Removal
! CAUTION
DO NOT allow lifting sling to hook or compress
engine components or damage will occur.
IMPORTANT: Stern drive unit must be removed
prior to engine removal. Refer to Stern Drive Ser-
vice Manual.
!
CAUTION
Engine Removal
Multi-Port engines MUST be lifted with a lifting
arm or damage to engine components will occur.
1.
2.
Disconnect battery cables from battery.
12.
Support engine with suitable sling through lifting
eyes on engine and remove front and rear engine
mounting bolts. Retain hardware.
Remove instrument harness connector plug from
engine harness receptacle after loosening
clamp.
a
!
WARNING
Be careful when working on fuel system. Gaso-
line is extremely flammable and highly explosive
under certain conditions. Do not smoke or allow
spark or open flame in area. Wipe up any spilled
fuel immediately.
b
72578
3.
Using wrench to stabilize brass filter nut at fuel in-
let, loosen fuel line fitting, disconnect and suitably
plug fuel line to prevent fuel in tank from leaking
into bilge.
a
4.
5.
Disconnect throttle cable from carburetor, or
throttle body on Fuel Injection models, and retain
locknuts and hardware.
Disconnect bullet connectors of trim senderwires
(coming from transom assembly) from engine
harness.
NOTE: After wires are disconnected be sure to loos-
en them from clamps or sta-straps retaining them to
engine or hoses.
6.
Disconnect MerCathode wires from MerCathode
controller if mounted on engine (some models).
7.
Disconnect seawater inlet hose from gimbal
housing.
72580
8.
9.
Disconnect exhaust elbow hoses (bellows).
Remove both shift cables from shift plate. Retain
locknuts and hardware.
b
a
10.
11.
Disconnect any grounding wires and accessories
that are connected to engine.
Disconnect (and suitably plug) fluid hoses from
power steering control valve on transom.
72579
a - Suitable Sling
b - Engine Lifting Eyes
!
CAUTION
13.
Carefully remove engine. DO NOT hit power
steering control valve.
Center lifting eye (located on top of thermostat
housing) is used for engine alignment only. DO
NOT use to lift entire engine.
Index
2A-2 - MCM MODELS - BRAVO AND BLACKHAWK DRIVES
90-823224--2 796
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | Mercury MerCruiser 454 CID, Mercury MerCruiser 502 CID |
| Model Year | 1993, 1994, 1995, 1996, 1997 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution Non-commercial |
(4 votes, average: 4.5 out of 5)
Marine readers have rated 1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16 4.5 out of 5.0 based on 4 product reviews. Hugely helpful service manual! Perfect. Thank you!
Manuals are all Important for Technician
This book is invaluable if you do your own repairs. Great book.
Could not find a copy until a search brought me here.
Excellent print.
Thank you