MerCruiser Sterndrive 5.0 MPI Manuals

Manuals and User Guides for MerCruiser Sterndrive 5.0 MPI. We have 5 MerCruiser Sterndrive 5.0 MPI manuals available for free PDF download: Service Manual, User Manual

MerCruiser Sterndrive 5.0 MPI Service Manual (895 pages)

Brand: MerCruiser | Category: Engine | Size: 12.9 MB

Important Information

6
- Marine Engines
  1
- Table of Contents
  6
- Electrical Systems
  9
- Fuel System
  11
- Cooling System
  15
- Exhaust System
  16
Section 2

19
- Table of Contents
  19
- How to Use this Manual
  20
  - Page Numbering
    20
- Introduction
  20
- How to Read a Parts Manual
  21
- Directional References
  22
- Engine Rotation
  22
- Engine Serial Number Locations
  23
  - Propeller Information
    23
  - Water Testing New Engines
    24
  - Boat and Engine Performance
    24
  - Boat Bottom
    24
  - Marine Fouling
    26
  - Weight Distribution
    27
Section 3

29
- Table of Contents
  29
- Lubricants / Sealants / Adhesives
  30
- Tools
  30
- Maintenance Schedules
  31
  - Maintenance Intervals
    31
- Engine and Tune-Up Specifications
  35
  - Fluid Capacities
    39
- 20-Hour Break-In Period
  41
- After Break-In Period
  41
- End of First Season Checkup
  41
- Specifications
  42
  - Fuel Recommendations
    42
  - Vapor Locking
    42
  - Procedure
    44
  - Test for Alcohol Content in Gasoline 1B-16
    44
- Coolant for Closed Cooling System
  44
- Power Steering Fluid
  44
- Transmission Fluid
  44
- Crankcase Oil
  45
  - Overfilled Crankcase Oil
    45
  - Checking Engine Oil Level / Filling
    46
- Changing Oil and Filter
  46
  - Changing Water Separating Fuel Filter
    47
  - MCM (Sterndrive) Models
    47
  - MIE (Inboard and Ski) Models
    48
  - Checking Fluid Level
    49
  - Engine Cold
    49
  - Engine Warm
    49
  - Filling and Bleeding
    50
- Closed Cooling System
  51
  - Checking Coolant Level
    51
  - Boat out of Water
    52
  - Flushing System MCM (Sterndrive) . 1B-24
    52
  - Boat in Water
    53
- Transmission Fluid
  55
- Lubrication
  56
- Cleaning Flame Arrestor
  60
  - Top Mounted Flame Arrestor
    60
  - Black Scorpion Flame Arrestor
    61
- Serpentine Drive Belt
  62
  - Component Location
    62
  - Inspection
    64
  - Installation and Adjustment
    64
  - Removal
    64
  - Replacing And/Or Adjusting Tension
    64
- Ignition Timing
  65
  - Thunderbolt V Models
    65
  - EFI/MPI Models
    66
- Cold Weather or Extended Storage
  67
- Used Spark Plug Analysis
  84
  - Chipped Insulator
    84
  - Normal Condition
    84
  - Cold Fouling
    85
  - Overheating
    85
  - Wet Fouling (Oil Deposits)
    85
  - High Speed Glazing
    86
  - Pre-Ignition Damage
    86
  - Scavenger Deposits
    86
  - Mechanical Damage
    87
  - Reversed Coil Polarity
    87
  - Splashed Deposits
    87
- Poor Boat Performance And/Or Poor Maneuverability
  88
- Improper Full Throttle Engine RPM
  89
  - RPM too High
    89
  - RPM too Low
    89
- Engine Cranks over but will Not Start or Starts Hard
  90
  - Important Information
    90
  - Testing Thunderbolt V Ignition System
    91
  - Fuel System Lean
    92
  - Fuel System Rich
    92
  - Miscellaneous
    92
- Charging System Inoperative
  93
- Engine will Not Crank over
  93
- Instrumentation Malfunction
  94
- Noisy Alternator
  94
- Radio Noise
  94
- Poor Fuel Economy
  95
- Carburetor Malfunctions
  96
- Engine Runs Poorly at Idle
  97
  - Engine Runs Poorly at High Rpm
    98
  - Engine Acceleration Is Poor
    99
  - Troubleshooting with Vacuum Gauge
    99
  - Engine Noise
    100
  - Valve Cover Area
    100
  - Camshaft Area
    101
  - Cylinder Area
    101
  - Crankshaft Area
    102
  - High Oil Pressure
    105
  - Low Oil Pressure
    105
  - Excessive Oil Consumption
    106
  - Water in Engine
    107
- Power Steering
  112
  - Poor, Erratic, or no Assist
    112
  - Fluid Leaks
    113
  - Noisy Pump
    113
- Troubleshooting Silent Choice Exhaust Silencer System
  114
- Removal and Installation
  
  117
- Section 2A - MCM Models
  
  117
  - Lubricants / Sealants / Adhesives
    118
  - Tools
    118
  - Torque Specifications
    118
  - Preparation
    119
  - Removal
    119
  - Installation
    121
    
    Drive Shaft Extension Models
    123
    
    Engine Mount Adjustment was Not Disturbed During Service
    123
    
    Engine Mount Adjustment was Disturbed During Service
    126
  - Alignment
    131
    
    Water Hose Connections
    133
    
    Electrical Connections
    134
    
    Fuel Supply Connections
    136
    
    Throttle Cable Installation and Adjustment
    137
    
    Power Steering Connections
    139
    
    Exhaust Hose Connections
    140
  - Identification
    143
- SECTION 2B - MIE Models
  
  143
  - Preparation
    146
  - Removal
    146
  - Installation and Alignment
    148
    
    Engine Final Alignment
    149
    
    Engine Connections
    152
    
    General Specifications
    172
    
    Engine Specifications
    173
    
    Bearing Failures
    181
    
    Piston Failures
    182
    
    Engine Mounts
    184
    
    Rocker Arm Cover
    186
    
    Valve Adjustment
    190
    
    Cylinder Head and Valve Conditioning
    199
    
    Valve Guide Bore Repair
    202
    
    Valve Seat Repair
    204
    
    All Engines
    208
    
    Oil Pan
    210
    
    Oil Pump
    213
    
    Torsional Damper
    216
    
    Crankcase Front Cover
    219
    
    Rear Main Oil Seal
    223
    
    Checking Clearances
    226
    
    Main Bearings
    226
    
    Connecting Rod Bearings
    230
    
    Inspection and Replacement
    230
    
    Cylinder Block
    249
    
    Positive Current Flow
    259
    
    Charging Guide
    263
    
    Standard Starter Slave Solenoid
    264
    
    Installation
    269
    
    Delco PG260F1 Starter
    273
    
    Description
    273
    
    Lubricants / Sealants / Adhesives
    273
    
    Specifications
    273
    
    Starter Specifications
    273
    
    Torque Specifications
    273
    
    Exploded View
    274
    
    Disassembly
    275
    
    Motor
    275
    
    Removal
    275
    
    Cleaning and Inspection
    279
    
    Reassembly
    279
    
    Checking Pinion Clearance
    283
    
    Installation
    284
    
    General Precautions
    287
    
    Ignition Control System Components
    287
    
    Replacement Parts Warning
    287
    
    EFI System Maintenance Precautions
    288
    
    Lubricants / Sealants / Adhesives
    288
    
    Tools
    288
    
    Torque Specifications
    288
    
    Coil
    289
    
    Distributor
    289
    
    Firing Order
    289
    
    Ignition System Specifications
    289
    
    Spark Plugs
    289
    
    Thunderbolt V Models
    290
    
    Timing
    290
    
    EFI / MPI Models
    291
    
    Inspection
    291
    
    Removal
    291
    
    Inspection
    293
    
    Replacing
    293
    
    Spark Plug Wires
    293
    
    Ignition Coil
    294
    
    Carbureted Engines - Thunderbolt V Ignition
    296
    
    Spark Control Features
    296
    
    Circuit Description
    297
    
    Thunderbolt V Spark Control Graph
    298
    
    Installation
    303
    
    Cleaning and Inspection
    306
    
    Removal
    306
    
    Sensor
    306
    
    Testing
    306
    
    Disassembly
    307
    
    Distributor Repair
    307
    
    Installation
    307
    
    Reassembly
    307
    
    Removal
    307
    
    Distributor Installation
    308
    
    Installation
    310
    
    Removal
    310
    
    Replacing Distributor Gear
    310
    
    Disassembly
    311
    
    GM EST Distributor
    311
    
    Removal
    311
    
    Cleaning and Inspection
    312
    
    Reassembly
    313
    
    Testing Pickup Coil
    313
    
    Installation
    314
    
    Alternator Repair
    316
    
    Charging System
    316
    
    Charging System Resistance
    316
    
    Circuitry
    316
    
    Component
    316
    
    Exploded View
    316
    
    Section 4C - Charging System
    316
    
    Testing
    316
    
    Efi Electrical System Precautions
    317
    
    Multiple Efi Engine Battery Precautions
    318
    
    Disassembly
    332
    
    Removal
    332
    
    Cleaning and Inspection
    337
    
    Reassembly
    337
    
    Installation
    341
    
    Pulley Removal
    342
    
    Battery Isolator Diagram
    343
    
    Water Temperature
    355
    
    Audio Warning System
    359
    
    Oil Pressure Switch
    360
    
    Fuel System Components
    388
    
    Section 5B - Mercarb
    392
    
    Replacement Parts Warning
    394
    
    Fuel Delivery System
    395
    
    Recommendations
    395
    
    Specifications
    396
    
    Tools
    396
    
    Torque Specifications
    396
    
    High Altitude Re-Jetting
    397
    
    Flooding at Idle RPM
    398
    
    Important Service Information
    398
    
    Point Carburetor Check List
    398
    
    Adjustable Accelerator Pump Lever
    399
    
    Description
    399
    
    Flame Arrestor with Carburetor Cover 5B-9
    400
    
    Choke Inspection
    403
    
    Pump Rod
    403
    
    Choke Setting
    405
    
    Choke Unloader
    405
    
    Final Idle Speed and Mixture
    407
    
    Removal
    408
    
    Repair
    408
    
    Exploded View Parts List
    410
    
    Disassembly
    411
    
    Cleaning and Inspection
    419
    
    Reassembly
    421
    
    Installation
    431
    
    Water Separating Fuel Filter
    434
    
    Water Separating Fuel Filter Replacement
    434
    
    Cool Fuel System Repair
    443
    
    Removal
    443
    
    Disassembly
    444
    
    Reassembly
    445
    
    Installation
    447
    
    350 Mag MPI Models
    450
    
    Vacuum and Vent Hose Routing
    450
    
    Scorpion Models
    451
    
    Throttle Body EFI
    452

MerCruiser Sterndrive 5.0 MPI User Manual (150 pages)

Gasoline Engines

Brand: MerCruiser | Category: Engine | Size: 9.23 MB

MerCruiser Sterndrive 5.0 MPI User Manual (150 pages)

with Emissions Control

Brand: MerCruiser | Category: Engine | Size: 10.22 MB

Read this Manual Thoroughly
3
Table of Contents
5
Warranty Registration: United States and Canada
10
Warranty Registration: Outside the United States and Canada
10
Transfer of Warranty
11
Mercury Product Protection Plan: United States and Canada
11
Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
12
3-Year Limited Warranty against Corrosion
14
4-Year Limited Corrosion Warranty: Seacore Sterndrive Models with Gas Engines
15
Global Warranty Charts
16
Mercury Installation Quality Certification Program
18
- Section 1 - Warranty
  18
California Emissions Limited Warranty
19
Mercury Installation Quality Certification Program 10 California Emissions Limited Warranty
19
- What Is Covered
  19
California Emission Control Warranty Statement
23
Emission Control Information Label
24
- Owner Responsibility
  25
Emission Certification Star Label
25
- Section 2 - Getting to Know Your Power Package
  27
Identification
28
Lanyard Stop Switch
31
Instrumentation
32
- Vesselview
  32
- Digital Gauges
  33
- Analog Gauges
  34
Remote Controls (Non-DTS Models)
34
- Remote Controls
  34
  - Panel Mount Features
    35
  - Console Mount Features
    36
Remote Controls (DTS Models)
36
Power Trim
43
- Single Engine Trim/Trailer
  44
- Dual Engine Trim/Trailer
  44
Electrical System Overload Protection
44
Audio Warning System
48
- Caution
  48
- Severe
  48
- Obdm
  49
- Testing the Audio Warning System
  49
Guardian Strategy
49
Section 3 - on the Water

51
- Safe Boating Suggestions
  52
- Be Alert to Carbon Monoxide Poisoning
  53
  - Good Ventilation
    53
  - Poor Ventilation
    54
- Basic Boat Operation (Non-DTS Models)
  54
  - Launching and Boat Operation
    54
    
    Operation Chart
    54
    
    Starting and Stopping the Engine
    55
    
    Starting the Engine
    55
    
    Freezing Temperature Operation
    56
    
    Starting the Engine after It Has Been Stopped While in Gear
    56
    
    Stopping the Engine
    56
    
    Throttle-Only Operation
    56
    
    Trailering the Boat
    56
    
    Drain Plug and Bilge Pump
    57
- Basic Boat Operation (DTS Models)
  57
  - Launching and Boat Operation
    57
    
    Operation Chart
    57
    
    Starting and Stopping the Engine
    57
    
    Starting the Engine
    57
    
    Stopping the Engine
    58
    
    Freezing Temperature Operation
    59
    
    Throttle-Only Operation
    59
    
    Trailering the Boat
    59
    
    Drain Plug and Bilge Pump
    60
- Protecting People in the Water
  60
  - While You Are Cruising
    60
  - While Boat Is Stationary
    60
- High-Speed and High-Performance Operation
  60
- Passenger Safety in Pontoon Boats and Deck Boats
  60
  - Boats Having an Open Front Deck
    61
  - Boats with Front-Mounted, Raised Pedestal Fishing Seats
    61
- Wave and Wake Jumping
  61
- Impact with Underwater Hazards
  62
  - Drive Unit Impact Protection
    63
- Operating with Low Water Inlets in Shallow Water
  63
- Conditions Affecting Operation
  63
  - Weight Distribution (Passengers and Gear) Inside the Boat
    63
  - The Bottom of the Boat
    63
  - Cavitation
    64
  - Ventilation
    64
  - Elevation and Climate
    64
  - Propeller Selection
    64
- Getting Started
  65
- Fuel Requirements
  68
- Engine Oil
  69
- Engine Specifications
  70
- Fluid Specifications
  70
Section 4 - Specifications

70
- Engine
  70
- Alpha Sterndrive
  70
- Bravo Sterndrives
  71
- Power-Assisted Steering and Power Trim Fluids
  71
  - Approved Power-Assisted Steering Fluids
    71
  - Approved Power Trim Fluids
    71
- Owner/Operator Responsibilities
  75
- Dealer Responsibilities
  75
- Maintenance
  75
- Do-It-Yourself Maintenance Suggestions
  76
- Inspection
  76
- Maintenance Schedule-Sterndrive Models
  77
  - Routine Maintenance
    77
  - Scheduled Maintenance
    77
- Maintenance Log
  78
- Engine Oil
  79
  - Checking
    79
  - Filling
    80

MerCruiser Sterndrive 5.0 MPI User Manual (148 pages)

Gasoline Engines

Brand: MerCruiser | Category: Engine | Size: 11.28 MB

MerCruiser Sterndrive 5.0 MPI User Manual (126 pages)

Gasoline Engines

Brand: MerCruiser | Category: Engine | Size: 9.02 MB

Read this Manual Thoroughly
2
Table of Contents
5
Warranty Registration: United States and Canada
10
Warranty Registration: Outside the United States and Canada
10
Transfer of Warranty
10
Mercury Product Protection Plan: United States and Canada
11
Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
11
3-Year Limited Warranty against Corrosion
13
4-Year Limited Corrosion Warranty: Seacore Sterndrive Models with Gas Engines
14
Global Warranty Charts
15
Mercury Installation Quality Certification Program
18
- Section 1 - Warranty
  18
California Emissions Limited Warranty
19
- What Is Covered
  19
- Duration of Coverage
  19
- How to Obtain Warranty Coverage
  20
- What Mercury will Do
  20
- What Is Not Covered
  20
- Disclaimers and Limitations
  20
California Emission Control Warranty Statement
20
Emission Control Information Label
21
- Owner Responsibility
  22
Emission Certification Star Label
22
- Section 2 - Getting to Know Your Power Package
  25
Identification
26
Lanyard Stop Switch
27
Instrumentation
28
- System View
  28
- Digital Gauges
  29
- Analog Gauges
  29
Remote Controls (Non-DTS Models)
29
- Remote Controls
  29
  - Console Mount Features
    30
  - Panel Mount Features
    30
Remote Controls (DTS Models)
31
Power Trim
35
- Single Engine Trim/Trailer
  36
- Dual Engine Trim/Trailer
  36
Electrical System Overload Protection
36
Audio Warning System
38
- Testing the Audio Warning System
  39
Engine Guardian Strategy
39
Warning Horn Signals
39
Safe Boating Suggestions
42
Be Alert to Carbon Monoxide Poisoning
43
- Good Ventilation
  43
- Poor Ventilation
  43
Basic Boat Operation (Non-DTS Models)
44
- Launching and Boat Operation
  44
  - Operation Chart
    44
  - Starting and Stopping the Engine
    44
  - Starting the Engine
    44
  - Drain Plug and Bilge Pump
    45
  - Freezing Temperature Operation
    45
  - Starting the Engine after It Has Been Stopped While in Gear
    45
  - Stopping the Engine
    45
  - Throttle-Only Operation
    45
  - Trailering the Boat
    45
Section 3 - on the Water

45
- Basic Boat Operation (DTS Models)
  46
  - Launching and Boat Operation
    46
    
    Operation Chart
    46
    
    Starting and Stopping the Engine
    46
    
    Starting the Engine
    46
    
    Stopping the Engine
    47
    
    Throttle-Only Operation
    47
    
    Trailering the Boat
    47
    
    Drain Plug and Bilge Pump
    48
    
    Freezing Temperature Operation
    48
- Protecting People in the Water
  48
  - While You Are Cruising
    48
  - While Boat Is Stationary
    48
- High-Speed and High-Performance Operation
  48
- Passenger Safety in Pontoon Boats and Deck Boats
  48
  - Boats Having an Open Front Deck
    48
  - Boats with Front-Mounted, Raised Pedestal Fishing Seats
    49
- Wave and Wake Jumping
  49
- Impact with Underwater Hazards
  50
  - Drive Unit Impact Protection
    50
- Operating with Low Water Inlets in Shallow Water
  51
- Conditions Affecting Operation
  51
  - Weight Distribution (Passengers and Gear) Inside the Boat
    51
  - The Bottom of the Boat
    51
  - Cavitation
    51
  - Ventilation
    51
  - Elevation and Climate
    52
  - Propeller Selection
    52
- Getting Started
  52
  - 20-Hour Break-In Period
    52
  - After Break-In Period
    52
  - End of First Season Checkup
    53
Section 4 - Specifications

55
- Fuel Requirements
  56
- Engine Oil
  56
- Engine Specifications (MPI)
  57
  - Engine Specifications
    57
- Fluid Specifications (MPI)
  58
  - Fluid Specifications
    58
  - Engine
    58
  - Alpha Sterndrive
    59
  - Bravo Sterndrives
    59
  - Power-Assisted Steering and Power Trim Fluids
    59
    
    Approved Power Trim Fluids
    59
    
    Approved Power-Assisted Steering Fluids
    59
- Owner/Operator Responsibilities
  62
- Dealer Responsibilities
  62
- Maintenance
  62
- Do-It-Yourself Maintenance Suggestions
  62
- Inspection
  63
- Maintenance Schedule - Sterndrive Models
  63
  - Routine Maintenance
    63
    
    Each Day End
    63
    
    Each Day Start
    63
    
    Every Two Months or 50 Hours
    63
    
    Weekly
    63
  - Scheduled Maintenance
    63
    
    After the Initial 20 Hour Break-In Period
    63
    
    Every 100 Hours or Annually (Whichever Occurs First)
    64
    
    Every 200 Hours or 3 Years
    64
    
    Every 300 Hours or 3 Years
    64
    
    Every 5 Years
    64
- Maintenance Log
  64
- Engine Oil
  65
  - Checking
    65
  - Filling
    65

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