CONTENTS

1 GENERAL INFORMATION
AND BOATING SAFETY
HOW TO USE THIS MANUAL
BOATING SAFETY
SAFETY IN SERVICE
1-1
1-3
1-10

2 TOOLS AND EQUIPMENT TOOLS AND EQUIPMENT

TOOLS
FASTENERS,MEASUREMENTS
AND CONVERSATIONS
2-1
2-3

2-10

ENGINE & DRIVE MAINTENANCE 3-2

FLUIDS AND LUBRICANTS 3-27
LUBRICATION POINTS 3-39
BOAT MAINTENANCE 3~6
WINTER STORAGE 3-51
SPRING COMMISSIONING 3-51
FIRING ORDERS 3-52
SPECIFICATION CHARTS 3-53

4
ENGINE MECHANICAL ENGINE MECHANICAL 4-2
4 CYLINDER SPECIFICATION CHARTS 4-9

5
ENGINE MECHANICAL ENGINE MECHANICAL 5-2
V6 &V8 SPECIFICATION CHARTS 5-24

6 ENGINE OVERHAUL ENGINE RECONDITIONING

7
FUEL SYSTEMS FUEL AND COMBUSTION 7-2
CARBURETORS CARBURETED FUEL SYSTEM 7-3
CARBURETOR SPECIFICATIONS 7-33
APPLICATION CHART 7~

FUEL AND COMBUSTION 8-2

ELECTRONIC FUEL INJECTION 8-3
SYSTEM DIAGNOSIS 8-26
VACUUM DIAGRAMS 8-39
WIRING SCHEMATICS 8~1
ECM PIN LOCATIONS 8-54
DIAGNOSTIC TROUBLE CODES 8-65

9
SPECIFICA'rlONS 8-68

COOLING SYSTEM COOLING SYSTEMS 9-2

MAINTENANCE AND TESTING 9-2
DRAIN DIAGRAMS 9-14
FLOW DIAGRAMS 9-18
 CONTENTS
UNDERSTANDING AND
TROllBLESHOOTING
ELECTRICAL SYSTEMS 10-2
BATTERY 10-9
CHARGING SYSTEM 10-11
STARTER CIRCUIT 10-24
BREAKER POINT
IGNITION SYSTEM 10-36
DIGITAL DISTRIBUTORLESS
IGNITION SYSTEM (DDIS) 10-42
ELECTRONIC SPARK
TIMING SYSTEM (EST) 10-44
THUNDERBOLT IGNITION SYSTEM 10-49
INSTRUMENTS AND GAUGES 10-55
SENDING UNITS AND SWITCHES 10-59
WIRING DIAGRAMS 10-62
SPECIFICATIONS 10-105

STERN DRIVE UNIT-ALPHA 11-2

GEAR HOUSING (LOWER UNIT) 11-5
DRIVESHAFT HOUSING (UPPER HOUSING) 11-19
TRANSOM ASSEMBLY 11-27
SPECIFICATIONS 11-40

STERN DRIVE UNIT

BRAVO/BLACKHAWK 12-2
GEAR HOUSING (LOWER UNIT) 12-5
DRIVESHAFT HOUSING (UPPER HOUSING) 12-24
TRANSOM ASSEMBLY 12-35
SPECIFICATIONS 12-49

BORG WARNERIVELVET TRANSMISSIONS

HURTHIZF TRANSMISSIONS
WALTER TRANSMISSIONS
13-2
13-10
13·15
DRIVE SYSTEMS
TRANSMISSIONS
13
14
SPECIFICATIONS 13·16

POWER TRIM AND TILT 14-2 TRIM AND TILT

WIRING SCHEMATICS 14-30

MANUAL STEERING SYSTEM

POWER STEERING SYSTEM
COMPACT HYDRAULIC SYSTEM
15-2
15-4
15-23
. STEERING 15
GLOSSARY 15·25 GLOSSARY

MASTER INDEX 15·28 MASTER INDEX

15-28 MASTER INDEX
ALTERNATOR 10·12 DRAINING FLUID 13-6
PRECAUTIONS 10-12 TRANSMISSION 13-8
CHARGING SYSTEM INSPECTION 10-12 REMOVAL & INSTALLATION 13-8
TESTING 10-12 PUMP INDEXING 13-9
REMOVAL & INSTALLATION 10-18 BREAKER POINT IGNITION SYSTEM 10-36
DISASSEMBLY 10-18 DESCRIPTION 10-36
CLEANING 10-22 TROUBLESHOOTING 10-37
ASSEMBLY 10-23 GENERAL TESTS 10-37
ANODES (ZINCS) 3-46 IGNITION VOLTAGE TESTS 10-38
SERVICING 3-47 DISTRIBUTOR CAP AND ROTOR 10-39
INSPECTION 3-48 REMOVAL &INSTALLATION 10-39
AUDIO WARNING SYSTEM 10-60 DISTRIBUTOR 10-39
AVOIDING THE MOST COMMON MISTAKES 1-3 REMOVAL 10-39
AVOIDING TROUBLE 1-2 INSTALLATION 10-40
BALANCE SHAFT 5-19 DISASSEMBLY & ASSEMBLY 10-40
REMOVAL & INSTALLATION 5-19 IGNITION COIL 10-41
BASIC ELECTRICAL THEORY 10-2 REMOVAL & INSTALLATION 10-41
HOW ELECTRICITY WORKS: BUY OR REBUILD? 6-2
THE WATER ANALOGY 10-2 CAMSHAFT AND GEAR 4·6
OHM'S LAW 10-2 REMOVAL & INSTALLATION 4·6
BATTERIES 3-48 CAMSHAFT 5-20
CLEANING 3-48 REMOVAL & INSTALLATION 5-20
CHECKING SPECIFIC GRAVITY 3-49 CAN YOU DO IT? 1-2
BATTERY TERMINALS 3-49 CARBURETED FUEL SYSTEM 7-3
BATTERY & CHARGING TROUBLESHOOTING 7-3
SAFETY PRECAUTIONS 3-50 COMMON PROBLEMS 7-3
BATTERY CHARGERS 3-50 COMBUSTION RELATED
REPLACING BATTERY CABLES 3·50 PISTON FAILURES 7·5
STORAGE 3-50 CARBURETOR APPLICATION CHART 7-4
BATTERY CONSTRUCTION 10-9 CARBURETOR CIRCUITS 7-6
MARINE BATTERIES 10-9 CARBURETOR SPECIFICATIONS 7-33
BATTERY RATINGS 10-9 CHARGING SYSTEM 10-11
BATTERY LOC,4;TlON 10-10 GENERAL INFORMATION 10-11
DUAL BATTERY INSTALLATION 10-10 CHEMICALS 2·2
BATTERY CHARGERS 10-10 LUBRICANTS & PENETRANTS 2·2
BATTERY CABLES 10-10 SEALANTS 2-3
BATTERY GAUGE 10-57 CLEANERS 2-3
TESTING 10-57 COMBINATION MANIFOLD 4-4
REMOVAL & INSTALLATION 10·57 REMOVAL & INSTALLATION 4-4
BATTERY 10-9 COMBUSTION 7-2
BELL HOUSING 11-32 COMBUSTION 8-2
REMOVAL & INSTALLATION 11-32 COMPACT HYDRAULIC SYSTEM 15-23
BELL HOUSING 12-40 HYDRAULIC FLUID 15·23
REMOVAL & INSTALLATION 12-40 FILLING/PURGING THE SYSTEM 15-23
BELTS 3-8 CHECKING THE LEVEL 15-23
INSPECTION 3-8 CONTROL VALVE 15-15
ADJUSTMENT 3-8 REMOVAL & INSTALL,4;TlON 15-15
REMOVAL & INSTALLATION 3-10 DISASSEMBLY & ASSEMBLY 15·15
BOAT MAINTENANCE 3-46 BALANCING 15-16
BOATING SAFETY 1-3 COOL FUEL SYSTEM 8·9
BOLTS, NUTS AND OTHER REMOVAL & INSTALLATION 8-9
THREADED RETAINERS 2-10 COOLING SYSTEM 3-31
BOOSTER CYLINDER 15-17 LEVEL CHECK 3-31
REMOVAL & INSTALLATION 15-17 FLUSHING THE SYSTEM 3·31
TESTING 15·17 COOLING SYSTEMS 9-2
BORG·WARNERNELVET DESCRIPTION & OPERATION 9-2
TRANSMISSIONS 13-2 SEAWATER SYSTEM 9-2
IDENTIFICATION 13·2 CLOSED SYSTEM 9·2
SHIFT CABLE 13·3 COURTESY MARINE EXAMINATIONS 1-10
ADJUSTMENT 13-3 CRANKSHAFT PULLEY
TRANSMISSION FLUID 13-6 TORSIONAL DAMPER 5-17
 MASTER INDEX 15-29
REMOVAL &INSTALLATION 5-17 DESCRIPTION 12-24
CROSSOVER 9-6 DRIVESHAFT HOUSING (UPPER UNIT) 12-25
REMOVAL & INSTALLATION 9-6 REMOVAL &INSTALLATION 12-25
CRUISELOG 10-57 ASSEMBLY &DISASSEMBLY 12-26
TESTING 10-57 DUAL POWER TRIM SYSTEM 14-29
REMOVAL &INSTALLATION 10-58 RELAY REPLACEMENT 14-29
CYLINDER COMPRESSION 3-17 DIODE MODULE REPLACEMENT 14-29
CHECKING COMPRESSION 3·17 ECM PIN LOCATIONS 11-54
CYLINDER HEAD 5-21 ELECTRIC FUEL PUMP 7·33
REMOVAL &INSTALLATION 5·21 DESCRIPTION 7·33
CYLINDER HEAD COVER 4-3 REMOVAL & INSTALLATION 7·33
REMOVAL &INSTALLATION 4·3 PRESSURE TEST 7·33
CYLINDER HEAD COVER 5·8 ELECTRICAL COMPONENTS 10-2
REMOVAL & INSTALLATION 5-8 POWER SOURCE 10-2
CYLINDER HEAD H GROUND 10-3
REMOVAL &INSTALLATION 4·7 PROTECTIVE DEVICES 10-3
CYLINDER HEAD 6·5 SWITCHES &RELAYS 10-3
DISASSEMBLY 6-6 LOAD 10-4
INSPECTION 6-6 WIRING &HARNESSES 10-4
REFINISHING &REPAIRING 6·10 CONNECTORS 10-4
ASSEMBLY 6-11 ELECTRONIC CONTROL MODULE (ECM) 8-22
DETERMINING ENGINE CONDITION 6·2 REMOVAL &INSTALLATION 8-22
COMPRESSION TEST 6-2 ELECTRONIC FUEL INJECTION 8-3
OIL PRESSURE TEST 6·2 DESCRIPTION AND OPERATION 8-3
DIAGNOSTIC TROUBLE CODES (DTC) 8·30 MODES OF OPERATION 8·3
READING CODES 8-30 SUBSYSTEMS 8-4
CLEARING CODES 8-30 RELIEVING FUEL PRESSURE 8-9
CODE 14 8-30 ELECTRONIC SPARK TIMING SYSTEM (ES1) 10-44
CODE 15 8-31 DESCRIPTION 10-44
CODE 21 8-31 TROUBLESHOOTING 10-44
CODE 22 8-33 VISUAL CHECKS 10-44
CODE 23 8-33 IGNITION COIL 10-44
CODE 25 8-34 PICK-UP COIL 10-46
CODE 33 8·34 IGNITION MODULE 10-46
CODE 34 8-35 DISTRIBUTOR CAP 10-46
CODE 41 8-35 REMOVAL &INSTALLATION 10-46
CODE 42 8-36 DISTRIBUTOR 10-46
CODE 43 8-36 REMOVAL 10-46
CODE 44 8-37 INSTALLATION 10-47
CODE 45 8-37 DISASSEMBLY 10-47
CODE 51 8·38 CLEANING AND INSPECTING 10-48
CODE 52 8-38 REMOVAL &INSTALLATION 10-48
CODE 61 8-38 ASSEMBLY 10-48
CODE 62 8-38 IGNITION COIL 10-48
DIAGNOSTIC TROUBLE CODES 8-65 ELECTRONIC TOOLS 2-7
DIGITAL DISTRIBUTORLESS BATIERY TESTERS 2-7
IGNITION SYSTEM (DDIS) 10-42 BATIERY CHARGERS 2-8
DESCRIPTION 10-42 MULTIMETERS 2-8
TROUBLESHOOTING 10-42 GAUGES 2-8
PRECAUTIONS 10-42 EMERGENCY (LANYARD) STOP SWITCH 10-60
IGNITION AMPLIFIER 10-42 ENGINE 5·3
IGNITION COIL 10-42 REMOVAL & INSTALLATION 5·3
DIRECTIONS AND LOCATIONS 1·2 ENGINE AND DRIVE MAINTENANCE 3·2
DRAIN DIAGRAMS 9-14 ENGINE BLOCK 6-11
DRIVE BELTS 9-6 GENERAL INFORMATION 6-11
DRIVESHAFT HOUSING (UPPER UNIT) 11-19 DISASSEMBLY 6-12
REMOVAL & INSTALLATION 11-19 INSPECTION 6-12
ASSEMBLY &DISASSEMBLY 11·20 REFINISHING 6·14
DRIVESHAFT HOUSING (UPPER UNIT) 11·19 ASSEMBLY 6-15
DESCRIPTION 11-19 ENGINE COOLANT
GEAR RATIO IDENTIFICATION 11-19 TEMPERATURE SENSOR (ECT) 8·22
DRIVESHAFT HOUSING (UPPER UNIT) 12·24 REMOVAL &INSTALLATION 8-22
15-30 MASTER INDEX
ENGINE COUPLERlU-JOINT SPLINES 3-43 FUEL FILTER 3-5
ENGINE IDENTIFICATION 4-2 REMOVAL & INSTALLATION 3-5
ENGINE IDENTIFICATION 5-2 FUEL GAUGE 10-56
ALL ENGINES EXC. 8.1 LV8 5-2 HOOKUP 10-56
8.1 LV8 ENGINES 5-3 TROUBLESHOOTING 10-56
ENGINE MECHANICAL 4 CYLINDER 4-2 TESTING 10-57
ENGINE MECHANICAL V6 & V8 5-2 REMOVAL & INSTALLATION 10-57
ENGINE OIL 3-27 FUEL INJECTORS 8-12
OIL LEVEL CHECK 3-28 REMOVAL & INSTALLATION 8-12
OIL & FILTER CHANGE 3-28 FUEL METER COVER 8-12
ENGINE OVERHAUL TIPS 6-3 REMOVAL & INSTALLATION 8-12
TOOLS 6-3 FUEL PRESSURE DAMPER 8-12
OVERHAUL TIPS 6-3 REMOVAL & INSTALLATION 8-12
CLEANING 6-3 FUEL PRESSURE REGULATOR 8-13
REPAIRING DAMAGED THREADS 6-4 REMOVAL & INSTALLATION 8-13
ENGINE PREPARATION 6-5 FUEL PUMP RELAY 8-13
ENGINE RECONDITIONING 6-2 REMOVAL & INSTALLATION 8-13
ENGINE START-UP AND BREAK·IN 6-18 FUEL PUMP-ELECTRIC 8-14
STARTING THE ENGINE 6-18 REMOVAL & INSTALLATION 8-14
BREAKING IT IN 6-18 FUEL PUMP-MANUAL 8-14
KEEP IT MAINTAINED 6-18 REMOVAL & INSTALLATION 8-14
ENGINE 4-2 FUEL RAIL AND INJECTORS 8-14
REMOVAL & INSTALLATION 4-2 REMOVAL & INSTALLATION 8-14
EQUIPMENT NOT REQUIRED INJECTOR BALANCE TEST 8-16
BUT RECOMMENDED 1-9 FUEL TANK SENDING UNIT 10-59
SECOND MEANS OF PROPULSION 1-9 FUEL 7·1
BAILING DEVICES 1-9 OCTANE RATING 7-2
FIRST AID KIT 1-9 VAPOR PRESSURE 7-2
ANCHORS 1-10 ALCOHOL·BLENDED FUELS 7-2
VHF-FM RADIO 1·10 HIGH ALTITUDE OPERATION 7-2
TOOLS AND SPARE PARTS 1-10 RECOMMENDATIONS 7-2
EXHAUST BELLOWS 11-30 FUElIWATER SEPARATOR 3-7
REMOVAL & INSTALLATION 11-30 SERVICE 3-7
EXHAUST BELLOWS 12-38 GEAR HOUSING (LOWER UNIT) BLACKHAWK 12-19
REMOVAL & INSTALLATION 12-38 REMOVAL & INSTALLATION 12-19
EXHAUST MANIFOLD 5-14 DISASSEMBLY 12-19
REMOVAL & INSTALLATION 5-14 CLEANING AND INSPECTING 12-21
FASTENERS,MEASUREMENTS ASSEMBLY 12-21
AND CONVERSIONS 2-10 GEAR HOUSING (LOWER UNIT) 11-5
FIRING ORDERS 3-52 DESCRIPTION 11-5
FLAME ARRESTOR 3-3 GEAR HOUSING (LOWER UNIT) 11-6
REMOVAL & INSTALLATION 3-3 REMOVAL & INSTALLATION 11-6
FLOW DIAGRAMS 9-18 DISASSEMBLY 11-7
FLUID DISPOSAL 3·27 CLEANING AND INSPECTING 11-11
FLUIDS AND LUBRICANTS 3·27 ASSEMBLY 11·11
FLYWHEEL 4-8 GEAR HOUSING (LOWER UNIT) 12-5
REMOVAL & INSTALLATION 4-8 DESCRIPTION 12-5
FLYWHEEL 5-23 GEAR HOUSING (LOWER UNIl)-BRAVO VII 12-5
REMOVAL & INSTALLATION 5-23 REMOVAL & INSTALLATION 12-5
FRONT COVER AND OIL SEAL 5·18 DISASSEMBLY 12-6
REMOVAL & INSTALLATION 5-18 CLEANING AND INSPECTING 12-11
FRONT COVER, OIL SEAL ASSEMBLY 12-11
FUEL AND COMBUSTION CARBURETOR 7-2 GEAR HOUSING (LOWER UNIT}-BRAVO III 12·12
FUEL AND COMBUSTION FUEL INJECTION 8-2 REMOVAL & INSTALLATION 12-12
FUEL 8·2 DISASSEMBLY 12-13
OCTANE RATING 6·2 CLEANING AND INSPECTING 12-17
VAPOR PRESSURE 8-2 ASSEMBLY 12-17
ALCOHOL-BLENDED FUELS 8-2 GEAR RATIO IDENTIFICATION 12-24
RECOMMENDATIONS 8-2 GENERAL DIAGNOSTIC TESTS 8-27
FUEL AND OIL RECOMMENDATIONS 3·27 ON·BOARD DIAGNOSTIC SYSTEM CHECK 8·27
FUEL 3-27 GENERAL INFORMATION 4-2
FUEL BOOST PUMP (ELECTRIC) 8-11 4 CYLINDER ENGINES 4-2
REMOVAL & INSTALLATION 8-11 GENERAL INFORMATION 5-2
 MASTER INDEX 15-31
4.3L V6 ENGINES 5-2 DRAINING & FILLING 9-3
V8 ENGINES 5-2 MAINTENANCE OR REPAIR? 1-2
GENERAL SYSTEM TROUBLESHOOTING 10-12 MANIFOLD ABSOLUTE PRESSURE
ALTERNATOR FAILS TO CHARGE 10-12 SENSOR (MAP) 8·25
ALTERNATOR CHARGES REMOVAL & INSTALLATION 8-25
LOW OR UNSTEADY 10·12 MANUAL STEERING SYSTEM 15-2
ALTERNATOR OUTPUT TOO HIGH BATTERY MASTER INDEX 15·28
OVERCHARGED 10·12 MEASURING TOOLS 2-9
ALTERNATOR TOO NOISY 10-12 MICROMETERS & CALIPERS 2-9
AMMETER FLUCTUATES CONSTANTLY 10-12 DIAL INDICATORS 2-10
GIMBAL BEARING 11-27 TELESCOPING GAUGES 2-10
REMOVAL 11-27 DEPTH GAUGES 2·10
GIMBAL BEARING 12-36 MECHANICAL FUEL PUMP 7-31
REMOVAL & INSTALLATION 12-36 DESCRIPTION 7-31
GIMBAL HOUSINGfTRANSOM PLATE 11-38 REMOVAL & INSTALLATION 7-32
REMOVAL & INSTALLATION 11-38 PRESSURE TEST 7-32
GIMBAL HOUSINGfTRANSOM PLATE 12-46 FUEL LINE TEST 7·32
REMOVAL & INSTALLATION 12-46 MERCARB2BBLCARBURETOR 7-7
GIMBAL RING 11-34 DESCRIPTION 7·7
REMOVAL & INSTALLATION 11-34 REMOVAL &INSTALLATION 7·7
GIMBAL RING 12-42 ADJUSTMENT 7-8
REMOVAL & INSTALLATION 12-42 DISASSEMBLY 7·10
GLOSSARY 15-25 CLEANING & INSPECTION 7-10
HAND TOOLS 2·4 ASSEMBLY 7-14
SOCKET SETS 2-4 MOTION SENSOR 10-43
WRENCHES 2-5 SHIFT INTERRUPTOR SWITCH 10-43
PLIERS 2-6 MOTION SENSOR 10-43
SCREWDRIVERS 2·6 REMOVAL & INSTALLATION 10-43
HAMMERS 2-6 IGNITION AMPLIFIER 10·43
HEAT EXCHANGER 9-6 REMOVAL & INSTALLATION 10-43
CLEANING 9-6 IGNITION COIL 10-43
TESTING 9-6 REMOVAL & INSTALLATION 10-43
HOW TO USE THIS MANUAL 1·2 OIL AND TEMPERATURE GAUGES 10-55
HURTH/ZF TRANSMISSIONS 13-10 TROUBLESHOOTING 10-55
SHIFT CABLE 13-10 TESTING 10-56
ADJUSTMENT 13-10 REMOVAL & INSTALLATION 10-56
TRANSMISSION FLUID 13-12 OIL PAN 4·5
DRAINING FLUID 13-12 REMOVAL & INSTALLATION 4·5
TRANSMISSION 13-14 OIL PAN 5-15
REMOVAL & INSTALLATION 13-14 REMOVAL & INSTALLATION 5-15
IDLE AIR CONTROL VALVE (lAC) 8-22 OIL PRESSURE SENDING UNIT 10·59
REMOVAL & INSTALLATION 8-22 OIL PRESSURE SWITCH 10-60
IDLE SPEED AND MIXTURE 3-25 OIL PUMP 4-5
ADJUSTMENT 3-25 REMOVAL & INSTALLATION 4-5
IGNITION SWITCH 10-59 OIL PUMP 5-17
IGNITION SYSTEM 10-36 REMOVAL & INSTALLATION 5-17
IGNITION TIMING 3-22 OPERATION 7-5
ADJUSTMENT 3·22 BASIC FUNCTIONS 7·5
INSIDE THE BOAT 3-46 FUEL & AIR METERING 7·5
INSTRUMENTS AND GAUGES 10-55 OTHER COMMON TOOLS 2-6
INTAKE AIR TEMPERATURE SENSOR (IAn 8-24 PCVVALVE 3-27
REMOVAL & INSTALLATION 8-24 REMOVAL & INSTALLATION 3-27
INTAKE MANIFOLD 5-10 INSPECTION 3-27
REMOVAL & INSTALLATION 5-10 POWER STEERING COOLER 15-22
KNOCK SENSOR (KS) 8-25 REMOVAL& INSTALLATION 15-22
REMOVAL & INSTALLATION 8-25 POWER STEERING PUMP 15·18
LANYARD STOP CIRCUIT CHECK 8·29 REMOVAL & INSTALLATION 15-18
LINKAGE PIVOT POINTS 3-40 FLOW CONTROL VALVE SERVICE 15·19
LUBRICATION POINTS 3-39 PUMP PULLEY 15-20
MAINTENANCE AND TESTING 9-2 OIL SEAL REPLACEMENT 15·20
COOLING SYSTEM 9-2 DISASSEMBLY &ASSEMBLY 15-21
PRESSURE TEST 9-3 POWER STEERING SYSTEM 15-4