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MerCruiser Alpha One, Bravo One, Two and Three Stern Drives, 1998-2004
Part #: B7452
624 pages
CHAPTER ONE / GENERAL INFORMATION
CHAPTER TWO / TOOLS AND TECHNIQUES
CHAPTER THREE / TROUBLESHOOTING
CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
CHAPTER FIVE / LAY-UP, WINTERIZING AND FITTING OUT
CHAPTER SIX / 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
CHAPTER SEVEN / 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
CHAPTER EIGHT / 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
CHAPTER NINE / 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
CHAPTER TEN / 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
CHAPTER ELEVEN / 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
CHAPTER TWELVE / 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
CHAPTER THIRTEEN / 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
CHAPTER FOURTEEN / STEERING SYSTEM
Safety precautions / Mechanical steering system / Power steering / Power steering pump / Specifications
CHAPTER FIFTEEN / CORROSION CONTROL SYSTEM
Anodes / Ground wires / Mercathode electrode / Specifications
CHAPTER SIXTEEN / SUPPLEMENT
INDEX
WIRING DIAGRAMS
Models covered:
1998 1999 2000 2001 2002 2003 2004 MERCRUISER ALPHA ONE
1998 1999 2000 2001 2002 2003 2004 MERCRUISER BRAVO ONE
1998 1999 2000 2001 2002 2003 2004 MERCRUISER BRAVO THREE
1998 1999 2000 2001 2002 2003 2004 MERCRUISER BRAVO TWO
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