Mercury Mercruiser Marine Engine Number 23, GM V-8 454 CID (7.4L)/502 CID (8.2L) service manual

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Document Details

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Document Number / Seller:
30630 / Peter Grant
File Size:
10.96 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Inboard Engine (Sterndrive)
Last updated / verified
May 3, 2025

Models Covered & Key Technical Specifications

Mercury Mercruiser Marine Engine Number 23

  • GM V-8 454 CID (7.4L)
  • GM V-8 502 CID (8.2L)
  • 454 Magnum MPI Bravo (Serial numbers: 0L010029 and up)
  • 502 Magnum MPI Bravo (Serial numbers: 0L017000 and up)
  • Gen. VI Engines

Sterndrive (MCM) Model and Serial Number

  • MCM 454 Mag MPI 0L010029 and up
  • MCM 502 Mag MPI 0L017000 and up
    • Inboard (MIE) Model and Serial Number
  • MIE 454 Mag MPI Horizon 0L002200 and up
  • MIE 8.2L MPI 0L002450 and up
    • L-29 Engines
  • Sterndrive (MCM) Model and Serial Number
    • MCM 7.4L MPI 0L010003 and up
  • Inboard (MIE) Model and Serial Number
    • MIE 7.4L MPI 0L002006 and up

Serial Numbers:

  • 7.4L engines: 0F000750 and up
  • 8.2L engines: 0C878221 and up

Professional Workshop Service Manual & Technical Specifications

Table of Contents:

Section 1 - Important Information

  • General Information
  • Maintenance
  • Troubleshooting

Section 2 - Removal and Installation

  • MCM Models - Bravo and Blackhawk Drives
  • MCM Models - Bravo and Blackhawk Drives with Driveshaft Extension
  • MIE Models - Velvet Drive Transmission
  • MIE Models - Hurth Transmission

Section 3 - Engine

  • 454 CID (7.4L) / 502 CID (8.2L)

Section 4 - Electrical System

  • Starting System
  • Ignition System
  • Charging System
  • Instrumentation
  • Wiring Diagrams

Section 5 - Fuel System

  • Fuel Delivery System for Electronic Fuel Injection
  • Multi-Port Fuel Injection Descriptions and System Operation
  • Multi-Port Fuel Injection Disassembly and Reassembly
  • Fuel Injection System Troubleshooting
  • General System Diagnostics
  • Trouble Code Diagnostics - 454/502 Mag MPI & 8.2L MPI
  • Trouble Code Diagnostics - 7.4L MPI

Section 6 - Cooling System

  • Seawater Cooled Models
  • Closed Cooled (Fresh Water) Models

Section 7 - Exhaust System

  • General
  • Manifolds and Elbows
  • Risers
  • Collectors

Section 8 - Drives

  • Velvet Drive In-Line Transmission
  • Velvet Drive 5000A Down Angle Transmission
  • Velvet Drive 5000V V-Drive Transmission
  • Hurth V-Drive Transmission
  • Walter V-Drive Transmission
  • Drive Shaft / Propeller Shaft Models

Section 9 - Power Steering

  • Pump
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FAQ

**Which GM V-8 marine configurations are supported in the Mercruiser archive?** keyboard_arrow_down

A: This comprehensive service manual (#23) provides exhaustive mechanical documentation for Mercruiser GM V-8 454 CID (7.4L) and 502 CID (8.2L) engine model variants. It specifically addresses the diagnostic requirements for the Gen. VI and L-29 series, ensuring all technical values for MCM Bravo, MIE Horizon, and Magnum MPI architectures are fully recorded across 10.96 MB of data.

**How do I perform effective multi-port fuel injection (MPI) diagnostics?** keyboard_arrow_down

A: Identify the exact fuel delivery specifications and MPI disassembly protocols within Section 5 to isolate mechanical or sensor failures. The manual provides a systematic approach for trouble code diagnostics, enabling technicians to identify root causes with factory-certified precision for the 454/502 Mag MPI and 8.2L MPI series.

**Determine the necessary steps for maintaining the Velvet Drive and Hurth transmissions?** keyboard_arrow_down

A: Identify the precise instructions for Velvet Drive in-line and Hurth V-drive configurations within the specialized technical groups to maintain propulsion reliability. The documentation guides technicians through the complete diagnostics of the drive shaft and propeller shaft assemblies, providing authoritative instructions for troubleshooting drivetrain components across the Mercruiser lineup.

**Identify the electrical system diagnostics and wiring schematic locations?** keyboard_arrow_down

A: Tool-ID "Mercruiser Electrical Reference" is essential for troubleshooting the starting system, ignition, and charging circuit as detailed in Section 4. The technical data provides expert insights into wiring diagrams and instrumentation diagnostics, facilitating more effective fault isolation within the marine engine's complex electrical network.

**What are the key technical specifications for cooling and exhaust overhaul?** keyboard_arrow_down

A: Tool-ID "Grant Technical Reference" must be used to verify seawater-cooled and closed-cooled (fresh water) standards found in the factory-style guide. The handbook encompasses the entire service journey, providing critical protocols for riser maintenance and manifold assembly to extend equipment life and ensure safe operation for the Mercruiser heavy-duty V-8 fleet.

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Reviews (4)

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The information in this manual is clear and easy to follow, making repairs much simpler. The download process was smooth, and the support was very professional when I reached out for assistance. I’m very satisfied with my purchase!
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This manual has been a lifesaver for my boat's maintenance. The detailed sections on troubleshooting and the electrical system were especially helpful. The download process was a breeze, and I received my link almost immediately! Highly recommend!
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I found this service manual to be extremely comprehensive and well-organized. The troubleshooting section saved me so much time. Plus, I had a question about my download, and the support team responded in minutes. Fantastic service!
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This manual covers everything you need for the GM V-8 engines. I appreciated the detailed diagrams included. The email support was prompt and helpful, ensuring I had no issues with my download. Definitely worth the investment!