2004 Mercury Mercruiser 5.0L 5.7L 6.2L Workshop Service Repair Manual PDF Download

This INSTANT DOWNLOAD 2001 2002 2003 2004 2005 2006 MerCruiser 5.0L, 5.7L & 6.2L engine service manual #31 was prepared primarily for professional technicians. However, adequate data is given for the majority of do-it-yourself mechanics and those performing repairs and maintenance procedures to your MerCruiser. This 2001-2006 MerCruiser repair manual was prepared to suite the needs of individuals who poses basic knowledge in electrical and mechanical concepts. For those without basic knowledge, you should avoid performing complicated repairs to the 2001-2006 MerCruiser equipment as it may render it unsafe. In any case, never attempt to service the 2001-2006 MerCruiser without the aid of a repair manual.

NOTE: This engine repair manual also contains the Gen III Cool Fuel Supplement (starts on page 1097) and Turn Key Start (TKS) carburetors supplement (starts on page 1141) for those models that are equipped.

EXACT MODELS COVERED

CARBURETED MODELS - Sterndrive (MCM) - Inboard (MIE) - Tow Sports (MIE)
5.0L Alpha and Bravo - Serial Numbers 0M087348 and Above
5.7L Alpha and Bravo - Serial Numbers 0M087348 and Above
5.7L - Serial Numbers 0L677227 and Above
5.7L - Serial Numbers 0L677946 and Above

MPI MODELS - Sterndrive (MCM) - Inboard (MIE) - Tow Sports (MIE)
5.0L MPI Alpha and Bravo - Serial Numbers 0M300000 and Above
350 MAG MPI Alpha and Bravo - Serial Numbers 0M300000 and Above
350 MAG MPI Bravo Horizon - Serial Numbers 0M300000 and Above
MX 6.2 MPI - Serial Numbers 0M300000 and Above
MX 6.2 MPI Horizon - Serial Numbers 0M300000 and Above
350 MAG MPI Inboard - Serial Numbers 0M310000 and Above
350 MAG MPI Horizon Inboard - Serial Numbers 0M310000 and Above
MX 6.2 MPI Inboard - Serial Numbers 0M310000 and Above
MX 6.2 MPI Horizon Inboard - Serial Numbers 0M310000 and Above
350 MAP MPI - Serial Numbers 0M0310000 and Above
Black Scorpion - Serial Numbers 0M391600 and Above
MX 6.2 MPI - Serial Numbers 0M310000 and Above
MX 6.2 Black Scorpion - Serial Numbers 0M391750 and Above

SERVICE MANUAL #31 OUTLINE

Section 1 - Important Information
A - General Information
B - Maintenance

C - Troubleshooting

D - California Emissions Information

Section 2 - Removal and Installation
A - MCM Models
B - MIE Models

Section 3 - Engine
A - Engine Mechanical

Section 4 - Electrical System
A - Starting System
B - Carbureted Ignition System
C - MPI Ignition System

D - Charging System
E - Instrumentation

Section 5 - Fuel System
A - Carbureted Fuel System

B - MPI Fuel System Excluding Scorpion Models
C - Scorpion Fuel System

Section 6 - Cooling System
A - All Models
B - Seawater Cooled Models
C - Closed Cooled Models

Section 7 - Exhaust System
A - Manifolds, Elbows, And Risers For Wet Joint
B - Dry Joint Identification

C - Manifolds And Elbows With Dry Joint

D - Cold Riser With Dry Joint
E - Warm Riser With Dry Joint
F - Collectors

Section 8 - Drives
A - Velvet Drive In-Line And V-Drive Transmission
B - Velvet Drive 5000 Series Transmission

C - ZF/Hurth 630 And 800 Series Transmission

D - ZF Marine/Hurth 45C In-Line Transmission

Section 9 - Power Steering
A - Power Steering Pump

Section 10 - Water Flow Diagrams
A - General Information
B - Seawater Cooled Carbureted Models
C - Seawater Cooled MPI Models

D - Closed Cooled Carbureted Models

E - Closed Cooled MPI Models


This 2001-2006 MerCruiser manual will guide you through fundamentals of maintaining and repairing, step-by-step, to teach you what the factory trained technicians already know by heart. By applying the knowledge in this 2001-2006 MerCruiser repair manual, any owner should be able to make the right decisions about what they need to do to maintain and repair the 2001-2006 MerCruiser.

This 2001-2006 MerCruiser manual covers all aspects of repair. The manual covers part removal, disassembly, cleaning, assembly, installation procedures and much more. The manual contains all necessary illustrations, diagrams and specifications to guide the mechanic through any repair procedure. The 2001-2006 MerCruiser manual also contains an advanced troubleshooting guide to help diagnose and correct any problem.

QUESTIONS AND ANSWERS

Q. How do I obtain this manual?
A. Simply click on the download button, complete the payment and a download link is sent to your computer in seconds FOR INSTANT DOWNLOAD.

Q. Once I download the repair manual how long do I have access to the manual?
A. Once you download the manual you can store it on your computer forever and refer to it when maintenance and repair is necessary.

Q. How does the manual appear?
A. Once the manual has been downloaded it appears exactly the same as a repair manual you'd buy in stores. It includes every aspect of repair, step-by-step repair procedures, pictures, illustrations, diagrams, troubleshooting and specifications.

Q. Is the repair manual model and year specific?
A. YES! This is not a generic manual.

Q. Does my computer need special software to view the manual?
A. Your computer wont need any special software to view the manual. It is a simple PDF manual. All computers come with the necessary software already installed from the manufacture to view the manual.

Q. Will the download hurt my computer?
A. NO! This manual is 100 percent safe to download!