1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16

SERVICE MANUAL
Number 16

MARINE ENGINES
1993,1994,1995,1996 and 1997 GM V-8 454 CID (7.4L) / 502 CID (8.2L)

Book 1 of 2 Sections 1 thru 4
Notice

Throughout this publication, “Dangers,” “Warnings” and “Cautions” are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “common sense” operation, are major accident prevention measures.

Notice to Users of This Manual

This service manual has been written and published by the service department of Mercury Marine to aid our dealers, mechanics and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures of these products, of like or similar products manufactured and marketed by Mercury Marine, and that they have been trained in the recommended servicing procedures for these products which include the use of mechanic’s common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product’s safety will be endangered by the service procedure selected.

Section 1 – Important Information
A – General Information
B – Maintenance
C – Troubleshooting

Section 2 – Removal and Installation
A – MCM Models – Bravo and Blackhawk Drives B – MCM Models – Bravo and Blackhawk with

Driveshaft Extension
C – MIE Models – Velvet Drive Transmissions D – MIE Models – Hurth Transmissions

Section 3 – Engine
A – 454 CID / 7.4L / 502 CID / 8.2L
Section 4 – Electrical Systems
A – Starting System
B – Ignition System
C – Charging System
D – Instrumentation
E – Electrical Kits
F – Wiring Diagrams
Section 5 – Fuel System
A – Fuel Delivery Systems and Fuel Pumps B – Weber 4 Barrel Carburetor
C – Electronic Fuel Injection
(Throttle Body and Multi-Port Injection)
Section 6 – Cooling System
A – Seawater Cooled Models
B – Closed Cooled Models
Section 7 – Exhaust System
A – General
B – Manifold and Elbows
C – Risers
D – Collectors
Section 8 – Drives
A – Velvet Drive In-Line Transmission
B – Velvet Drive V-Drive Transmission C – Hurth Down Angle Transmission
D – Hurth V-Drive Transmission
E – Drive Shaft Models/Propeller Shaft
Section 9 – Power Steering
A – Pump

Important
Information 1

Removal and
Installation 2
Engine 3
Electrical System 4
Fuel System 5
Cooling System 6
Exhaust System 7
Drives 8
Power Steering 9

90-823224–2 796 v
IMPORTANT INFORMATION 1
A
GENERAL INFORMATION
Table of Contents

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
How to Use This Manual . . . . . . . . . . . . . . . . . . 1A-1
Page Numbering . . . . . . . . . . . . . . . . . . . . . . 1A-1
How To Read Parts Manual . . . . . . . . . . . . . . . . 1A-2
Directional References . . . . . . . . . . . . . . . . . . . . 1A-3
Engine Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Engine Serial Number Locations . . . . . . . . . . . 1A-4
Propeller Information . . . . . . . . . . . . . . . . . . . . . 1A-4
Water Testing New Engines . . . . . . . . . . . . . . . 1A-4
Boat and Engine Performance . . . . . . . . . . . . . 1A-5
Boat Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Marine Fouling . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Weight Distribution . . . . . . . . . . . . . . . . . . . . 1A-6
Water in Boat . . . . . . . . . . . . . . . . . . . . . . . . . 1A-7
Elevation and Climate . . . . . . . . . . . . . . . . . . 1A-7
Introduction

Source: maxumownersclub.com