INSTANTLY DOWNLOAD a MerCruiser engine & sterndrive repair manual straight to your computer and fix your problems now. The instant downloads will guide you through simple maintenance to complete engine overhaul. Don’t know the source of the problem? Refer to the troubleshooting section to pinpoint the source of the fault, and the remedy to fix your engine to factory specifications. All repair manuals contain pictures and illustrations to guide you through the repair process. Fixing your motor has never been easier!

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Rear oil seal service procedures for 2001 2002 2003 2004 2005 and 2006 MerCruisers. Note, procedures may differ depending on year and model. See repair manual for additional instructions and pictures for additional repair procedures.

Models Covered in This Manual

Sterndrive (MCM

5.0L MPI Alpha and Bravo

350 MAG MPI Alpha and Bravo

350 MAG MPI Alpha and Bravo Horizon

MX 6.2 MPI

MX 6.2 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

Rear Oil Seal

It is not necessary to remove the oil pan or rear main bearing cap from the motor when replacing the rear crankshaft oil seal. 

Removal

1. Take off the flywheel.
2. Take off the rear oil seal. You can use a screwdriver to or similar tool to pry out the rear oil seal from the seal retainer.

Cleaning

1. Clean off the crankshaft sealing area and mating surface.
2. Clean off the rear oil seal retainer bore.

Inspection

1. Check the seal retainer bore for chips or burrs. Use an emery cloth to remove any slight imperfections.
2. Check the crankshaft sealing surface for damage, this includes possible scoring, chips or burrs.
3. Check the outside diameter of the motor flywheel pilot flange or slight imperfections, rust or very minor surface corrosion. Very minor imperfections can be removed with a fine grade emery cloth.

Installation

Note: Use motor oil as the lubricant for the following:

1. Apply a small amount of lubrication to the bore of the rear oil seal retainer.
2. Apply a small amount of lubrication to the outside diameter of the flywheel pilot flange.
3. Apply a small amount of lubrication to the outside diameter of the flywheel locator pin.
4. Apply a small amount of lubrication to the outer diameter of the rear oil seal.
5. Take off the installation guide from the new crankshaft rear oil seal.
6. Apply a small amount of lubrication to the outside diameter of the new crankshaft rear oil seal.
7. Reinstall the new crankshaft rear oil seal on the seal installer.
8. Reinstall the rear oil seal installer on the rear crankshaft, then tighten the tool bolts until the come in contact.
9. Never allow any other forms of lubricant to come in contact to the seal surface on the rear oil seal.
10. Correct crankshaft rear oil seal alignment is very important. See repair manual for caution details.
11. Rotate the rear oil seal installer nut by turning counterclockwise to detach the rear oil seal installer from the rear oil seal.
12. Take off the rear oil seal installer from the crankshaft.
13. Clean away any excess motor oil with a clean shop rag.

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Troubleshooting can determine faults and help correct mechanical or cooling system problems. This troubleshooting guide will focus on actions needed to correct engine overheating issues for MerCruiser Inboard motors. 

Components my differ depending on MerCruiser year, these guidelines are typical for most model MerCruisers for 1998 1999 2000 2001 2002 2003 2004 2005 2006. Since these are general guidelines, the following years may be relevant: 1989 1990 1991 1992 1993 1994 1995 1996 1997.

The following is a check list of probable causes, but keep in mind, more than one of these conditions could be present. 

Engine Overheats Mechanical:

IMPORTANT: First, verify if the engine is actually overheating, the temperature gauge or sender could be faulty.

IMPORTANT: Best way to test the gauge or sender is just to replace it. 

Key features of interest will be focused on overheating due to mechanical problems:

• Engine laboring
• Timing
• Distributor
• Spark plug wires
• Fuel mixture
• Spark plugs
• Exhaust
• Valve timing
• Head-gasket
• Lubrication

1. The engine rpm is below specifications at WOT (wide open throttle), this could be do to a damaged or incorrect propeller. Check for excessive growth on the bottom of the boat. Is bilge working? Check to see if the hull is filled with water causing excessive drag (engine laboring). Also, excessive air bubbles due to growth on bottom hull could cause the sea water pick-up insufficient water for cooling (if equipped), see engine overheats cooling system. These issues can cause an engine to overheat.

2. Worn down ignition timing, check to see if the timing is retarded or possibly to far advanced.

3. Inspect the distributor advance weights to see if there sticking.

4. Spark plug wires can be transversed (wrong firing order), make sure spark plug wires are in correct order.

5. Lean fuel mixture.

6. Incorrect heat range for spark plugs.

7. Restriction in exhaust system.

8. Is the timing off? Possibly the timing chain has jumped or installed improperly.

9. Blown head gasket, a compression test will not reveal if the head gasket is blown. Typically, an engine will not overheat until the engine has reached speeds above 3000 rpm. For engines that are sea water cooled: use a clear plastic hose, inspect for air bubbles between seawater pump and engine. If you do not notice bubbles, install the hose between the thermostat housing and manifold(s). Any bubbles detected at higher rpm is an indication of a blown head gasket. 

10. Lubrication issues for moving parts. A fouled oil pun, blocked oil passages or low oil level may be the problem.

Engine Overheats Cooling System

Key features of interest will be focused on overheating due to cooling system problems:

• Drive belt
• Seawater shutoff valve (if equipped)
• Sea strainer
• Seawater pick-up (models with belt driven seawater pump only)
• Seawater kinks or collapsed hose
• Seawater blockage 
• Hull obstructions
• Thermostat
• Exhaust elbow
• Faulty seawater pump
• Obstruction in cooling system
• Engine circulating pump faulty
• Coolant
• Antifreeze
• Heat exchanger
• Water hoses
• Drive belt
• Seawater shutoff valve

1. Possible broken or loose drive belt.

2. The seawater shutoff valve may be partially or completely closed (if equipped).

3. Incorrectly installed sea water strainer

4. Loose hose connections between seawater pickup and pump inlet, this applies only to models equipped with belt driven seawater pumps). Note: the pump will suck air. The pump may also fail to prime or will force bubbles into the cooling system.

5. The seawater inlet hose could possibly be kinked or collapsed, this may or may not be noticeable until under load. 

6. Blocked or clogged sea water pick-up.

7. Obstructions on the bottom hull of boat causing to much water turbulence. If there are obstructions in front of the seawater pick-up, it could cause air bubbles to be forced into the cooling system.

8. Check thermostat for proper operation.

9. Make sure the exhaust elbow water outlet in not blocked, clogged or plugged. 

10. Seawater pump may have a worn pump impeller, replace if necessary.

11. Possible obstructions in cooling system. Check items such as casting flash, salt, sand, rust, etc. Check your service manual for water flow diagram.

12. Engine circulating pump could be faulty. 

13. Check coolant level.

14. Is the antifreeze mixed correctly? A good mix ratio should be 50/50 or maximum 60/40 (antifreeze = 60%, water = 40%)

15. Inspect heat exchanger for plugged cores.

16. Water hoses transversed, make sure water hoses are not reversed at the water distribution block.

17. Broken, worn or loose drive belt. 

18. Seawater shut off valve fully or partially closed. 

Service procedures apply to some of the following models:

• mercruiser overheating at high rpm
• mercruiser very high temperature at idle
• mercruiser 3.0 overheating
• mercruiser 470 overheating
• mercruiser 4.3 overheating
• 470 mercruiser overheating problem
• will the mercruiser impeller cause engine to run hot
• 1997 mercruiser 3.0 lx overheating problem
• 1997 mercruiser 3.0 overheating
• 1997 mercruiser 3.0 overheating idle
• 1998 7.4 mercruiser overheating
• 454 marine engine overheating not reaching rpm
• 454 mercruiser boat engines overheating issue
• 496 8.1 mercruiser check valves glogged causing overheating
• 82 mercruiser 350 engine overheating problem
• 89 3.0 l mercruiser alpha 1 overheating problem

MerCruiser Inboard Engine Model

• 496 Mag HO 8.1S Horizon HO
• GM V8 454 cid 7.4L 502 cid 8.2L
• 4.3L MPI Alpha and Bravo
• 3.0L & 3.0LX 
• 4 Cylinder
• 305 CID 5.0L 350 CID 5.7L 6.2L
• GM V8 305-350-454-482-540 CID
• D1.7L DTI
• In-ine Diesel D2.8L D4.2L D-Tronic Manual
• GM 6-Cylinder Engines

While this guide was written to help you diagnose problems. Its recommended you refer to the factory service manual before performing any work. Improper service or repairs can magnify existing issues. Also, MercCruiser repair manuals may contain more detail information including important safety notations or warnings. 

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INSTANTLY DOWNLOAD a MerCruiser engine & sterndrive repair manual straight to your computer and fix your problems now. The instant downloads will guide you through simple maintenance to complete engine overhaul. Don’t know the source of the problem? Refer to the troubleshooting section to pinpoint the source of the fault, and the remedy to fix your engine to factory specifications. All repair manuals contain pictures and illustrations to guide you through the repair process. Fixing your motor has never been easier!

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INSTANTLY DOWNLOAD a outboard engine repair manual straight to your computer and fix your problems now. The instant downloads will guide you through simple maintenance to complete engine overhaul. Don’t know the source of the problem? Refer to the troubleshooting section to pinpoint the source of the fault, and the remedy to fix your engine to factory specifications. All repair manuals contain pictures and illustrations to guide you through the repair process. Fixing your motor has never been easier!

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INSTANTLY DOWNLOAD a MerCruiser engine & sterndrive repair manual straight to your computer and fix your problems now. The instant downloads will guide you through simple maintenance to complete engine overhaul. Don’t know the source of the problem? Refer to the troubleshooting section to pinpoint the source of the fault, and the remedy to fix your engine to factory specifications. All repair manuals contain pictures and illustrations to guide you through the repair process. Fixing your motor has never been easier!

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2003 mercruiser 5.7 mpi spark plugs 2003 mercruiser 5.7 owners manual pdf 2003 mercruiser 5.7 service manual 2003 mercruiser 5l mpi flame arrestor 2003 mercruiser 6.2 liter maintence manual 2003 mercruiser 6.2 mpi horizon thermostat 2003 mercruiser 6.2 running rough 2003 mercruiser 6.2 slave solenoid diagram 2003 mercruiser 6.2l iac 2003 mercruiser 6.2l wiring diagram 2003 mercruiser low rpms 2003 mercruiser magnum 350 power steering fluid 2003 mercruiser mcm 5.0 service 2003 mercruiser mx 6.2 mpi 2003 mercruiser remote control 2003 mercruiser tach wiring diagram 2003 mercruisers 5.0l harness2003 safety switch for mercruiser 2003 sea ray 4.3 litre mercruiser specifications 2003+mercruiser+5.7+manual 2004 1.7 dti mercruiser manual 

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