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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

MerCruiser Stern Drives 454 Magnum (1995 - 1997)

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    Fault Finder - Diagnose 400+ problems
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    Wiring diagrams for key vehicle systems
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    Suitable for novice and pro mechanics
  • Online edition only!
  • What's Included

    Use the online manual straight away
    Includes ALL content of a printed manual
    Fault Finder - Diagnose 400+ problems
    Take on bigger jobs with Haynes’ help
    Wiring diagrams for key vehicle systems
    Extra videos in online manual
    Print any page at home
    700+ pictures & diagrams of your vehicle

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This MerCruiser manual is 712 pages.

QUICK REFERENCE DATA

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

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

CHAPTER THREE / TROUBLESHOOTING
Starting system / Charging system / Pestolite charging system / Mando charging system / Ignition system / Fuel system-Carbureted models / Fuel system-fuel-injected models / Engine performance / Engine overheating / Engine oil pressure indicator / Engine oil leaks / Engine noises / Engine troubleshooting / Cooling system / Stern drive unit

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-operational checks / Starting checklist / Post-operational checks / Cooling system flushing / Engine maintenance and lubrication / Engine oil and filter change / Power steering service / Fuel filter service / Flame arrestor / Drive unit oil change / Stern drive lubrication / Fuel pump housing (454 and 502 cid engines) / General lubrication points / Shift cable / Propeller shaft / Steering system / Transom gimbal housing, swivel shaft, swivel pin, hinge pins and gimbal bearing / Power trim/tilt lubrication / Oildyne/Singer pump / Engine tune-up / Compression check / Ignition system / Spark plugs / Thunderbolt IV ignition system / Thunderbolt V ignition system / EST ignition system - carburetored models / EST ignition system - fuel-injected models / Carburetor adjustments / Specifications

CHAPTER FIVE / LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT
Cooling system draining / Cooling system refilling / Cooling system conversion / Fitting out / Specifications

CHAPTER SIX / INLINE ENGINES
Removal installation / Valve cover / Intake / exhaust manifolds / Rocker arm assemblies / Crankshaft pulley and torsional damper / Timing gear cover and seal / Camshaft / Oil pan / Oil pump / Cylinder head / Valves and valve seats / Valve filters / Piston / connecting rod assembly / Rear main oil seal / Crankshaft / Flywheel / Cylinder block / Core plug / Specifications

CHAPTER SEVEN / V6 AND V8 ENGINES
Removal installation / Valve covers / Intake manifold / Exhaust manifold / Rocker arms / Valve lash / Crankshaft pulley and torsional / Specifications

CHAPTER EIGHT / FUEL SYSTEM - CARBURETED MODELS
Flame arrestor / Carburetors / Fuel pump and antisiphon devices / Specifications

CHAPTER NINE / FUEL SYSTEM - THROTTLE BODY FUEL INSPECTION (TBI)
Acronyms / Gasoline requirements / Fuel injections system components / Fuel injection system operation / Depressurizing the fuel system / System diagnosis / Troubleshooting / Throttle body / Plenium / Fuel injectors and fuel rails / Electric fuel pump / vapor separator tank / Fuel lift pump / Fuel pressure regulator / Fuel injection pump relay / System relay / Throttle position TP sensor / Manifold absolute pressure MAP sensor / Idle air control IAC valve / Engine coolant temperature ECT sensor / Engine control module ECM / Intake air temperature IAT sensor / Antisiphon devices / Specifications

CHAPTER TEN / FUEL SYSTEM - MULTIPORT FUEL INJECTION (MPI)
Acronyms / Gasoline requirements / Fuel injections system components / Fuel injection system operation / Depressurizing the fuel system / System diagnosis / Troubleshooting / Throttle body / Plenum (305 Magnum) / Plenum (454 Magnum, 502 Magnum and 7.4LX) / Fuel injectors and fuel rails (350 Magnum) / Fuel injectors and fuel rails (454 Magnum, 502 Magnum and 7.4LX) / Electric fuel pump (1997 350 Magnum and later 1997 454 Magnum, 502 Magnum and 7.4LX) / Electric fuel pump and vapor separator tank (models so equipped) / Fuel lift pump (models so equipped) / Fuel pressure regulator (305 Magnum) / Fuel pressure regulator (454 Magnum, 502 Magnum and 7.4LX) / Fuel injection pump relay / System relay / Throttle position (TP) sensor / Manifold absolute pressure (MAP) sensor / Idle air control (IAC) valve / Engine coolant temperature (ECT) sensor / Engine control module (ECM) / Intake air temperature (IAT) sensor / Antisiphon devices / Fuel lines / Specifications

CHAPTER ELEVEN / COOLING SYSTEM
Thermostat / Engine circulating pump / Stern drive water pump / Engine-mounted seawater pump / Drive belts / Cooling system maintenance / Specifications

CHAPTER TWELVE / ELECTRICAL SYSTEM
Charging system / Starting system / Ignition system / Thunderbolt IV ignition / Thunderbolt V ignition / EST ignition (model 3.0LX) / EST ignition (fuel-injected models) / Ignition coil / Switches and connectors / Solenoids / Oil pressure switch / Water temperature sending unit / Audio warning system / Specifications

CHAPTER THIRTEEN / MERCRUISER DRIVE SYSTEM
Alpha One drive / Bravo One, Bravo Two and Bravo Three drive / Specifications

CHAPTER FOURTEEN / DRIVE SHAFT HOUSING
Alpha One drive / Bravo One, Bravo Two and Bravo Three drive / Specifications

CHAPTER FIFTEEN / GEARCASE HOUSING (LOWER UNIT)
Alpha One drive / Brave One and Bravo Two drives / Bravo Three / Specifications

CHAPTER SIXTEEN / BELL HOUSING, GIMBAL BEARING AND GIMBAL RING
Exhaust bellows tube / Shift cable service / Gimbal bearing / Bell housing service / Water hose tube / Gimbal ring, swivel shaft and steering lever service / Gimbal housing service / Specifications

CHAPTER SEVENTEEN / POWER TRIM AND TILT SYSTEMS
Low-pressure pump system / Auto trim system / Trim cylinders / Specifications

CHAPTER EIGHTEEN / STEERING SYSTEMS
Mechanical steering system / Power steering system / Specifications

CHAPTER NINETEEN / CORROSION PROTECTION SYSTEMS
Corrosion / Sacrificial anodes / Continuity devices / Galvanic isolator / MerCathode system / Corrosion protection / Specifications

INDEX

WIRING DIAGRAMS

Stern Drives Covered:
1995 1996 1997 MerCruiser Alpha One
1995 1996 1997 MerCruiser Bravo One
1995 1996 1997 MerCruiser Bravo Two
1995 1996 1997 MerCruiser Bravo Three
Engines covered:
1995 1996 1997 MerCruiser 3.0 L
1995 1996 1997 MerCruiser 4.3 L
1995 1996 1997 MerCruiser 5.0 L
1995 1996 1997 MerCruiser 5.7 L
1995 1996 1997 MerCruiser 7.4 L
1995 1996 1997 MerCruiser 8.2 L
1995 1996 1997 MerCruiser 350 Magnum
1995 1996 1997 MerCruiser 454 Magnum
1995 1996 1997 MerCruiser 502 Magnum

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Stern Drives Covered:
MerCruiser Alpha One (1995-1997)
MerCruiser Bravo One (1995-1997)
MerCruiser Bravo Two (1995-1997)
MerCruiser Bravo Three (1995-1997)
Engines covered:
MerCruiser 3.0 L (1995-1997)
MerCruiser 4.3 L (1995-1997)
MerCruiser 5.0 L (1995-1997)
MerCruiser 5.7 L (1995-1997)
MerCruiser 7.4 L (1995-1997)
MerCruiser 8.2 L (1995-1997)
MerCruiser 350 Magnum (1995-1997)
MerCruiser 454 Magnum (1995-1997)
MerCruiser 502 Magnum (1995-1997)

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