MerCruiser Alpha One, Bravo One, Two & Three Stern Drives 1998 - 2013

Clymer Owners Marine Service & Repair Manual

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013

by Clymer Staff

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MerCruiser Alpha One, Bravo One, Two & Three Stern Drives 1998 - 2013 - Front Cover

Front Cover

Front Cover

description

MerCruiser Alpha One, Bravo One, Two & Three Stern Drives 1998 - 2013 Clymer Owners Marine Service & Repair Manual covers the following:
Stern Drives:
● MerCruiser Alpha One (1998-2013)
● MerCruiser Bravo One (1998-2013)
● MerCruiser Bravo Two (1998-2013)
● MerCruiser Bravo Three (1998-2013)

Engines:
● 3.0 L (1998-2013)
● 4.3 L (1998-2013)
● 5.0 L (1998-2013)
● 5.7 L (1998-2013)
● 350 Mag (1998-2013)
● MX 6.2 L (1998-2013)
● 454 Mag (1998-2013)
● 502 Mag (1998-2013)
● 496 Mag (1998-2013)
● 496 Mag HO (1998-2013)
● 7.4 L MPI (1998-2013)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques

TROUBLESHOOTING
Starting system / Charging system Drive unit identification / Starting system / Ignition system /Spark test / Knock control test / Shift interrupt switch test / Battery charging system / Fuses, circuit breaker and wiring harness / Fuel system / Oil pressure switch test / Carburetor / Electronic fuel injection (EFI) / Trouble codes / Idle air control motor test / Warning system / Engine mechanical / Cooling system / Drive unit / Trim system / Power steering / Mercathode system

LUBRICATION, MAINTENANCE AND TUNE-UP
Before each use / After each use / Lubrication / Engine oi land filter change / Gearcase lubricant change / Propeller shaft lubrication / Engine coupler lubrication / Gimbal bearing lubrication / Universal joint lubrication and inspection / Steering system lubrication / Periodic inspection / Bellow inspection / Engine alignment / Winter inlet inspection / Gimbal ring fastener inspection / Anode and ground wire inspection / Engine coolant change (closed cooling system) / Heat exchanger cleaning / Pressure cap test / Coolant test / Clamps and fittings / Fuel requirements / Fuel filter service / Flame arrestor / PVC Valve / Carburetor and throttle body / Throttle and shift cable / Tune-up / Compression test / Spark plugs / Valve adjustment / Carburetor adjustment / Ignition timing / Test running engine / Specifications

LAY-UP, WINTERIZING AND FITTING OUT
Lay-up / Winterizing / Testing the coolant / Fitting out / Specifications

ADJUSTMENTS
Drive belts / Trim position sender adjustment / Shift cable adjustment / Throttle cable / Ignition timing adjustment / Idle mixture and idle speed adjustment / Trim tab adjustment / Specifications

ENGINE
Removal installation / Engine alignment / Valve adjustment / Placing the No. 1 piston at TDC / Camshaft lobe lift / Cylinder head / Pushrod, rocker arm and rocker arm cover / Oil pan / Oil pump / Harmonic balancer / Timing gear cover / Timing chain and sprocket / Balance shaft / Camshaft and lifter / Piston and connecting rod / Crankshaft and rear main seal / Break-in / Specifications

FUEL SYSTEM
Carburetor / Cool fuel system / Boost pump removal installation (496 Mag and 496 Mag HO) / Throttle body TBI / Fuel rail and injectors / Air pressure sensor / Engine temperature sensor / Air temperature sensor / Fuel pressure sensor / Throttle position sensor / Knock sensor module / Idle air control motor / Manifold temperature sensor / Camshaft position sensor / Crankshaft position sensor / System relay and fuel pump relay / Engine control unit ECU / Manifold / Specifications

EXHAUST AND COOLING SYSTEM
Exhaust elbow / Exhaust flapper valve / Exhaust manifold / Water rail / Heat exchanger / Engine circulating pump / Thermostat and housing / Seawater pump / Coolant reservoir / Specifications

ELECTRICAL AND IGNITION SYSTEMS
Starting system / Ignition system / Warning system / Oil pressure sender / Oil pressure switch / Overheat switch / Engine temperature sensor / Engine temperature sender / Gearcase lubricant monitor / Water pressure sensor / Charging system / Specifications

DRIVE UNIT AND PROPELLER
Alpha drive / Bravo drive / Drive ratio identification / Propeller / Drive unit removal installation / Water pump / Gearcase / Bravo I II III models / Drive shaft housing / Drive shaft unit inspection / Specifications

TRANSOM ASSEMBLY
Gimbal bearing / Shift cable / Trim limit switch and trim sender / Water hose / Bell housing / Gearcase lubricant hose and fitting / Exhaust bellows / Exhaust tube / Universal joint bellows / Speedometer hose and fitting / Gimbal ring, swivel shaft and steering lever / Inner transom plate / Transom assembly / Specifications

TRIM AND TILT SYSTEM
Relieving system pressure / Trim pump / Fluid reservoir / Trim motor / Hydraulic pump and pump adapter / Hydraulic trim cylinder and anchor pins / External hoses / Terminal block / Internal hose / Filling and bleeding the system / Specifications

STEERING SYSTEM
Safety precautions / Mechanical steering system / Power steering / Power steering pump / Specifications

CORROSION CONTROL SYSTEM
Anodes / Ground wires / Mercathode electrode / Specifications

CHAPTER SIXTEEN / SUPPLEMENT 2002-2004 MODELS

WIRING DIAGRAMS

Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 162092143X (1-620-92143-X)
  • ISBN-13: 9781620921432 (978-1-620-92143-2)
  • Format: Softcover, 544 pages
  • Date Published: 10-2001

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