Mercury-MerCruiser GM V6 262 CID 4.3L Marine Engines Service Manual Number 25 Sections 1-3

Section 4A - Starting Systems
Identification . . . . . . . . . . . . . . . . . . . . . . . .
4A-2
4A-2
4A-2
4A-3
4A-4
4A-4
4A-4
4A-6
4A-7
4A-7
4A-8
Periodic Inspection  . . . . . . . . . . . . . . . . . .
4A-13
4A-13
4A-13
4A-13
4A-16
4A-17
4A-21
4A-22
4A-23
4A-23
4A-23
4A-23
4A-23
4A-24
4A-25
4A-25
4A-26
4A-26
4A-26
4A-30
4A-31
4A-32
4A-32
4A-33
4A-33
4A-34
Replacement Parts Warning  . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . .
Starting System Components  . . . . . . . . .
Positive Current Flow  . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cable Recommendations  . . .
Maintenance  . . . . . . . . . . . . . . . . . . . . .
Testing  . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage  . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Guide  . . . . . . . . . . . . . . . . . .
How Temperature Affects
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly  . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Reassembly  . . . . . . . . . . . . . . . . . . . . .
Checking Pinion Clearance  . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Delco PG260 Starter . . . . . . . . . . . . . . . . .
PG260 Specifications  . . . . . . . . . . . . .
Torque Specification  . . . . . . . . . . . . . .
Lubricants / Sealants . . . . . . . . . . . . . .
Description  . . . . . . . . . . . . . . . . . . . . . .
PG260 Exploded View  . . . . . . . . . . . . . . .
Solenoid Switch . . . . . . . . . . . . . . . . . . . . .
Periodic Inspection  . . . . . . . . . . . . . . . . . .
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly  . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection  . . . . . . . . . . .
Armature Tests  . . . . . . . . . . . . . . . . . . .
Armature Bearing (Commutator End)
Gear Bearing   . . . . . . . . . . . . . . . . . . . .
Shaft Assembly Bearing  . . . . . . . . . . .
Drive End Housing Bearing  . . . . . . . .
Brushes and Brush Holder  . . . . . . . . .
Battery Power  . . . . . . . . . . . . . . . . . . .
Standard Starter Slave Solenoid  . . . . . .
Identification  . . . . . . . . . . . . . . . . . . . . .
Standard Type Slave Solenoid   . . . . .
Testing / Replacement . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Permanent Magnet - Gear Reduction
(PG260F1) Starter Motor . . . . . . . . . . . . .
Starter Specifications   . . . . . . . . . . . . .
Torque Specifications  . . . . . . . . . . . . .
Lubricants / Sealants . . . . . . . . . . . . . .
Description  . . . . . . . . . . . . . . . . . . . . . .
PG260F1 Exploded View . . . . . . . . . . . . .
Solenoid Switch . . . . . . . . . . . . . . . . . . . . .
4A-8
4A-9
4A-9
4A-9
4A-9
4A-10
4A-10
4A-10
4A-10
4A-10
4A-11
4A-12
4A-13
Section 4B - Thunderbolt V Ignition System
Replacement Parts Warning  . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . .
EFI System Maintenance Precautions   .
Thunderbolt V Ignition System  . . . . . . . .
Identification  . . . . . . . . . . . . . . . . . . . . .
Timing and Idle Adjustment Procedures
Setting Base Ignition Timing . . . . . . . .
Adjusting Idle Mixture  . . . . . . . . . . . . .
Spark Plugs  . . . . . . . . . . . . . . . . . . . . . . . .
Specifications  . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Inspection  . . . . . . . . . . . . . . . . . . . . . . .
Replacing   . . . . . . . . . . . . . . . . . . . . . . .
Description  . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Speed Spark Control  . . . . . . . . . .
Acceleration Spark Advance  . . . . . . .
Mean-Best-Timing (MBT)
4B-2
4B-2
4B-3
4B-4
4B-4
4B-5
4B-5
4B-5
4B-6
4B-6
4B-6
4B-6
4B-7
4B-7
4B-7
4B-8
Circuit Description . . . . . . . . . . . . . . . . . . .
Ignition Control Module . . . . . . . . . . . .
Knock Control Module . . . . . . . . . . . . .
Ignition Control System Timing Lead
Thunderbolt V Spark Control Graph   . . .
Distributor Advance Curves . . . . . . . . . . .
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly  . . . . . . . . . . . . . . . . . . . . .
Reassembly  . . . . . . . . . . . . . . . . . . . . .
Installation - Engine Not Disturbed  . .
Installation - Engine Disturbed . . . . . .
Distributor Cap . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Inspection  . . . . . . . . . . . . . . . . . . . . . . .
Rotor/Sensor Wheel  . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Inspection  . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal   . . . . . . . . . . . . . . . . . . . . . . . .
Inspection  . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
4B-10
4B-10
4B-10
4B-10
4B-11
4B-12
4B-12
4B-12
4B-13
4B-13
4B-14
4B-14
4B-15
4B-15
4B-15
4B-16
4B-16
4B-16
4B-17
4B-17
4B-17
4B-18
4B-18
Spark Advance  . . . . . . . . . . . . . . . . . .
Over-Speed Control . . . . . . . . . . . . . . .
Knock Retard Spark Control   . . . . . . .
Spark Plug Wires . . . . . . . . . . . . . . . . . . . .
Adjusting Engine Idle Speed  . . . . . . .
4B-8
4B-8
4B-8
4B-9
4B-9
90-861328--1
NOVEMBER 1999
Page vii
Product Specification
CategoriesMercury MerCruiser Manuals
Tags,
Model Year1998, 1999, 2000, 2001
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Mercury-MerCruiser GM V6 262 CID 4.3L Marine Engines Service Manual Number 25 Sections 1-3 SKU UPC Model
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