The following information covers factory service procedures for servicing the starter on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 2001 2002 2003 2004 2005 and 2006 models.
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
STERNDRIVE MCM
- 5.0L V8 MPI Alpha and Bravo
- 350 MAG MPI Alpha and Bravo
- 350 Mag MPI Alpha and Bravo Horizon
- MX 6.2L MPI
- MX 6.2L MPI Horizon
Testing and diagnosis helps determine problems and possible causes. Its important to perform extensive testing and troubleshooting prior to any major tear down or repair work. This ensures that the full extent of the problem is understood beforehand and may prevent any unnecessary repair work. Its recommended you use a factory repair manual when performing repairs on any vehicle, additional safety precautions, or technical data maybe included.
STARTER REMOVAL
WARNING: Always disconnect both the battery cables from the battery before serving your engine. Removing battery cables can prevent electrical shock and a ignition source for collecting fumes.
1. Remove the battery cables from the battery.
2. Remove the wires from the solenoid terminals.
3. Remove the mounting bolts from the starter.
4. Remove the starter assembly from the engine.
SOLENOID SWITCH
The solenoid switched on the starter can be removed if it is damaged or defective. Replace if necessary.
1. To remove the solenoid switch, take off the three fasteners that retain the solenoid. Then, remove the solenoid from the drive housing.
INSPECTION
The solenoid and cranking motor are enclosed in the drive housing, this prevents moisture and debris from entering. However, its important to routinely inspect it in the following order:
1. Check the terminals for tightness and corrosion.
2. Check for damaged or frayed wires and any bad insulated wires.
3. Inspect the starter mounting bolts and make sure there tightened.
INSTALLATION
NOTE: On some models, a special mooting shim may be equipped. Install the mounting shim between the engine block and starter motor.
1. Align the starter motor into position and reinstall the bolts.
Torque Specifications: Starter motor mounting bolts 41 Nm (30 lb-ft)
2. Attach the yellow/red wire to the upper solenoid terminal. Attach the red wire, the orange wire and the battery cable to the lower solenoid terminal. Apply sealant (Liquid Neoprene, part number 92-25711-3) to the terminals and install the battery cable boot, if equipped.
Torque Specification PG 260 Series:
- Battery Terminal: 9.5 Nm (84 lb-in)
- Switch Terminal: 2.3 Nm (20 lb-in)
- Resistor Terminal 2.3 Nm (20 lb-in)
- External Thru-bolt 4.6 Nm (41 lb-in)
- All Other Fasteners: Tighten Securely
Torque Specification 14MT:
- Battery Terminal: 10.3 Nm (91 lb-in)
- Switch Terminal: 2.3 Nm (20 lb-in)
- Resistor Terminal: 2.3 Nm (20 lb-in)
- All Other Fasteners: Tighten Securely
3. Reconnect the positive (+) battery cable to the positive (+) battery terminal and tighten down the cable clamp.
4. Reconnect the negative (-) battery cable to the negative (-) battery terminal and tighten down the clamp.
MerCruiser Starter Repair Manuals
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- 2003 mercruiser 496 mag ho starter
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- 2006 mercruiser 350 mag mpi starter replacement
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