Index

A Rochester 4GC . . . . . . . . . . . . 317-323 drive shaft housing

Rochester 4MV and 4MY .. .323-326 bearingcups............. 493
Alternator troubleshooting MerCarb intermediate shift shaft/seal . . . 493
direct drive . . . . . . . . . . . . . . . . . . 368 acceleration “Bog” . . . . . . . . . . 289 top cover/water
Mando...................384-385 vapor lock (MCM 120/140 pocket cover . . . . . . . . . 488-489
MetCruiser 470 . . . . . . . . . . , . . . 369 17OMR/19OMR). . . . . . . . .289-290 universal joint . . . . . . . . . . . . . . 48 1
Motorola. . . . . . . . . . . . . . . . , 380-384 Charging system. . . . . . . . . . . . . . .33-35 universal joint, drive gear
rotor/&&or . . . . . . . . . . . . . . . 258-259 Compression test. . . . . . . . . . . . . . . 69-70 and bearing. . . . . . . . . . 489-492
Alternator charging system upper drive shaft bearing
Cooling system
MerCruiser 470 preload. . . . . . . . . . . . . . 494-495
closed cooling system. . . . . . .344-363
(air-cooled regulator) . . . . . . . . 369 upper drive shaft/driven
alkalinity test. . . . . . . . . . . . . . . 348
MetCruiser 470,485 and 488 gear assembly . . . . . . . . 492-493
cleaning fresh water section. .. 348
(water-cooled regulator). . . 369-370 cleaning seawater section water shutter clatter. . . . . . . . . . 48 1
of heat exchanger. . . . . . . . . 348 ModelII . . . . . . . . . . . . . . . . 495-499
B system draining. . . . . . . . . . . 89-101 Model II-TR and II-TRS drive
engine circulating pump. . . . . 342-345 drive gear clearance . . . . . . . . . 506
Battery . . . . . . . . . . . . . . . . . 60,364-368 filling . . . . . . . . . . . . . . . . . . . . 101-103 driven gear clearance . . . . . . . . 506
Bell housing (I, I-R and I-MR) flushing . . . . . . . . . . . . . . . . . . . . 50-52 drive shaft and driven
assembly., . . . . . . . . . . . . . . . 517-519 hose replacement . . . . . . . . . . 34 l-342 gear assembly . . . . . . . . 504506
cleaning and inspection . . . . . 516-517 inline engines . . . . . . . . . . . . . . . 89-90 drive shaft housing . . . . . . . . . . 499
disassembly . . . . . . . . . . . . . . . . . 516 seawater engine lower drive shaft bearing cup,
installation . . . . . . . . . . . . . . . 5 19-520 pump . . . . . . . . . . . . . . . . . . . . . 347 spacer and coupling . . . 502-503
removal . . . . . . . . . . . . . . . . . . 513-516 seawater pickup pump top and rear cover. . . . . . . . . . . 502
shift cable inner core . . . . . . . . . . 523 (stem drive unit). . . . . . . . . 345-347 universal joint/drive gear . 503-504
Bell housing (II-TRS) . . . . . . . . 520-521 standard cooling system service precautions . . . . . . , . 480-48 1
Breaker point distributor . . . . . . 392-396 maintenance . . . . . . . . . . . . . . . 363 Drive system, MetCruiser
thermostat . . . . . . . . . . . . . . . . 338-341 MetCruiser model 0. . . . . . . 404-410
C troubleshooting. . . . . . . . . . . . . . . . 44 MetCruiser model I
V6 and V8 engines . . . . . . . . . . . 94-97 remote control cable
Carburetor fuel inlet filter . . . . . , . . . 58 adjustment.. . . . . . . . . 418-419
Carburetor fundamentals . . . . . , . . . 288 ride-guide steering cable
Carburetors D attachment.. . . . . . . . . . 414-416
Carter RBS assembly. . . . . , . 297-305 shift cable adjustment. . . . 417-418
Holley 2300-C and 6317-1 Delco-Remy external stem drive. . . . . . . . . . . . . 410-412
assembly.. . . . . . . . . . . . . . 312-317 regulator system. . . . . . . . . . .370-373 stem drive and remote
Holley 4160,6407 and 6576 Direct drive alternator control shift cables . . . . 416-417
assembly. . . . . . . . . . . . . . . 326-332 chargingsystem.............. 368 tilt/trim cylinder
maintenance . . . . . . . . . . . . . . . . 75-76 Distributor installation. . . . . . . . . . . 419-42 1
MerCarb right turn lean-out. . . . , 289 breaker point. . . . . . . . . . . . . . 392-396 transom plate. . . . . . . . . . . 412-414
Mercury MD. . . . . . . . . . . . . . 305-306 Thunderbolt . . . . . . . . . . . . . . 396-397 MetCruiser model II
no idle mixture adjustment Drive belt adjustment non-transom mounted
(MerCarb carburetor). . . . . . . . 289 replacement. . . . . . . . . . . . . . .385-386 changing propeller shaft
preparation for overhaul. . . . . . . . 290 Drive shaft housing rotation . . . . . . . . . . . . . . . . . 430
removal/installation . . . . . . . . . . . 290 Model I drive ride-guide attachment. . . . 429-430
Rochester B and BC . . . . . . . . 291-306 drive gear clearance . . . . . .493-494 shift cable adjustment. . . . 423-428 19
Rochester 2GC, 2GV and driven gear clearance . . . . . . . . 494 stem drive . . . . . . . . . . . . . 421-423
MerCarb 2-bbl.. . . . . . . . . . 306-312 drive shaft housing . . . . . . .481-488 throttle control cable. . . . . 428-429
552 INDEX

MetCruiser model II (continued) piston/connecting rod replacement parts . . . . . . . . . . . . . 2 19

tilt/trim cylinder installation. . . 43 1 assembly . . . . . . . . . . . . . . . 125-131 rocker arm assembly. . . . . . . 226-227
transom plate . . . . . . . . . . . . . . 423 piston clearance check . . . . . . . . . 127 rocker arm cover. . . . . . . . . . . . . . 224
MetCruiser model II piston pin removal/installation . . . 127 serial number . . . . . . . . . . . . . . . . . 218
transom mounted . . . . . . . . 43 l-432 piston removal . . . . . . . . . . . . 125-127 special tools. . . . . . . . . . . . . . . . . . 218
MerCruiser II-TR, II-IRS, piston ring fit/installation . . . . 127-129 valves and valve seats. . . . . . 236-241
lII and 215-H . . . . . . . . . . . 432-436 removal. . . . . . . . . . . . . . . . . . 105-106 Engines, MetCruiser 470,485,488,
MetCruiser 215-E. . . . . . . . . . 436-439 replacement parts . . . . . . . . . . . . . 105 170MR and 19OMR
rocker arm assemblies . . . . . . . . . 113 alternator rotor/stator . . . . . . . 258-259
rocker arm cover. . . . . . . . . . . . . . 108 camshaft. . . . . . . . . . . . . . . . . 262-263
E
serial number . . . . . . . . . . . . . . . . 104 core plugs . . . . . . . . . . . . . . . . . . . 279
Engine noises . . . . . . . . . . . . . . . . . 41-43 special tools . . . . . . . . . . . . . . . . . 104 crankshaft . . . . . . . . . . . . . . . 275-277
Engine oil and filter change. . . . . . 54-56 timing gear cover and seal . . . 112-113 cylinder block. . . . . . . . . . . . 278-279
Engine oil leaks . . . . . . . . . . . . . . . . . 41 valves and valve seats. . . . . . . 121-125 cylinder head. . . . . . . . . . . . . 266-267
Engine oil level check . . . . . . . . . . 52-54 Engines, GM V6 and V8 disassembly checklists . . . . . . . . . 256
Engine oil pressure indicator . . . . . 39-41 camshaft . . . . . . . . . . . . . . . . . 149-152 exhaust manifold. . . . . . . . . . 257-258
Engine performance . . . . . . . . . . . . 38-39 core plugs . . . . . . . . . . . . . . . . . . . 168 flywheel housing, coupler
Engines, Ford V8 crankshaft . . . . . . . . . . . . . . . . 164-165 and flywheel . . . . . . . . . . . 277-278
camshaft . . . . . . . . . . . . . . . . . 194-196 crankshaft pulley and front cover and seals. . . . . . . 259-260
core plugs . . . . . . . . . . . . . . . . 213-214 torsional damper. . . . . . . . . . . . 146 installation. . . . . . . . . . . . . . . 254-256
crankshaft................208-211 cylinder block. . . . . . . . . . . . . 167-168 intake manifold. . . . . . . . . . . 256-257
crankshaft pulley and cylinder head. . . . . . . . . . . . . . 154-155 oil pan . . . . . . . . . . . . . . . . . . 264-265
vibration damper . . . . . . . . . . . 190 disassembly checklists . . . . . . 142-143 oil pump . . . . . . . . . . . . . . . . 265-266
cylinder block. . . . . . . . . . . . . 212-213 exhaust manifolds . . . . . . . . . . 145-146 piston/connecting rod
cylinder head . . . . . . . . . . . . . 198- 199 flywheel . . . . . . . . . . . . . . . . . 166-167 assembly . . . . . . . . . . . . . . 27 l-275
disassembly checklists . . . . . . 186-187 front cover and seal . . . . . . . . . . . 147 removal . . . . . . . . . . . . . . . . . 253-254
exhaust manifolds. . . . . . . . . . 189-190 installation . . . . . . . . . . . . . . . . . . . 142 replacement parts . . . . . . . . . 252-253
flywheel . . . . . . . . . . . . . . . . . . . . 212 intake manifold . . . . . . . . . . . . 144-145 rocker arm assemblies. . . . . . 260-261
front cover and seal . . . . . . . . 190-191 oil pan. . . . . . . . . . . . . . . . . . . 152-153 rocker arm cover. . . . . . . . . . . . . . 256
installation . . . . . . . . . . . . . . . . . . 186 oil pump . . . . . . . . . . . . . . . . . . 153-154 serial number. . . . . . . . . . . . . . . . . 252
intake manifold . . . . . . . . . . . . 187-189 piston/connecting rod special tools. . . . . . . . . . . . . . . . . . 252
oilpan . . . . . . . . . . . . . . . . . . . . . . 196 assembly . . . . . . . . . . . . . . . 160-164 timing chain and
oil pump. . . . . . . . . . . . . . . . . 197-198 rear main oil seal. . . . . . . . . . . . . . 147 sprockets. . . . . . . . . . . . . . 263-264
piston/connecting rod removal . . . . . . . . . . . . . . . . . . 141-142 valves and valve seats. . . . . . 268-270
assembly. . . . . . . . . . . . . . . 203-208 replacement parts . . . . . . . . . . 140-141
rearmainbearingoilseal.... 211-212 rocker arm assemblies . . . . . . 148-149 F
removal . . . . . . . . . . . . . . . . . . 183-186 rocker arm cover. . . . . . . . . . . . . . 143
replacement parts . . . . . . . . . . . . . 183 serial number . . . . . . . . . . . . . . . . 140 Fitting out . . . . . . . . . . . . . . . . . . . . . 103
rocker arm assemblies . . . . . . . . . 193 special tools . . . . . . . . . . . . . . . . . 140 Flame arrestor. . . . . . . . . . . . . . . 60,287
rocker arm cover. . . . . . . . . . . . . . 187 timing chain and Fuel system (see also Carburetors)
serial number . . . . . . . . . . . . . . . . 182 sprockets . . . . . . . . . . . . . . . 147-148 filter (canister-type) . . . . . . . . . . . . 58
special tools . . . . . . . . . . . . . . 182-183 valves and valve seats. . . . . . . 156-161 fuel inlet filter . . . . . . . . . . . . . . . . . 58
timing chain and sprocket . . . 192-193 Engines, MerCruiser 60,80 and 90 fuel lines . . . . . . . . . . . . . . . . 334-3,35
valves and valve seats . . . . . . 200-202 camshaft and timing chain .. .227-231 fuel pump . . . . . . . . . . . . .
Engines, GM inline core plugs . . . . . . . . . . . . . . . . . . . 248 fuel quality . . . . . . . . . 58-
camshaft . . . . . . . . . . . . . . . . . 113-116 crankshaft . . . . . . . . . . . . . . . .244-246 system service. . . . . . . . . .
connecting rod . . . . . . . . . . . . 129- 130 cylinder block. . . . . . . . . . . . .247-248 troubleshooting. . . . . . . . . . . . . 43-44
core plugs. . . . . . . . . . . . . . . . 134-135 cylinder head. . . . . . . . . . . . . .234-236
crankshaft . . . . . . . . . . . . . . . . 131-133 disassembly checklists . . . . . . 223-224
crankshaft pulley/torsional flywheel . . . . . . . . . . . . . . . . .246-247 G
damper . . . . . . . . . . . . . . . . . . . 190 front cover and seal . . . . . . . . . . . 226 Gasoline recommendations. . . . . . 59-60
cylinder block. . . . . . . . . . . . . 133- 136 inner transom plate. . . . . . . . .225-226 Gear housing
cylinder head . . . . . . . . . . . . . 119-121 installation. . . . . . . . . . . . . . . .221-223 Model I drive
disassembly checklist. . . . . . . 107-108 intake/exhaust manifolds . . . .224-225 bearing carrier/
flywheel . . . . . . . . . . . . . . . . . . . . 133 oilpan . . . . . . . . . . . . . . . . . . . . . . 232 reverse gear. . . . . . . . . . 450-454
installation . . . . . . . . . . . . . . . 106-107 oil pump . . . . . . . . . . . . . . . . .232-234 drive shaft/pinion gear . . . 452-454
intake/exhaust manifolds . . . . 108-l 11 piston/connecting rod Model I-MR drive
oilpan....................... assembly . . . . . . . . . . . . . . .241-244 bearing carrier/
oilpump.. . . . . . . . . . . . . . . . . . . . 118 removal . . . . . . . . . . . . . . . . . .219-221 reverse gear. . . . . . . . . . . . . . 473
 553

Model I-MR drive (continued) MetCruiser 215, II-TR, hydraulic sub-system . . . . . 539-543
drive shaft pinion gear . . . . 473-476 II-TRS and III. . . . . . . . . . . . . 68-69 low pressure pump system . . . . . 543
drive shaft roller bearing, Model 0 (60,80 and 90) . . . . . .62-63
drive shaft and forward
gear bearing cups . . . . . . . . . 475 R
M
forward and reverse Rectifier test . . . . . . . . . . . . . . . . . . . 340
gear backlash . . . . . . . . . . . . 476 Mando alternator system . . . . . . 384-385
Regulator (see Integral regulator system)
gear housing. . . . . . . . . . . . 469-473 Manifolds
Rocker arm cover
propeller shaft/forward gear. .. 475 Ford V8 . . . . . . . . . . . . . . . . . . 187-190
FordV8.. . . . . . . . . . . . . . . . . . . . 187
shift shaft . . . . . . . . . . . . . . . . . 475 GM inline . . . . . . . . . . . . . . . . 108-111
GM inline . . . . . . . . . . . . . . . . . . . 108
Model II drive GM V6 and V8 . . . . . . . . . . . . 144-146
GMV6andV8 . . . . . . . . . . . . . . . 143
drive shaft . . . . . . . . . . . . . . 461-463 MetCruiser 60,80 and 90. .. .224-225
MerCruiser 60,80 and 90. . . . . . . 224
gear housing. . . . . . . . . . . . 469-473 MerCruiser 470,485,488,
propeller shaft. . . . . . . . . . . . . . 461 170MR and 190MR . . . . . . . . . 256 MerCruiser 470,485,488,
Motorola alternator system. . . . . 380-384 17OMR and 190MR . . . . . . . . . 256
Model II-TR and II-TRS drive
bearing carrier . . . . . . . . . . 464-466
drive shaft/pinion gear. . . . 466-467 N S
gear housing. . . . . . . . . . . 463,468
propeller shaft assembly. .. 467-468 Neutral safety switch . . . . . . . . . . . . 402 Starting system
shimming . . . . . . . . . . . . . . 468-469 brush replacement. . . . . . . . . 388-392
service precautions. . . . . . . . . 444-445 on-boat testing. . . . . . . . . . . . . . . . 387
0
Gimbal bearing. . . . . . . . . . . . . . 524-525 relay removal/installation. . . . . . . 388
Gimbal ring Gil and filter change. . . . . . . . . . . .54-56 solenoid removal/
without side-mounted rotary Gil level check . . . . . . . . . . . . . . . .52-54 installation . . . . . . . . . . . . . 387-388
trim-switch. . . . . . . . . . . . . 525-528 Gil pan starter removal/installation. . . . . . 388
with side-mounted rotary FordV8 . . . . . . . . . . . . . . . . . . . . . 196 troubleshooting. . . . . . . . . . . . . . . . 33
trim-switch. . . . . . . . . . . . . 528-529 GM inline . . . . . . . . . . . . . . . . 117-118 Stem drive lubrication. . . . . . . . . . 60-62
with square upper GM V6 and V8 . . . . . . . . . . . . 152-153 Stem drive unit . . . . . . . . . . . . . . . . . . 44
swivel shaft. . . . . . . . . . . . . 529-53 1 MerCruiser 60,80 and 90. .. .232-234 Switches
MetCruiser 470,485,488, ignition system . . . . . . . . . . . 397-398
170MR and 190MR . . . . . .264-265 power trim control panel
I Gil pump switch . . . . . . . . . . . . . . . . 400-401
Ignition system Ford V8 . . . . . . . . . . . . . . . . . . 197-198 switch panel test . . . . . . . . . . . . . . 400
breaker point gap GM inline . . . . . . . . . . . . . . . . 118-119 three-button switch . . . . . . . . . . . . 401
adjustment . . . . . . . . . . . . . . . 73-74 GM V6 and V8. . . . . . . . . . . . 153-153 toggle switch. . . . . . . . . . . . . 401-402
coil . . . . . . . . . . . . . . . . . . . . . . . . MetCruiser 60,80 and 90. .. .232-234 two-station tachometer
397
contact breaker point , MetCruiser 470,485,488, switch . . . . . . . . . . . . . . . . 398-399
replacement . . . . . . . . . . . . . . . . 170MR and 190MR . . . . . .265-266
73
distributor cap, wires T
and rotor. . . . . . . . . . . . . . . . . 72-73 P
electrical system. . . . . . . . . . . 392-397 Thunderbolt distributor. . . . . . 396-397
Power trim and tilt system
ignition resistance wire. . . . . . . . . 397 Troubleshooting
auto trim system . . . . . . . . . . . 546-550
ignition timing . . . . . . . . . . . . . . 74-75 high pressure pump system . . 533-539 charging system . . . . . . . . . . 33-35
spark plug. . . . . . . . . . . . . . . . . . 71-72 dual solenoid system. . . . . . . . . 534 cooling system . . . . . . . . . . . . . . 44
troubleshooting . . . . . . . . . . . . . . 35-38 dual trim test sequence. . . . 537-539 engine noises. . . . . . . . . . . . . 41-43
Integral regulator system electrical sub-system . . . . . . . . 533 engine oil leaks . . . . . . . . . . . . . . 41
early model Delco-Remy . . . . 373-374 port trim switch testing. . . . . . . 539 engine oil pressure indicator . 39-41
late model Delco-Remy . . . . . 374-380 power trim indicator sender . . . 402 engine performance. . . . . . . . 38-39
pump protection . . . . . . . . . . . . 534 fuel system . . . . . . . . . . . . . . 43-44
single solenoid system . . . . . . . 533 ignition system . . . . . . . . . . . 35-38
L starting system . . . . . . . . . . . . . . 33
starboard trim switch testing . . 539
Lay-up . . . . . . . . . . . . . . . . . . . . . . 84-88 trailer switch testing . . . . . . . . . 539 stem drive unit . . . . . . . . . . : ’ 69-7644
Lubrication trim indicator gauge . . . . . . . . . 537 Tune-up . . . . . . . . . . . . . . . . . .
early model I, IA and IB trim limit/trim position
(includes E-Z shift) . . . . . . . . 63-64 sender switches. . . . . . . . 535-537 W
late model I. . . . . . . . . . . . . . . . . 64-66 trim position sender . . . . . .535-537
MetCruiser II . . . . . . . . . . . . . . . 66-67 trim switch testing . . . . . . .537-539 Wiring diagrams . . . . . . . . . . . . 554-600