The following information covers factory service procedures for servicing the alternator on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 and 2006 models.
A download repair manual, also termed service manual, workshop manual or shop manual is a digitally delivered book of repair instructions. Digital books are virtually identical to a book you'd buy in a book store. The books are instantly delivered to your computer.
- 5.0L V8 MPI Alpha and Bravo
- 350 MAG MPI Alpha and Bravo
- 350 Mag MPI Alpha and Bravo Horizon
- MX 6.2L MPI
- MX 6.2L MPI Horizon
INBOARD AND TOW SPORTS (MIE)
- 350 MAG MPI Inboard
- 350 MAG MPI Horizon Inboard
- MX 6.2 MPI Inboard
- MX 6.2 MPI Horizon Inboard
- 350 MAG MPI Tow Sports
Testing and diagnosis helps determine problems and possible causes. Its important to perform extensive testing and troubleshooting prior to any major tear down or repair work. This ensures that the full extent of the problem is understood beforehand and may prevent any unnecessary repair work. Its recommended you use a factory repair manual when performing repairs on any vehicle, additional safety precautions, or technical data maybe included.
ALTERNATOR REMOVAL
WARNING: Always remove both battery cables from the battery before servicing your engine. Failure to remove cables can lead to shock and ignition of accumulated ignitable fumes or materials.
1. Remove the positive and negative cables from the battery.
2. Remove the lead and ground wires.
3. Remove the excitation wire.
4. Remove the drive belt.
5. Take off the alternator mounting bolts including washers.
6. Take off the alternator.
ALTERNATOR BRACKET REMOVAL
1. Drain the cooling system fluid.
2. Take off the water circulating pump hose.
3. Take off the bracket.
ALTERNATOR BRACKET INSTALLATION
1. Reinstall the alternator bracket.
Torque Specifications: Alternator Mounting Bracket 41 Nm (30 lb-ft)
2. Reinstall the water circulating pump hose and tighten the hose clamps securely.
ALTERNATOR INSTALLATION
1. Reinstall the idler brace.
2. Place the alternator in the alternator mounting bracket.
3. Reinstall the mounting bolts and torque to specifications.
Torque Specifications: Mounting Bolts M8 x 1.25 11 Nm (8 lb-ft)
4. Reinstall the alternator drive belt on the pulleys and adjust the tensioner.
5. Connect the wiring harness to the alternator.
6. Reconnect both the negative and positive cables to the battery.
7. Fill the cooling system with the proper fluid.
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The following information covers factory service procedures for electronic control module (or ECM) on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 2001 2002 2003 2004 2005 and 2006 models.
- 5.0L V8 MPI Alpha and Bravo
- 350 MAG MPI Alpha and Bravo
- 350 Mag MPI Alpha and Bravo Horizon
- MX 6.2L MPI
- MX 6.2L MPI Horizon
- 350 V8 5.7L MAG MPI Inboard
- 350 V8 MAG MPI Horizon Inboard
- MX 6.2 Multi-Port Injection Inboard
- MX 6.2 MPI Horizon Inboard
- 350 MAG MPI Tow Sports
Testing and diagnosis helps determine problems and possible causes. Its important to perform extensive testing and troubleshooting prior to any major tear down or repair work. This ensures that the full extent of the problem is understood beforehand and may prevent any unnecessary repair work. Its recommended you use a factory repair manual when performing repairs on any vehicle, additional safety precautions, or technical data maybe included.
ECM REMOVAL
IMPORTANT: The ECM is a very sensitive piece of electrical equipment and is subject to electrostatic damage. Never touch the connector pins when installing or removing the electronic control module.
1. Detach the electrical connectors on the ECM. Never touch the connector pins.
2. Take off the ECM from the module bracket.
ECM CLEANING AND INSPECTION
1. Clean the outer exterior of the ECM with a dry and clean shop towel. Do not touch the touch or come in contact with the connector pins.
2. Check the outer housing for signs of excessive wear, corrosion or damage.
Mercruiser 5.7 Manual Download For Pc
3. Carefully inspect the electrical pins at both ends of the ECM for corrosion and straightness.
Mercruiser 5.7 Service Manual
4. Carefully inspect the wiring harness connectors for signs of corrosion and terminals for loose connections.
NOTE: The ECM is a designed to be a sealed electrical device, if the item appears to be damaged, replace the ECM.
ECM INSTALLATION
1. Install the ECM back on the module bracket using the existing washers and brackets.
2. Reconnect the ECM wiring harness connectors, never touch the connector pins.
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