Index

A

Alternatordirect drive . . . . . . . . . . . . . . . . . . 368Mando...................384-385MetCruiser 470 . . . . . . . . . . , . . . 369Motorola. . . . . . . . . . . . . . . . , 380-384rotor/&&or . . . . . . . . . . . . . . . 258-259

Alternator charging systemMerCruiser 470

(air-cooled regulator) . . . . . . . . 369MetCruiser 470,485 and 488

(water-cooled regulator). . . 369-370

B

Battery . . . . . . . . . . . . . . . . . 60,364-368Bell housing (I, I-R and I-MR)

assembly., . . . . . . . . . . . . . . . 517-519cleaning and inspection . . . . . 516-517disassembly . . . . . . . . . . . . . . . . . 516installation . . . . . . . . . . . . . . . 5 19-520removal . . . . . . . . . . . . . . . . . . 513-516shift cable inner core . . . . . . . . . . 523

Bell housing (II-TRS) . . . . . . . . 520-521Breaker point distributor . . . . . . 392-396

C

Carburetor fuel inlet filter . . . . . , . . . 58Carburetor fundamentals . . . . . , . . . 288Carburetors

Carter RBS assembly. . . . . , . 297-305Holley 2300-C and 6317-1

assembly.. . . . . . . . . . . . . . 312-317Holley 4160,6407 and 6576

assembly. . . . . . . . . . . . . . . 326-332maintenance . . . . . . . . . . . . . . . . 75-76MerCarb right turn lean-out. . . . , 289Mercury MD. . . . . . . . . . . . . . 305-306no idle mixture adjustment

(MerCarb carburetor). . . . . . . . 289preparation for overhaul. . . . . . . . 290removal/installation . . . . . . . . . . . 290Rochester B and BC . . . . . . . . 291-306Rochester 2GC, 2GV and

MerCarb 2-bbl.. . . . . . . . . . 306-312

Rochester 4GC . . . . . . . . . . . . 317-323Rochester 4MV and 4MY .. .323-326troubleshooting MerCarb

acceleration “Bog” . . . . . . . . . . 289vapor lock (MCM 120/140

17OMR/19OMR). . . . . . . . .289-290Charging system. . . . . . . . . . . . . . .33-35Compression test. . . . . . . . . . . . . . . 69-70Cooling system

closed cooling system. . . . . . .344-363alkalinity test. . . . . . . . . . . . . . . 348cleaning fresh water section. .. 348cleaning seawater section

of heat exchanger. . . . . . . . . 348system draining. . . . . . . . . . . 89-101

engine circulating pump. . . . . 342-345filling . . . . . . . . . . . . . . . . . . . . 101-103flushing . . . . . . . . . . . . . . . . . . . . 50-52hose replacement . . . . . . . . . . 34 l-342inline engines . . . . . . . . . . . . . . . 89-90seawater engine

pump . . . . . . . . . . . . . . . . . . . . . 347seawater pickup pump

(stem drive unit). . . . . . . . . 345-347standard cooling system

maintenance . . . . . . . . . . . . . . . 363thermostat . . . . . . . . . . . . . . . . 338-341troubleshooting. . . . . . . . . . . . . . . . 44V6 and V8 engines . . . . . . . . . . . 94-97

D

Delco-Remy externalregulator system. . . . . . . . . . .370-373

Direct drive alternatorchargingsystem.............. 368

Distributorbreaker point. . . . . . . . . . . . . . 392-396Thunderbolt . . . . . . . . . . . . . . 396-397

Drive belt adjustmentreplacement. . . . . . . . . . . . . . .385-386

Drive shaft housingModel I drive

drive gear clearance . . . . . .493-494driven gear clearance . . . . . . . . 494drive shaft housing . . . . . . .481-488

drive shaft housingbearingcups............. 493

intermediate shift shaft/seal . . . 493top cover/water

pocket cover . . . . . . . . . 488-489universal joint . . . . . . . . . . . . . . 48 1universal joint, drive gear

and bearing. . . . . . . . . . 489-492upper drive shaft bearing

preload. . . . . . . . . . . . . . 494-495upper drive shaft/driven

gear assembly . . . . . . . . 492-493water shutter clatter. . . . . . . . . . 48 1

ModelII . . . . . . . . . . . . . . . . 495-499Model II-TR and II-TRS drive

drive gear clearance . . . . . . . . . 506driven gear clearance . . . . . . . . 506drive shaft and driven

gear assembly . . . . . . . . 504506drive shaft housing . . . . . . . . . . 499lower drive shaft bearing cup,

spacer and coupling . . . 502-503top and rear cover. . . . . . . . . . . 502universal joint/drive gear . 503-504

service precautions . . . . . . , . 480-48 1Drive system, MetCruiser

MetCruiser model 0. . . . . . . 404-410MetCruiser model I

remote control cableadjustment.. . . . . . . . . 418-419

ride-guide steering cableattachment.. . . . . . . . . . 414-416

shift cable adjustment. . . . 417-418stem drive. . . . . . . . . . . . . 410-412stem drive and remote

control shift cables . . . . 416-417tilt/trim cylinder

installation. . . . . . . . . . . 419-42 1transom plate. . . . . . . . . . . 412-414

MetCruiser model IInon-transom mountedchanging propeller shaft

rotation . . . . . . . . . . . . . . . . . 430ride-guide attachment. . . . 429-430shift cable adjustment. . . . 423-428stem drive . . . . . . . . . . . . . 421-423throttle control cable. . . . . 428-429

19

5 5 2 INDEX

MetCruiser model II (continued)tilt/trim cylinder installation. . . 43 1transom plate . . . . . . . . . . . . . . 423

MetCruiser model IItransom mounted . . . . . . . . 43 l-432

MerCruiser II-TR, II-IRS,lII and 215-H . . . . . . . . . . . 432-436

MetCruiser 215-E. . . . . . . . . . 436-439

EEngine noises . . . . . . . . . . . . . . . . . 41-43Engine oil and filter change. . . . . . 54-56Engine oil leaks . . . . . . . . . . . . . . . . . 41Engine oil level check . . . . . . . . . . 52-54Engine oil pressure indicator . . . . . 39-41Engine performance . . . . . . . . . . . . 38-39Engines, Ford V8

camshaft . . . . . . . . . . . . . . . . . 194-196core plugs . . . . . . . . . . . . . . . . 213-214crankshaft................208-211crankshaft pulley and

vibration damper . . . . . . . . . . . 190cylinder block. . . . . . . . . . . . . 212-213cylinder head . . . . . . . . . . . . . 198- 199disassembly checklists . . . . . . 186-187exhaust manifolds. . . . . . . . . . 189-190flywheel . . . . . . . . . . . . . . . . . . . . 212front cover and seal . . . . . . . . 190-191installation . . . . . . . . . . . . . . . . . . 186intake manifold . . . . . . . . . . . . 187-189oilpan . . . . . . . . . . . . . . . . . . . . . . 196oil pump. . . . . . . . . . . . . . . . . 197-198piston/connecting rod

assembly. . . . . . . . . . . . . . . 203-208rearmainbearingoilseal.... 211-212removal . . . . . . . . . . . . . . . . . . 183-186replacement parts . . . . . . . . . . . . . 183rocker arm assemblies . . . . . . . . . 193rocker arm cover. . . . . . . . . . . . . . 187serial number . . . . . . . . . . . . . . . . 182special tools . . . . . . . . . . . . . . 182-183timing chain and sprocket . . . 192-193valves and valve seats . . . . . . 200-202

Engines, GM inlinecamshaft . . . . . . . . . . . . . . . . . 113-116connecting rod . . . . . . . . . . . . 129- 130core plugs. . . . . . . . . . . . . . . . 134-135crankshaft . . . . . . . . . . . . . . . . 131-133crankshaft pulley/torsional

damper . . . . . . . . . . . . . . . . . . . 190cylinder block. . . . . . . . . . . . . 133- 136cylinder head . . . . . . . . . . . . . 119-121disassembly checklist. . . . . . . 107-108flywheel . . . . . . . . . . . . . . . . . . . . 133installation . . . . . . . . . . . . . . . 106-107intake/exhaust manifolds . . . . 108-l 11oilpan.......................oilpump.. . . . . . . . . . . . . . . . . . . . 118

piston/connecting rodassembly . . . . . . . . . . . . . . . 125-131

piston clearance check . . . . . . . . . 127piston pin removal/installation . . . 127piston removal . . . . . . . . . . . . 125-127piston ring fit/installation . . . . 127-129removal. . . . . . . . . . . . . . . . . . 105-106replacement parts . . . . . . . . . . . . . 105rocker arm assemblies . . . . . . . . . 113rocker arm cover. . . . . . . . . . . . . . 108serial number . . . . . . . . . . . . . . . . 104special tools . . . . . . . . . . . . . . . . . 104timing gear cover and seal . . . 112-113valves and valve seats. . . . . . . 121-125

Engines, GM V6 and V8camshaft . . . . . . . . . . . . . . . . . 149-152core plugs . . . . . . . . . . . . . . . . . . . 168crankshaft . . . . . . . . . . . . . . . . 164-165crankshaft pulley and

torsional damper. . . . . . . . . . . . 146cylinder block. . . . . . . . . . . . . 167-168cylinder head. . . . . . . . . . . . . . 154-155disassembly checklists . . . . . . 142-143exhaust manifolds . . . . . . . . . . 145-146flywheel . . . . . . . . . . . . . . . . . 166-167front cover and seal . . . . . . . . . . . 147installation . . . . . . . . . . . . . . . . . . . 142intake manifold . . . . . . . . . . . . 144-145oil pan. . . . . . . . . . . . . . . . . . . 152-153oil pump . . . . . . . . . . . . . . . . . . 153-154piston/connecting rod

assembly . . . . . . . . . . . . . . . 160-164rear main oil seal. . . . . . . . . . . . . . 147removal . . . . . . . . . . . . . . . . . . 141-142replacement parts . . . . . . . . . . 140-141rocker arm assemblies . . . . . . 148-149rocker arm cover. . . . . . . . . . . . . . 143serial number . . . . . . . . . . . . . . . . 140special tools . . . . . . . . . . . . . . . . . 140timing chain and

sprockets . . . . . . . . . . . . . . . 147-148valves and valve seats. . . . . . . 156-161

Engines, MerCruiser 60,80 and 90camshaft and timing chain .. .227-231core plugs . . . . . . . . . . . . . . . . . . . 248crankshaft . . . . . . . . . . . . . . . .244-246cylinder block. . . . . . . . . . . . .247-248cylinder head. . . . . . . . . . . . . .234-236disassembly checklists . . . . . . 223-224flywheel . . . . . . . . . . . . . . . . .246-247front cover and seal . . . . . . . . . . . 226inner transom plate. . . . . . . . .225-226installation. . . . . . . . . . . . . . . .221-223intake/exhaust manifolds . . . .224-225oilpan . . . . . . . . . . . . . . . . . . . . . . 232oil pump . . . . . . . . . . . . . . . . .232-234piston/connecting rod

assembly . . . . . . . . . . . . . . .241-244removal . . . . . . . . . . . . . . . . . .219-221

replacement parts . . . . . . . . . . . . . 2 19rocker arm assembly. . . . . . . 226-227rocker arm cover. . . . . . . . . . . . . . 224serial number . . . . . . . . . . . . . . . . . 218special tools. . . . . . . . . . . . . . . . . . 218valves and valve seats. . . . . . 236-241

Engines, MetCruiser 470,485,488,170MR and 19OMRalternator rotor/stator . . . . . . . 258-259camshaft. . . . . . . . . . . . . . . . . 262-263core plugs . . . . . . . . . . . . . . . . . . . 279crankshaft . . . . . . . . . . . . . . . 275-277cylinder block. . . . . . . . . . . . 278-279cylinder head. . . . . . . . . . . . . 266-267disassembly checklists . . . . . . . . . 256exhaust manifold. . . . . . . . . . 257-258flywheel housing, coupler

and flywheel . . . . . . . . . . . 277-278front cover and seals. . . . . . . 259-260installation. . . . . . . . . . . . . . . 254-256intake manifold. . . . . . . . . . . 256-257oil pan . . . . . . . . . . . . . . . . . . 264-265oil pump . . . . . . . . . . . . . . . . 265-266piston/connecting rod

assembly . . . . . . . . . . . . . . 27 l-275removal . . . . . . . . . . . . . . . . . 253-254replacement parts . . . . . . . . . 252-253rocker arm assemblies. . . . . . 260-261rocker arm cover. . . . . . . . . . . . . . 256serial number. . . . . . . . . . . . . . . . . 252special tools. . . . . . . . . . . . . . . . . . 252timing chain and

sprockets. . . . . . . . . . . . . . 263-264valves and valve seats. . . . . . 268-270

FFitting out . . . . . . . . . . . . . . . . . . . . . 103Flame arrestor. . . . . . . . . . . . . . . 60,287Fuel system (see also Carburetors)

filter (canister-type) . . . . . . . . . . . . 58fuel inlet filter . . . . . . . . . . . . . . . . . 58fuel lines . . . . . . . . . . . . . . . . 334-3,35fuel pump . . . . . . . . . . . . .fuel quality . . . . . . . . . 58-system service. . . . . . . . . .troubleshooting. . . . . . . . . . . . . 43-44

GGasoline recommendations. . . . . . 59-60Gear housing

Model I drivebearing carrier/

reverse gear. . . . . . . . . . 450-454drive shaft/pinion gear . . . 452-454

Model I-MR drivebearing carrier/

reverse gear. . . . . . . . . . . . . . 473

553

Model I-MR drive (continued)drive shaft pinion gear . . . . 473-476drive shaft roller bearing,

drive shaft and forwardgear bearing cups . . . . . . . . . 475

forward and reversegear backlash . . . . . . . . . . . . 476

gear housing. . . . . . . . . . . . 469-473propeller shaft/forward gear. .. 475shift shaft . . . . . . . . . . . . . . . . . 475

Model II drivedrive shaft . . . . . . . . . . . . . . 461-463gear housing. . . . . . . . . . . . 469-473propeller shaft. . . . . . . . . . . . . . 461

Model II-TR and II-TRS drivebearing carrier . . . . . . . . . . 464-466drive shaft/pinion gear. . . . 466-467gear housing. . . . . . . . . . . 463,468propeller shaft assembly. .. 467-468shimming . . . . . . . . . . . . . . 468-469

service precautions. . . . . . . . . 444-445Gimbal bearing. . . . . . . . . . . . . . 524-525Gimbal ring

without side-mounted rotarytrim-switch. . . . . . . . . . . . . 525-528

with side-mounted rotarytrim-switch. . . . . . . . . . . . . 528-529

with square upperswivel shaft. . . . . . . . . . . . . 529-53 1

I

Ignition systembreaker point gap

adjustment . . . . . . . . . . . . . . . 73-74coil . . . . . . . . . . . . . . . . . . . . . . . . 397contact breaker point

replacement . . . . . . . . . . . . . . . . 73distributor cap, wires

and rotor. . . . . . . . . . . . . . . . . 72-73electrical system. . . . . . . . . . . 392-397ignition resistance wire. . . . . . . . . 397ignition timing . . . . . . . . . . . . . . 74-75spark plug. . . . . . . . . . . . . . . . . . 71-72troubleshooting . . . . . . . . . . . . . . 35-38

Integral regulator systemearly model Delco-Remy . . . . 373-374late model Delco-Remy . . . . . 374-380

L

Lay-up . . . . . . . . . . . . . . . . . . . . . . 84-88Lubrication

early model I, IA and IB(includes E-Z shift) . . . . . . . . 63-64

late model I. . . . . . . . . . . . . . . . . 64-66MetCruiser II . . . . . . . . . . . . . . . 66-67

MetCruiser 215, II-TR,II-TRS and III. . . . . . . . . . . . . 68-69

Model 0 (60,80 and 90) . . . . . .62-63

M

Mando alternator system . . . . . . 384-385Manifolds

Ford V8 . . . . . . . . . . . . . . . . . . 187-190GM inline . . . . . . . . . . . . . . . . 108-111GM V6 and V8 . . . . . . . . . . . . 144-146MetCruiser 60,80 and 90. .. .224-225MerCruiser 470,485,488,

170MR and 190MR . . . . . . . . . 256Motorola alternator system. . . . . 380-384

N

Neutral safety switch . . . . . . . . . . . . 402

0

Gil and filter change. . . . . . . . . . . .54-56Gil level check . . . . . . . . . . . . . . . .52-54Gil pan

FordV8 . . . . . . . . . . . . . . . . . . . . . 196GM inline . . . . . . . . . . . . . . . . 117-118GM V6 and V8 . . . . . . . . . . . . 152-153MerCruiser 60,80 and 90. .. .232-234MetCruiser 470,485,488,

170MR and 190MR . . . . . .264-265Gil pump

Ford V8 . . . . . . . . . . . . . . . . . . 197-198GM inline . . . . . . . . . . . . . . . . 118-119GM V6 and V8. . . . . . . . . . . . 153-153MetCruiser 60,80 and 90. .. .232-234

, MetCruiser 470,485,488,170MR and 190MR . . . . . .265-266

P

Power trim and tilt systemauto trim system . . . . . . . . . . . 546-550high pressure pump system . . 533-539

dual solenoid system. . . . . . . . . 534dual trim test sequence. . . . 537-539electrical sub-system . . . . . . . . 533port trim switch testing. . . . . . . 539power trim indicator sender . . . 402pump protection . . . . . . . . . . . . 534single solenoid system . . . . . . . 533starboard trim switch testing . . 539trailer switch testing . . . . . . . . . 539trim indicator gauge . . . . . . . . . 537trim limit/trim position

sender switches. . . . . . . . 535-537trim position sender . . . . . .535-537trim switch testing . . . . . . .537-539

hydraulic sub-system . . . . . 539-543low pressure pump system . . . . . 543

R

Rectifier test . . . . . . . . . . . . . . . . . . . 340Regulator (see Integral regulator system)Rocker arm cover

FordV8.. . . . . . . . . . . . . . . . . . . . 187GM inline . . . . . . . . . . . . . . . . . . . 108GMV6andV8 . . . . . . . . . . . . . . . 143MerCruiser 60,80 and 90. . . . . . . 224MerCruiser 470,485,488,

17OMR and 190MR . . . . . . . . . 256

S

Starting systembrush replacement. . . . . . . . . 388-392on-boat testing. . . . . . . . . . . . . . . . 387relay removal/installation. . . . . . . 388solenoid removal/

installation . . . . . . . . . . . . . 387-388starter removal/installation. . . . . . 388troubleshooting. . . . . . . . . . . . . . . . 33

Stem drive lubrication. . . . . . . . . . 60-62Stem drive unit . . . . . . . . . . . . . . . . . . 44Switches

ignition system . . . . . . . . . . . 397-398power trim control panel

switch . . . . . . . . . . . . . . . . 400-401switch panel test . . . . . . . . . . . . . . 400three-button switch . . . . . . . . . . . . 401toggle switch. . . . . . . . . . . . . 401-402two-station tachometer

switch . . . . . . . . . . . . . . . . 398-399

T

Thunderbolt distributor. . . . . .Troubleshooting

charging system . . . . . . . . .cooling system . . . . . . . . . .engine noises. . . . . . . . . . . .engine oil leaks . . . . . . . . . .engine oil pressure indicatorengine performance. . . . . . .fuel system . . . . . . . . . . . . .ignition system . . . . . . . . . .starting system . . . . . . . . . .stem drive unit . . . . . . . . . .

Tune-up . . . . . . . . . . . . . . . . . .

396-397

. 33-35

. . . . 44

. 41-43

. . . . 41

. 39-41

. 38-39

. 43-44

. 35-38

. . . . 33: ’ 69-76 44

W

Wiring diagrams . . . . . . . . . . . . 554-600