Description
A service manual is a must have safety item for every boater and should be kept with your boat in the event of an emergency on the water. This Clymer MerCruiser Alpha One Bravo One Bravo Two Bravo Three Stern Drive 1995 1996 1997 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1995-1997 MerCruiser Alpha One, Bravo One, Bravo Two, and Bravo Three stern drive marine engines.
Includes general information on each model, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, storage, cooling system, inline engines, V6 and V8 engines, fuel systems (carbureted models, throttle body fuel injection (TBI), multiport fuel injection (MPI)), cooling system, electrical system, MerCruiser drive system, drive shaft housing, gearcase housing (lower unit), bell housing, Gimball bearing and ring, power trim and tilt systems, steering system, corrosion protection and complete wiring diagrams. Features 712 illustrated pages.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers
CHAPTER TWO, TOOLS AND TECHINIQUES
Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanics techniques
CHAPTER THREE, TROUBLESHOOTING
Starting system, Charging system, Prestolite charging system troubleshooting, Mando charging system troubleshooting, Ignition system, Fuel system—Carbureted models, Fuel system—Fuel-injected models, Engine performance, Engine overheating, Engine oil pressure indicator, Engine oil leaks, Engine noises, Engine troubleshooting, Cooling system, Stern drive unit
CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Preoperational checks, Starting checklist, Post-operational checks, Cooling system flushing, Engine maintenance and lubrication, Stern drive lubrication, Fuel pump housing (454, 502 cid engines), General lubrication points, Engine tune-up
CHAPTER FIVE, LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT
Cooling system draining, Cooling system refilling, Cooling system conversion, Fitting out
CHAPTER SIX, INLINE ENGINES
Engine serial number and code, Special tools, Gasket sealant, Replacement parts, Engine removal, Engine installation, Disassembly checklists, Valve cover, Intake, exhaust manifolds, Rocker arm assemblies, Crankshaft pulley and torsional damper, Timing gear cover and seal, Camshaft, Oil pan, Oil pump, Cylinder head, Valves and valve seats, Valve filters, Piston, connecting rod assembly, Rear main oil seal, Crankshaft, Flywheel, Cylinder block, Core plug replacement
CHAPTER SEVEN, V6 AND V8 ENGINES
Engine serial number and code, Special tools, Gasket sealant, Replacement parts, Engine removal, Engine installation, Disassembly checklists, Valve covers, Intake manifold (carbureted engines), Intake manifold (engines equipped with throttle body fuel injection), Intake manifold (engines equipped with multiport fuel injection), Exhaust manifolds, Rocker arms, Valve lash adjustment (except big blocks and V6 engines), Crankshaft pulley and torsional
CHAPTER EIGHT, FUEL SYSTEM—CARBURETED MODELS
Flame arrestor, Carburetor fundamentals, Carburetors, Fuel pump and antisiphon devices, Fuel lines
CHAPTER NINE, FUEL SYSTEM—THROTTLE BODY FUEL INSPECTION (TBI)
Acronyms, Gasoline requirements, Fuel injection system components, Fuel injection system operation, Depressurizing the fuel system, System diagnosis, Troubleshooting, Fuel injection pump, Vapor separator tank and fuel injection pump, Fuel lift pump, Fuel injection pump relay, System relay, Fuel pressure regulator, Throttle position (TP) sensor, Manifold absolute pressure (MAP) sensor, Fuel injectors and fuel metering body, Throttle body, Idle air control (IAC) valve, Engine coolant temperature (ECT) sensor, Engine control module (ECM), Antisiphon devices, Fuel lines
CHAPTER TEN, FUEL SYSTEM—MULTIPORT FUEL INJECTION (MPI)
Acronyms, Gasoline requirements, Fuel injections system components, Fuel injection system operation, Depressurizing the fuel system, System diagnosis, Troubleshooting, Throttle body, Plenium (350 Magnum), Plenium (454 Magnum, 502 Magnum and 7.4LX), Fuel injectors and fuel rails (350 Magnum), Fuel injectors and fuel rail (454 Magnum, 502 Magnum and 7.4LX), Electric fuel pump (1997 350 Magnum and later 1997 454 Magnum, 502 Magnum and 7.4LX), Electric fuel pump and vapor separator tank (so equipped), Fuel lift pump (so equipped), Fuel pressure regulator (350 Magnum), Fuel pressure regulator (454 Magnum, 502 Magnum and 7.4LX), Fuel injection pump relay, System relay, Throttle position (TP) sensor, Manifold absolute pressure (MAP) sensor, Idle air control (IAC) valve, Engine coolant temperature (ECT) sensor, Engine control module (ECM), Intake air temperature (IAT) sensor, Antisiphon devices, Fuel lines
CHAPTER ELEVEN, COOLING SYSTEM
Thermostat, Hose replacement, Engine circulating pump, Stern drive water pump, Engine-mounted seawater pump, Drive belts, Closed cooling system maintenance, Standard cooling maintenance
CHAPTER TWELVE, ELECTRICAL SYSTEM
Battery, Charging system, Starting system, Ignition system, Thunderbolt IV ignition, Thunderbolt V ignition, EST ignition (model 3.0LX), EST ignition (fuel-injected models), Ingition coil, Switches and connectors, Solenoids, Oil pressure switch, sender unit, Water temperature sending unit, Electrical protection, Audio warning system
CHAPTER THIRTEEN, MERCRUISER DRIVE SYSTEM
MerCruiser Alpha One drive, MerCruiser Bravo One, Bravo Two and Bravo Three drive
CHAPTER FOURTEEN, DRIVE SHAFT HOUSING
Fastener removal, Service precautions, Alpha One drive, Bravo One, Bravo Two and Bravo Three drive
CHAPTER FIFTEEN, GEARCASE HOUSING (LOWER UNIT)
Fastener removal, Service precautions, Alpha One drive, Brave One and Bravo Two drives, Bravo Three
CHAPTER SIXTEEN, BELL HOUSING, GIMBAL BEARING AND GIMBAL RING
Exhaust bellows, tub, Shift cable service, Gimbal bearing, Bell housing service, Water hose and water tube, Gimbal ring, swivel shaft and steering lever service, Gimbal housing service
CHAPTER SEVENTEEN, POWER TRIM AND TILT SYSTEMS
Low-pressure pump system, Auto trim system, Trim cylinders
CHAPTER EIGHTEEN, STEERING SYSTEMS
Safety precautions, Mechanical steering system, Power steering system
CHAPTER NINETEEN, CORROSION PROTECTION SYSTEMS
Corrosion, Sacrificial anodes, Continuity devices, Galvanic isolator, MerCathode system, Corrosion protection set
INDEX
WIRING DIAGRAMS
SKU: B744
