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MerCruiser 1998-2013 Clymer Stern Drive Boat Engine Repair Manual

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Description

This Clymer MerCruiser 1998-2013 Stern Drive Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1998-2013 MerCruiser Alpha, Bravo One, Bravo Two, and Bravo Three MerCruiser Stern Drive engines.

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Includes general information on each model, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, storage, winterizing, adjustments, engine, fuel system, exhaust and cooling systems, electrical and ignition systems, drive unit and propeller, transom assembly, trim and tilt systems, steering system, corrosion control and complete wiring diagrams. Features 528 illustrates pages.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Warnings, cautions and notes, Engine operation, Torque specifications, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers

CHAPTER TWO, TOOLS AND TECHNIQUES

Safety, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques

CHAPTER THREE, TROUBLESHOOTING

Preliminary inspection, Engine and drive identification, Drive unit identification, Starting system, Ignition system, Spark test, Knock control test, Shift interrupt switch test, Battery charging system, Fuses, circuit breaker and wire harness, Fuel system, Oil pressure switch test, Carburetor, Electronic fuel injection, Trouble codes, Idle air control motor test, Warning system, Engine mechanical, Cooling system, Drive unit, Trim system, Power steering, Mercathode system

CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP

Before each use, After each use, Lubrication, Periodic inspection, Heat exchanger cleaning, Pressure cap test, Coolant test, Clamps and fittings, Fuel requirements, Flame arrestor, PVC valve, Carburetor or throttle body, Throttle and shift cable, Tune-up

CHAPTER FIVE, LAY-UP, WINTERIZING AND FITTING OUT

Lay-up, Winterizing, Testing the coolant, Fitting out

CHAPTER SIX, ADJUSTMENTS

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

CHAPTER SEVEN, ENGINE

Special tools, Replacement parts, Service precautions, Engine alignment, Valve adjustment, Placing the No. 1 piston at TDC, Camshaft lobe lift, Cylinder head, Pushrod, rocker arm and rocker arm cover, Engine removal and installation, 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 procedure

CHAPTER EIGHT, FUEL SYSTEM

Gaskets, seals and O-rings, Carburetor inspection, Carburetor, Cool fuel system, Boost pump removal and 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, Intake manifold

CHAPTER NINE, 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

CHAPTER TEN, ELECTRICAL AND IGNITION SYSTEMS

Battery, 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

CHAPTER ELEVEN, DRIVE UNIT AND PROPELLER

Alpha drive, Bravo drive, Drive ratio identification, Propeller, Drive unit removal and installation, Water pump, Gearcase, Bravo I and II, Bravo III drive, Drive shaft housing, Drive shaft unit inspection

CHAPTER TWELVE, TRANSOM ASSEMBLY

Gimbal bearing, Shift cable replacement, Trim limit switch and trim sender, Water hose replacement, 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

CHAPTER THIRTEEN, 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

CHAPTER FOURTEEN, STEERING SYSTEM

Safety precautions, Mechanical steering system, Power steering, Power steering pump

CHAPTER FIFTEEN, CORROSION CONTROL SYSTEM

Anodes, Ground wires, Mercathode electrode

CHAPTER SIXTEEN, SUPPLEMENT

INDEX

WIRING DIAGRAMS

Additional information

Weight 3.35 lbs
Dimensions 8 × 12 × 1 in
ISBN

9780892879144