Mercruiser 7.5L/454 Magnum, Gen 5 service manuals

List of Mercruiser service manuals:  http://www.boatered.com/forum/topic.asp?TOPIC_ID=103451

List of Mercruiser service bulletins:  http://www.boatfix.com/bulletins.htm

BoatFix.com has posted the service manual for the mid-1990’s Gen V big-block Mercruiser, Service Manual 16.  Cover page is http://www.boatfix.com/merc/servmanl/16/16cov2_1.pdf

Each section may be found using link above with the file name as 16z9r2.pdf where z is the sub-section letter and 9 is the section number. Example:  Wiring diagrams…  http://www.boatfix.com/merc/servmanl/16/16f4r2.pdf

Service Manual Outline

Section 1 – Important Information

A – General Information http://www.boatfix.com/merc/Servmanl/16/16a1R2.PDF

B – Maintenance http://www.boatfix.com/merc/Servmanl/16/16b1R2.PDF

C – Troubleshooting Section http://www.boatfix.com/merc/Servmanl/16/16c1R2.PDF

2 – Removal and Installation

A – MCM Models – Bravo and Blackhawk Drives http://www.boatfix.com/merc/Servmanl/16/16a2R2.PDF

B – MCM Models – Bravo and Blackhawk with Driveshaft Extension http://www.boatfix.com/merc/Servmanl/16/16b2R2.PDF

C – MIE Models – Velvet Drive Transmissions http://www.boatfix.com/merc/Servmanl/16/16c2R2.PDF

D – MIE Models – Hurth Transmissions http://www.boatfix.com/merc/Servmanl/16/16d2R2.PDF

Section 3 – Engine

A – 454 CID / 7.4L / 502 CID / 8.2L Section http://www.boatfix.com/merc/Servmanl/16/16a3R2.PDF

4 – Electrical Systems

A – Starting System http://www.boatfix.com/merc/Servmanl/16/16a4R2.PDF

B – Ignition System http://www.boatfix.com/merc/Servmanl/16/16b4R2.PDF

C – Charging System http://www.boatfix.com/merc/Servmanl/16/16c4R2.PDF

D – Instrumentation http://www.boatfix.com/merc/Servmanl/16/16c4R2.PDF

E – Electrical Kits http://www.boatfix.com/merc/Servmanl/16/16e4R2.PDF

F – Wiring Diagrams Section http://www.boatfix.com/merc/Servmanl/16/16F4R2.PDF

5 – Fuel System

A – Fuel Delivery Systems and Fuel Pumps http://www.boatfix.com/merc/Servmanl/16/16a5R2.PDF

B – Weber 4 Barrel Carburetor http://www.boatfix.com/merc/Servmanl/16/16b5R2.PDF

C – Electronic Fuel Injection (Throttle Body and Multi-Port Injection) http://www.boatfix.com/merc/Servmanl/16/16c5R2.PDF

Section 6 – Cooling System

A – Seawater Cooled Models http://www.boatfix.com/merc/Servmanl/16/16a6R2.PDF

B – Closed Cooled Models Section http://www.boatfix.com/merc/Servmanl/16/16b6R2.PDF

7 – Exhaust System

A – General http://www.boatfix.com/merc/Servmanl/16/16a7R2.PDF

B – Manifold and Elbows http://www.boatfix.com/merc/Servmanl/16/16b7R2.PDF

C – Risers http://www.boatfix.com/merc/Servmanl/16/16c7R2.PDF

D – Collectors Section http://www.boatfix.com/merc/Servmanl/16/16d7R2.PDF

8 – Drives

A – Velvet Drive In-Line Transmission http://www.boatfix.com/merc/Servmanl/16/16a8R2.PDF

B – Velvet Drive V-Drive Transmission http://www.boatfix.com/merc/Servmanl/16/16b8R2.PDF

C – Hurth Down Angle Transmission http://www.boatfix.com/merc/Servmanl/16/16c8R2.PDF

D – Hurth V-Drive Transmission http://www.boatfix.com/merc/Servmanl/16/16d8R2.PDF

E – Drive Shaft Models/Propeller Shaft http://www.boatfix.com/merc/Servmanl/16/16e8R2.PDF

Section 9 – Power Steering

A – Pump http://www.boatfix.com/merc/Servmanl/16/16a9R2.PDF

Bravo Sterndrive Service Manual:

Service Manual 11 is for Bravo sterndrives, a 1998 publication.  Online version is tough to come by.

Service Manual 28: Bravo Sterndrives, a 2000 publication:  http://www.ta-group.at/dokus/service_manual_all_bravo_drives.pdf