DOWNLOAD 2001-2006 MerCruiser 5.0L 5.7L 6.2L Repair Manual

MerCruiser 5.0 5.7 6.2 2001 2002 2003 2004 2005 2006

Download a MerCruiser repair manual instantly! A MerCruiser repair manual, also termed online factory repair guide or MerCruiser service manual, is a handbook giving information and instructions for maintenance, service and repair of the inboard engine or sterndrive. It’s a how-to guide that covers all aspects of maintenance and repair.

Models Covered in This Repair Manual

Carbureted Models

Sterndrive (MCM) Serial Number
5.0L Alpha and Bravo 0M087348 and Above
5.7L Alpha and Bravo 0M087348 and Above
Inboard (MIE) Serial Number
5.7L 0L677227 and Above
Tow Sports (MIE) Serial Number
5.7L 0L677946 and Above

MPI Models

Sterndrive (MCM) Serial Number
5.0L MPI Alpha and Bravo 0M300000 and Above
350 MAG MPI Alpha and Bravo 0M300000 and Above
350 MAG MPI Bravo Horizon 0M300000 and Above
MX 6.2 MPI 0M300000 and Above
MX 6.2 MPI Horizon 0M300000 an Above
Inboard (MIE) Serial Number
 350 MAG MPI Inboard  0M310000 and Above
350 MAG MPI Horizon Inboard 0M310000 and Above
MX 6.2 MPI Inboard 0M310000 and Above
MX 6.2 MPI Horizon Inboard  0M310000 and Above
Tow Sports (MIE) Serial Number
350 MAG MPI 0M310000 and Above
Black Scorpion 0M391600 and Above
MX 6.2 MPI 0M310000 and Above
MX 6.2 Black Scorpion 0M391750 and Above

This repair manual has been written and published by master marine mechanics to aid dealership technicians when performing maintenance, service and repair to the engine models described herein, but adequate data is given to aid most backyard mechanics who possess a basic background in mechanical theory.

This MerCruiser repair manual covers all aspects of repair—whether preforming a tune-up or replacing piston rings—this manual covers it all. Main chapters and subchapters include:


Important Information

  • General Information
  • California Emissions Information
  • Maintenance
  • Troubleshooting


  • Engine Mechanical

Fuel System

  • Carbureted Fuel System
  • MPI Fuel System Excluding Scorpion Models
  • Scorpion Fuel System

Exhaust System

  • Collectors
  • Warm Riser with Dry Joint
  • Manifolds, Elbows, and Risers for Wet Joint
  • Cold Riser with Dry Joint
  • Manifolds and Elbow with Dry Joint
  • Dry Joint Identifications

Water Flow Diagrams

  • General Information
  • Seawater Cooled Carb Models
  • Seawater Cooled MPI Models
  • Closed Cooled Carbureted Models
  • Closed Cooled MPI Models

Engine Removal and Installation

  • MCM Models
  • MIE Models

Electrical System

  • Starting System
  • Carbureted Ignition System
  • MPI Ignition System
  • Charging System
  • Instrumentation

Cooling System

  • All Models
  • Seawater Cooled Models
  • Closed Cooled Models


  • Velvet Drive In-Line and V-Drive Transmission
  • Velvet Drive 5000 Series Transmission
  • ZF/Hurth 630 and 800 Series Transmission
  • ZF Marine/Hurth 45C In-Line Transmission

Power Steering

  • Power Steering Pump

All chapters in this MerCruiser repair manual begin with important information about the chapter and component specifications, followed by step-by-step service and repair procedures. Illustrations, schematics and diagrams are included when necessary.

MerCruiser 5.0L 5.7L 6.2L Repair Manual 2001 2002 2003 2004 2005 2006

A detailed trouble shooting guide is also included. Troubleshooting guides help to trace and correct faults in both the electrical and mechanical system. It’s especially helpful when the cause of the problem is unknown. Troubleshooting information helps to match a symptom to its corrective action. A few topics outlined in the troubleshooting guide include:

  • Engine turns over but will not start or hard to start
  • Engine will not turn over
  • Charging system inoperative
  • Noisy alternator
  • Instrumentation malfunction
  • Poor fuel economy
  • Rough idle
  • Carburetor flooding (equipped models)
  • Hesitation or acceleration flatness
  • Engine surges
  • Lack of power or low top speed
  • Poor cold engine operation
  • Engine stalls
  • Engine misses
  • Engine runs poorly at high rpm
  • Poor engine acceleration
  • Full throttle engine rpm too low
  • Full throttle engine rpm to high

This repair manual is a digitally delivered book of repair instructions. It can be downloaded instantly. The manual is in Portable Document Format (PDF) and delivered in PDF format. This means your computer, laptop or tablet will NOT require any special software to open, view or save the manual. Just download the manual and save it to your device, it’s that simple.

How does the book appear? The download manual appears exactly like a printed book you’d obtain at a book store. However, this download book contains clickable chapters and sub-chapters to help you locate the maintenance, service or repair information fast.

eBook Specifications

Pages: 1246
File size: 117 MB
File format: PDF


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