Note: Each MerCruiser repair manual differs depending on year and model. However, every manual contains all of the information needed to completely maintain, service, troubleshoot, overhaul and restore the complete unit to it's factory specifications.
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These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning the inboard engine or stern drive. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.
Spark plug condition can suggest a variety of possible engine malfunctions and indicate needed engine repairs. When the old plugs are replaced, replace the entire set. Perform plug service only on those plugs suitable for additional service, using the following procedures:
The plug becomes shorted by excessive oil entering the combustion chamber, usually in the engine with many hours of operation. Worn piston rings, cylinder walls, valve guides or valve stem seals are causes of oil entering the combustion chamber. Only engine repairs will permanently relieve oil wet fouling.
1.0 Poor fuel economy 1.0 Fuel leak1.0 Locate the leak and repair.1.1 Operator habits - Prolonged idling, slow acceleration, failure to cut back on throttle once boat is on plane, boat overloaded, uneven weight distribution1.1 Educate the operator.1.2 Engine laboring - Bent, damaged or wrong propeller1.2 Water test the boat for proper operating rpm at WOT.1.3 Clogged flame arrestor 1.3 Clean the flame arrestor.1.4 Engine compartment sealed too tight1.4 Vent the engine hatch appropriately.1.5 Boat bottom dirty (marine growth), hook, rocker1.5 Clean the boat bottom.1.6 Improper fuel 1.6 Drain the fuel tank and refill with the correct fuel.1.7 Crankcase ventilation system clogged or dirty1.7 Clean the crankcase ventilation hoses.1.8 Engine needs tune-up 1.8 Change the spark plugs.
1. Engine surges 1.0 Leaking idle air control (IAC), intake manifold or throttle body gaskets1.0 Find and replace the leaking gaskets.1.1 Throttle valves worn or damaged1.1 Inspect the throttle valves. Replace the throttle body if necessary.1.2 Worn or leaking IAC hose or vacuum hose to the pressure regulator1.2 Find and replace the leaking hose.2. Low top speed or lack of power2.0 Leaking idle air control (IAC), intake manifold or throttle body gaskets2.0 Find and replace the leaking gaskets.3. Poor cold engine operation 3.0 Engine is not reaching normal operating temperature3.0 Replace thermostat or thermostat housing gasket.3.1 Faulty engine temperature sensor (ECT)3.1 Replace the ECT.3.2. Fuel PSI too high or too low 3.2 Determine the cause and repair.3.3 Throttle valves worn or damaged3.3 Inspect the throttle valves. Replace the throttle body if necessary.3.4 Engine flooding 3.4 Check the fuel pressure. If too high, find cause and correct. Clean the flame arrestor. Perform the cylinder balance test.4. Engine stalls 4.0 Idle rpm too low 4.0 Clean the flame arrestor. Test the IAC to see if it opens and closes properly.4.1 Engine flooding 4.1 Check the fuel pressure. If too high, find cause and correct. Inspect the fuel pressure regulator. Inspect the injectors.4.2 Leaking idle air control (IAC), intake manifold or throttle body gaskets4.2 Find and replace the leaking gaskets.5.0 Engine misses 5.0 Fault in the ignition system 5.0 Check the spark plugs. Check the spark plug wires. Check the distributor cap for cracks or marks. Check the ignition coil operation. Replace the faulty component.
Here you can search for operator manuals and other product related information for your Volvo Penta product. You can download a free digital version or purchase printed paper copies. Please note that some publications, e.g., workshop manuals, are only available for purchase in print.
Here are links for downloadable .pdf files of the military Technical Manuals (TM) for Humvees (HMMWV manuals) that we have collected from various online sources. If you have other manuals please leave a comment and we will add them to the list.
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