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Mercruiser 3.0-181 4cyl,  4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard Preview image 1
Mercruiser 3.0-181 4cyl,  4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard Preview image 2
Mercruiser 3.0-181 4cyl,  4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard Preview image 3
Mercruiser 3.0-181 4cyl,  4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard Preview image 4
Mercruiser 3.0-181 4cyl,  4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard Preview image 5
Mercruiser 3.0-181 4cyl,  4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard Preview image 6

Mercruiser 3.0-181 4cyl, 4.3 262 v6, 5.0 305 v8gm, 5.7 350 v8gm,6.2 377 v8, 8.1 496 v8, black scorpion 377 v8, alpha stern drive, bravo 1/2/3 stern drive, bravo x/xr/xz sterndrive, inboard

Includes the following models

  • 3.0-181 4cyl
  • 4.3 262 v6
  • 5.0 305 v8gm
  • 5.7 350 v8gm
  • 6.2 377 v8
  • 8.1 496 v8
  • Black Scorpion 377 v8
  • Alpha stern drive
  • Bravo 1/2/3 stern drive
  • Bravo x/xr/xz sterndrive
  • Hurth inboard
  • Velvet inboard
  • ZF inboard

Mercruiser 3.0-181 4cyl - Available from 1995-2010
4.3 262 v6 - Available from 1998-2015
5.0 305 v8gm - Available from 2000-2016
5.7 350 v8gm - Available from 2001-2018
6.2 377 v8 - Available from 2003-2020
8.1 496 v8 - Available from 2005-2021
Black Scorpion 377 v8 - Special edition, available from 2007-2012
Alpha stern drive - Production from 1995-2015
Bravo 1/2/3 stern drive - Production spanning 1996-2019
Bravo x/xr/xz sterndrive - Production from 2000-2022
Inboard engines - Ongoing production from 1998-present.

Production/model years: 2001, 2002, 2003, 2004, 2005, 2006

File specifications

File size: 36.55 MB
File type: PDF
Language: English (some of our manuals are multilingual)

Printable: Yes
Estimated download time: 0.75 Minutes
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Product Information

Table of Contents

General Information

  1. How to Use This Manual
  2. Safety Precautions
  3. Engine and Drive Identification
  4. Specifications
  5. Maintenance and Lubrication
  6. Tools

Engine and Drive Maintenance

  1. General Maintenance
  2. Engine Lubrication System
  3. Engine Cooling System
  4. Drive Lubrication System
  5. Drive Cooling System
  6. Winter Storage
  7. Winter Operation

Engine Mechanical - GM Inline Engines

  1. Engine Mechanical Specifications
  2. Engine Rebuild Procedures
  3. Cylinder Head
  4. Cylinder Block
  5. Valve Train
  6. Pistons and Connecting Rods
  7. Crankshaft

Engine Mechanical - GM V6 and V8 Engines

  1. Engine Mechanical Specifications
  2. Engine Rebuild Procedures
  3. Cylinder Head
  4. Cylinder Block
  5. Valve Train
  6. Pistons and Connecting Rods
  7. Crankshaft

Engine Overhaul

  1. General Engine Overhaul Procedures
  2. Engine Disassembly
  3. Cleaning and Inspection
  4. Engine Reassembly

Fuel System - Carburetors

  1. Fuel System Operation
  2. Carburetor Adjustment
  3. Carburetor Rebuild Procedures
  4. Fuel Pump
  5. Fuel Lines and Filters

Fuel System - Fuel Injection (EFI)

  1. Fuel System Operation
  2. EFI System Diagnostics
  3. EFI System Adjustment
  4. EFI Component Replacement
  5. Fuel Pump
  6. Fuel Lines and Filters

Cooling System

  1. Cooling System Operation
  2. Cooling System Testing
  3. Cooling System Maintenance
  4. Water Pump
  5. Thermostat
  6. Hoses and Belts

Ignition and Electrical

  1. Ignition System Operation
  2. Ignition System Diagnostics
  3. Battery and Charging System
  4. Alternator Replacement
  5. Starter Replacement
  6. Wiring Diagrams

Stern Drive Unit - Alpha

  1. Alpha Drive Identification
  2. Alpha Drive Specifications
  3. Alpha Drive Maintenance
  4. Alpha Drive Rebuild Procedures

Stern Drive Unit - Bravo

  1. Bravo Drive Identification
  2. Bravo Drive Specifications
  3. Bravo Drive Maintenance
  4. Bravo Drive Rebuild Procedures

Drive Systems - Transmissions

  1. Transmission Identification
  2. Transmission Specifications
  3. Transmission Maintenance
  4. Transmission Rebuild Procedures

Trim and Tilt

  1. Trim and Tilt System Operation
  2. Trim and Tilt System Diagnostics
  3. Trim Pump Replacement
  4. Trim Cylinder Replacement
  5. Tilt Mechanism Maintenance

Steering

  1. Steering System Operation
  2. Steering System Diagnostics
  3. Steering Pump Replacement
  4. Steering Cylinder Replacement
  5. Steering Cable Adjustment

Remote Controls

  1. Remote Control Operation
  2. Remote Control Adjustment
  3. Remote Control Cable Replacement
  4. Throttle and Shift Cable Adjustment

Master Index

  1. Comprehensive Index of Topics
  2. Quick Reference Guide
  3. Troubleshooting Index

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