . . . . . . . . . . . . 3A-28 Front Cover Oil Seal. . . . . . . . . . . . . . . . . 3A-88 Removal . . . . . . . . . . . . 3A-29 Oil Seal Replacement Installation . . . . . . . . . . 3A-30 Without Removing Front Cover . . . . 3A-88 Intake Manifold Assembly . . . . . . . . . . . . 3A-33 Front Cover . 3A-89 Exploded View . . . . . . . . . . . . . . . . . . . 3A-33 Removal . . . . . . . . . . . . 3A-89 Removal . . . . . . . . . . . . 3A-34 Cleaning and Inspection . . . . . . . . . . . 3A-90 Cleaning . . . . . . . . . . . . 3A-35 Installation . . . . . . . . . . 3A-90 Inspection . . . . . . . . . . 3A-35 Upper And Lower Intake Manifolds. . 3A-36 Installation . . . . . . . . . . 3A-36 Section 3A - Engine Mechanical (continued) Connecting Rod, Bearings Flywheel . 3A-153 and Piston Assembly . . . . . . . . . . . . . . . . 3A-92 Removal . . . . . . . . . . . . 3A-153 Exploded View . . . . . . . . . . . . . . . . . . . 3A-92 Cleaning and Inspection . . . . . . . . . . . 3A-154 Removal. . . . . . . . . . . . . . . . . . . . . . . . . 3A-93 Installation . . . . . . . . . . 3A-154 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-95 Rear Oil Seal. . . . . . . . . . . . . . . . . . . . . . . 3A-156 Cleaning . . . . . . . . . . . . 3A-95 Removal . . . . . . . . . . . . 3A-156 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-96 Cleaning . . . . . . . . . . . . 3A-156 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-111 Inspection . . . . . . . . . . 3A-156 Installation . . . . . . . . . . 3A-114 Installation . . . . . . . . . . 3A-157 Crankshaft, Main Bearings Rear Oil Seal Retainer 3A-159 and Engine Block . . . . . . . . . . . . . . . . . . . 3A-118 Removal . . . . . . . . . . . . 3A-159 Exploded View . . . . . . . . . . . . . . . . . . . 3A-118 Cleaning . . . . . . . . . . . . 3A-159 Removal. . . . . . . . . . . . . . . . . . . . . . . . . 3A-119 Inspection . . . . . . . . . . 3A-159 Cleaning . . . . . . . . . . . . 3A-123 Installation . . . . . . . . . . 3A-160 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-125 Oil Filter By-Pass Valve and Installation . . . . . . . . . . 3A-137 Block Adapter . . . . . . . . . . . . . . . . . . . . . . 3A-161 Timing Chain And Sprockets . . . . . . . . . . 3A-147 Exploded View . . . . . . . . . . . . . . . . . . . 3A-161 Removal. . . . . . . . . . . . . . . . . . . . . . . . . 3A-147 Removal . . . . . . . . . . . . 3A-162 Cleaning . . . . . . . . . . . . 3A-148 Cleaning . . . . . . . . . . . . 3A-163 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-148 Inspection . . . . . . . . . . 3A-163 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-148 Installation . . . . . . . . . . 3A-164 Installation . . . . . . . . . . 3A-150 Flywheel Housing . . . . . . . . . . . . . . . . . . . 3A-151 Removal. . . . . . . . . . . . . . . . . . . . . . . . . 3A-151 Cleaning . . . . . . . . . . . . 3A-152 Installation . . . . . . . . . . 3A-152 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-152 ELECTRICAL SYSTEM Section 4A - Starting System Identification . . . . . . . . . . . 4A-2 Lubricants / Sealants / Adhesives . . . . . 4A-5 Replacement Parts Warning . . . . . . . . . . 4A-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Precautions . 4A-2 Testing . . . . . . . . . . . . . 4A-6 Typical Starting System Components . . 4A-3 Removal . 4A-8 Positive Current Flow . . . . . . . . . . . . . . . . 4A-4 Solenoid Switch . . . . . . . . . . . . . . . . . . 4A-9 Battery . . . 4A-4 Inspection . . . . . . . . . . . . . 4A-9 Battery Cable Recommendations . . . 4A-4 Installation . . . . . . . . . . . . 4A-10 Delco PG260F1 Starter . . . . . . . . . . . . . . 4A-5 Specifications 4A-5 Starter Specifications. . . . . . . . . . . . . . 4A-5 Torque Specifications . . . . . . . . . . . . . 4A-5 ELECTRICAL SYSTEM Section 4B - Ignition System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Ignition Coil . . . . . . . . . . . . . . 4B-7 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Distributor . . . . . . . . . . . . 4B-2 Installation . . . . . . . . . . . . 4B-8 Coil . . . . . 4B-2 Distributor . . . . . . . . . . . . . . . 4B-9 Firing Order . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Torque Specifications . . . . . . . . . . . . . . . . . . 4B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . 4B-10 Lubricants / Sealants / Adhesives . . . . . . . 4B-3 Cleaning and Inspection . . . . . . . . . . . . 4B-12 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . 4B-12 Removal . . . . 4B-3 Installation . . . . . . . . . . . 4B-13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Spark Plug Wires . . . . . . . . . . . . . . . . . . . . . . 4B-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5 Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5 ELECTRICAL SYSTEM Section 4C - Charging System Delco Alternator . . . . . . . . . . . . . . . . . . . . . 4C-2 Troubleshooting Tests Identification . . . . . . . . . . . . . . . . . . . . . 4C-2 (Alternator on Engine) . . . . . . . . . . . . . . . 4C-5 Replacement Parts Warning . . . . . . . 4C-2 Charging System . . . . . . . . . . . . . . . . . 4C-6 Specifications . . . . . . . . . . . . . . . . . . . . 4C-3 Resistance 4C-7 Torque Specifications . . . . . . . . . . . . . 4C-3 Circuitry . . . . . . . . . . . . 4C-9 Special Tools . . . . . . . . . . . . . . . . . . . . . 4C-3 Removal . 4C-11 Precautions . 4C-4 Alternator . . . . . . . . . . . 4C-11 EFI Electrical System Precautions . . 4C-4 Alternator Bracket . . . . . . . . . . . . . . . . 4C-11 Charging System Components . . . . . . . . 4C-5 Installation . . . . . . . . . . . . 4C-12 Periodic Maintenance . . . . . . . . . . . . . . . . 4C-5 Alternator Bracket . . . . . . . . . . . . . . . . 4C-12 Alternator . . . . . . . . . . . 4C-12 Battery Isolator Diagram . . . . . . . . . . . 4C-14 ELECTRICAL SYSTEM Section 4D - Wiring Diagrams Instrumentation . . . . . . . . . . . . . . . . . . . . . 4D-2 MerCathode System Wiring Diagram . . 4D-5 Single Station Installations - Typical . 4D-2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 4D-6 Power Trim System . . . . . . . . . . . . . . . . . . 4D-4 FUEL SYSTEM Section 5A - Fuel Delivery System Specifications 5A-2 Water Separating Fuel Filter . . . . . . . . . . 5A-19 Torque Specifications . . . . . . . . . . . . . . . . 5A-2 Removal . . 5A-20 Special Tools 5A-3 Installation 5A-20 Lubricants / Sealants / Adhesives . . . . . 5A-3 Cool Fuel System . . . . . . . . . . . . . . . . . . . 5A-20 Replacement Parts Warning . . . . . . . . . . 5A-3 Removal . . 5A-20 Abbreviations 5A-4 Disassembly . . . . . . . . . . . . . . . . . . . . . 5A-22 Precautions . 5A-5 Reassembly . . . . . . . . . . . . . . . . . . . . . 5A-24 Fuel Supply Connections . . . . . . . . . . . . . 5A-5 Installation 5A-28 Fuel Delivery System . . . . . . . . . . . . . . . . 5A-6 Intake Manifold . . . . . . . . . . . . . . . . . . . . . 5A-29 Recommendations . . . . . . . . . . . . . . . . 5A-6 Removal . . 5A-29 Exploded Views . . . . . . . . . . . . . . . . . . . . . 5A-7 Disassembly . . . . . . . . . . . . . . . . . . . . . 5A-31 Fuel Rail and Injectors . . . . . . . . . . . . . 5A-7 Cleaning and Inspection . . . . . . . . . . . 5A-36 Throttle Body. . . . . . . . . . . . . . . . . . . . . 5A-8 Assembly . 5A-36 Cool Fuel System . . . . . . . . . . . . . . . . . 5A-9 Installation 5A-39 Fuel System Flow Diagrams . . . . . . . . . . 5A-10 Sensors . . . . . 5A-43 Sensor Locations . . . . . . . . . . . . . . . . . . . . 5A-11 Manifold Air Pressure / Temperature Fuel Pressure Relief Procedure . . . . . . . 5A-13 (MAPT) Sensor . . . . . . . . . . . . . . . . . . 5A-43 Throttle Position Sensor (TPS) . . . . . 5A-44 Idle Air Control (IAC) Valve . . . . . . . . . 5A-46 Flame Arrestor . . . . . . . . . . . . . . . . . . . . . . 5A-13 Knock Sensor . . . . . . . . . . . . . . . . . . . . 5A-47 Removal . . 5A-13 Oil Pressure Sensor. . . . . . . . . . . . . . . 5A-48 Oil Pressure Switch . . . . . . . . . . . . . . . 5A-49 Fuel Pump Relay . . . . . . . . . . . . . . . . . 5A-50 Main Power Relay . . . . . . . . . . . . . . . . 5A-51 Cleaning and Inspection . . . . . . . . . . . 5A-13 Installation 5A-13 Throttle Body 5A-14 Removal . . 5A-14 Cleaning and Inspection . . . . . . . . . . . 5A-16 Installation 5A-17 Electronic Control Module (ECM) . . . . . . 5A-18 Removal . . 5A-18 Cleaning and Inspection . . . . . . . . . . . 5A-18 Installation 5A-18 COOLING SYSTEM Section 6A - All Models COOLING SYSTEM Section 6B - Seawater Cooled Models COOLING SYSTEM Section 6C - Closed Cooled Models Torque Specifications . . . . . . . . . . . . . . . . 6C-2 Thermostat . . 6C-12 Lubricants / Sealants / Adhesives . . . . . 6C-2 Removal . . . . . . . . . . . . 6C-12 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Testing 6C-12 Closed Cooling System Capacity . . . 6C-2 Installation . . . . . . . . . . 6C-14 Coolant Specification . . . . . . . . . . . . . . 6C-2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 6C-15 Thermostat . . . . . . . . . . . . . . . . . . . . . . 6C-2 Testing 6C-15 Pressure Cap Rating . . . . . . . . . . . . . . 6C-2 Removal . . . . . . . . . . . . 6C-15 Description . . . . . . . . . . . . . . . . . 6C-3 Disassembly . . . . . . . . . . . . . . . . . . . . . 6C-16 Coolant Recommendations . . . . . . . . . . . 6C-3 Cleaning And Inspection . . . . . . . . . . . 6C-16 Maintaining Coolant Level. . . . . . . . . . . . 6C-4 Repair . 6C-16 Pressure Cap Maintenance . . . . . . . . . . . 6C-5 Assembly . 6C-17 Testing Closed Cooling System . . . . . . . 6C-6 Installation . . . . . . . . . . 6C-18 Testing Coolant for Alkalinity . . . . . . . 6C-6 Heat Exchanger Bracket Hardware . . . . 6C-19 Pressure Testing System . . . . . . . . . . 6C-7 Heat Exchanger Hose Connections . . . . 6C-20 Testing for Cylinder Head Closed Cooling System Water Flow Gasket Leak . . . . . . . . . . . . . . . . . . . . . 6C-9 Diagram . 6C-21 Testing Pressure Cap . . . . . . . . . . . . . 6C-10 Page xii 90-864261 NOVEMBER 2001 Torque Specifications . . . . . . . . . . . . . . . . 6A-2 Lubricants / Sealants / Adhesives . . . . . 6A-2 Seawater Inlet Recommendations . . . . . 6A-3 Seacock (Seawater Inlet Valve) . . . . . 6A-3 Seawater Strainer . . . . . . . . . . . . . . . . 6A-3 Seawater Pickups . . . . . . . . . . . . . . . . . . . 6A-4 Through the Hull Mounted . . . . . . . . . 6A-4 Transom Mounted . . . . . . . . . . . . . . . . 6A-6 Quicksilver Sea Strainer. . . . . . . . . . . . . . 6A-8 Removal . . 6A-8 Cleaning and Inspection . . . . . . . . . . . 6A-9 Installation 6A-10 Auxiliary Hot Water Heater Installation . 6A-11 Supply Hose Connection . . . . . . . . . . 6A-11 Return Hose Connection . . . . . . . . . . . 6A-12 Seawater Pump . . . . . . . . . . . . . . . . . . . . . 6A-12 Output Test . . . . . . . . . . . . . . . . . . . . . . 6A-12 Removal . . 6A-14 Disassembly . . . . . . . . . . . . . . . . . . . . . 6A-15 Cleaning and Inspection . . . . . . . . . . . 6A-16 Reassembly . . . . . . . . . . . . . . . . . . . . . 6A-16 Installation 6A-19 Water Circulating Pump . . . . . . . . . . . . . . 6A-20 Removal . . 6A-20 Cleaning and Inspection . . . . . . . . . . . 6A-21 Installation 6A-22 Water Distribution Housing . . . . . . . . . . . 6A-23 Removal . . 6A-23 Cleaning And Inspection . . . . . . . . . . . 6A-23 Installation 6A-23 Torque Specifications . . . . . . . . . . . . . . . . 6B-2 Lubricants / Sealants / Adhesives . . . . . 6B-2 Specifications 6B-2 Seawater Cooling System Capacity . 6B-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . 6B-2 Flushing Seawater Cooling System . . . . 6B-3 Thermostat . . 6B-3 Removal . . 6B-3 Testing . . . 6B-4 Installation 6B-5 Water Flow Diagrams . . . . . . . . . . . . . . . . 6B-6 Seawater Cooled Models With An Engine Mounted Seawater Pump 6B-6 Seawater Cooled Models Without An Engine Mounted Seawater Pump 6B-7 EXHAUST SYSTEM Section 7A - Manifolds, Elbows And Risers Torque Specifications . . . . . . . . . . . . . . . . . . 7A-2 Lubricants / Sealants / Adhesives . . . . . . . 7A-2 Exploded View . 7A-3 Removal . . . . . . 7A-5 Cleaning and Inspection . . . . . . . . . . . . . . . . 7A-6 Manifold Leak Test . . . . . . . . . . . . . . . . . . . . 7A-7 Installation . . . . 7A-7 DRIVES Section 8A - Power Steering Pump Torque Specifications . . . . . . . . . . . . . . . . 8A-2 Lubricants / Sealants / Adhesives . . . . . 8A-2 Special Tools 8A-2 Precautions . 8A-3 Power Steering Pump And Components Exploded View . . . . . . . . . . . . . . . . . . . . . . 8A-4 Power Steering Pump Pulley Replacement . . . . . . . . . . . . . . . . . 8A-5 Removal . . 8A-5 Installation 8A-5 Power Steering Pump . . . . . . . . . . . . . . . . 8A-6 Removal . . 8A-6 Flow Control Valve Servicing . . . . . . . 8A-7 Pump Shaft Oil Seal Replacement . . 8A-8 Installation 8A-10 Replacing Belt And/Or Adjusting Tension 8A-11 Filling And Bleeding . . . . . . . . . . . . . . . . . 8A-11 Checking Fluid Level. . . . . . . . . . . . . . . . . 8A-11 Hydraulic Hoses And Fluid Cooler . . . . . 8A-12 High Pressure Hose (Pump-To-Control Valve) . . . . . . . . . . 8A-12 Low Pressure Hose (Pump-To-Fluid Cooler) . . . . . . . . . . . 8A-14 Low Pressure Hose (Control Valve-To-Fluid Cooler) . . . . 8A-16 90-864261 NOVEMBER 2001 Page xii New Page 1 ENGINE MECHANICAL Section 3A - 4.3 liter (262 cid) Identification . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . 4.3 liter (262 cid) . . . . . . . . . . . . . . . . . 3A-3 3A-4 3A-4 Hydraulic Valve Lifters . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Special Information . . . . . . . . . . . . . . . 3A-39 3A-39 3A-39 Engine Specifications - 4.3 liter (262 cid) 3A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40 Cylinder Head . . . . . . . . . . . . . . . . . . . . Cylinder Bore . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . Piston Bore Clearance . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . Piston Pin . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve (continued) . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . Repair Procedures . . . . . . . . . . . . . . . . Special Notice . . . . . . . . . . . . . . . . . . . . Engine Rotation . . . . . . . . . . . . . . . . . . 3A-5 3A-5 3A-5 3A-5 3A-6 3A-6 3A-7 3A-8 3A-8 3A-9 3A-10 3A-10 3A-10 3A-11 3A-15 3A-16 3A-18 3A-19 3A-19 3A-19 3A-19 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Camshaft Bearings . . . . . Measuring Camshaft Lobe Lift . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-41 3A-41 3A-42 3A-43 3A-43 3A-45 3A-49 3A-50 3A-51 3A-58 3A-58 3A-59 3A-60 3A-61 3A-66 3A-69 3A-73 3A-75 3A-75 3A-76 3A-76 Crankcase Oil Dipstick Measurements 3A-20 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-76 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . Exploded Views . . . . . . . . . . . . . . . . . . Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm / Valve Pushrod . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal / Valve Spring - Cylinder Head Installed . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold Assembly . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Upper And Lower Intake Manifolds . . Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-21 3A-21 3A-22 3A-22 3A-22 3A-23 3A-24 3A-24 3A-25 3A-25 3A-26 3A-28 3A-28 3A-29 3A-30 3A-33 3A-33 3A-34 3A-35 3A-35 3A-36 3A-36 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Balancer . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Front Cover Oil Seal . . . . . . . . . . . . . . . . . Oil Seal Replacement Without Removing Front Cover . . . . Front Cover . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-78 3A-78 3A-79 3A-79 3A-80 3A-81 3A-82 3A-84 3A-85 3A-85 3A-85 3A-85 3A-86 3A-88 3A-88 3A-89 3A-89 3A-90 3A-90 Page viii 90-864261 NOVEMBER 2001

Condition	New other (see details) : A new, unused item with absolutely no signs of wear. The item may be missing the original packaging, or in the original packaging but not sealed. The item may be a factory second or a new, unused item with defects. See the seller’s listing for full details and description of any imperfections.
Seller Notes	“Mailed CD, Not printed material !!!”