2000 Mercury MerCruiser 5.0L MPI / 350 MAG MPI / MX 6.2 MPI Service Manual (P/N 90-863161)

Mercury Marine Service Manual No. 31 covers the 5.0L MPI, 350 MAG MPI and MX 6.2 MPI gasoline engines listed for MCM sterndrive and MIE inboard and Tow Sports installations. Its cover is marked P/N 90-863161, September 2000; the service pages are marked P/N 90-864260, October 2001.

• Engine installation: Separate MCM and MIE removal and installation procedures, engine alignment, electrical and fluid connections, and throttle and shift cable adjustment.
• Internal engine service: Cylinder-head repair, valve adjustment, camshaft and timing-chain service, piston and crankshaft inspection, and oil-pump disassembly and reassembly.
• MPI fuel system: Fuel-pressure testing, fuel rail and injector diagrams, Cool Fuel system service, and throttle-body, ECM and sensor procedures.
• Electrical systems: Starter and alternator tests, ignition service, instrumentation, power-trim and MerCathode diagrams, plus MCM and MIE engine-harness schematics.
• Cooling and exhaust: Seawater-pump service, thermostat and closed-cooling tests, heat-exchanger work, manifold leak testing, and exhaust-collector procedures.
• Inboard transmissions and steering: Fluid and pressure checks, transmission removal and installation, shift-linkage adjustment, and power-steering pump service.

This manual is intended for marine service technicians and experienced mechanics working on the listed engine installations. Its model and engine-code tables help match the procedures and specifications to the power package before work begins.

Engine Installation and Mechanical Repair

MCM procedures distinguish Alpha and Bravo water pickups and shift-cable connections. MIE procedures address initial and final engine alignment for down-angle and V-drive installations. The engine chapter includes exploded views, torque tables, special tools and inspection limits for internal repairs; the MCM engine-alignment tool is identified as P/N 91-805475A1.

Fuel, Ignition and Electrical Diagnosis

Fuel-system diagrams identify the fuel rail, injectors, throttle body, Cool Fuel components and sensor locations. The procedures cover fuel-pressure relief, component removal and inspection, while the troubleshooting section helps trace hard starting, poor running, charging faults, oil-pressure problems and overheating.

Starting, ignition and charging chapters provide component tests and service procedures. Wiring pages include instrumentation, power trim and MerCathode circuits, with separate GM EFI harness diagrams for MCM and MIE installations. Fuel and ignition work is accompanied by marine-component and electrical safety precautions.

Cooling, Exhaust and Drive Scope

The cooling chapters distinguish seawater-cooled and closed-cooled systems, including pump output, thermostat and pressure-cap tests, heat-exchanger service and water-flow diagrams. Exhaust coverage includes manifold leak testing, collectors and the Silent Choice system.

The transmission chapters cover Velvet Drive and ZF/Hurth identification, fluid service, pressure tests, installation and shift adjustment. Internal transmission overhaul procedures are not included: those chapters direct the reader to the transmission manufacturers’ service literature. Sterndrive-unit repairs and Alpha sterndrive seawater-pump repair likewise refer to the applicable sterndrive service manual.

Selected Fuel and Engine Test Values

For the MPI fuel-system check, the engine tune-up table specifies fuel pressure of 43 psi at 1,800 rpm. It also gives a minimum engine oil pressure of 18 psi at 2,000 rpm, checked at normal operating temperature.

For cylinder testing, the table specifies a minimum compression reading of 100 psi; the lowest recorded cylinder must also be at least 70% of the highest recorded cylinder. These conditions help distinguish the manual's test values from general engine specifications.

Text Search, Bookmarks and Wiring Sheets

PDF navigation and diagram detail: The main service text is searchable, and embedded bookmarks link to the principal sections. Some wiring pages have unusable extracted text, and the appended color harness sheets have no searchable labels. Small connector and wire labels are best read with zoom.

The download is one printable PDF with 636 pages: one cover page, 632 service pages and three appended wiring pages, including larger MCM and MIE GM EFI harness diagrams.