The following information covers factory service procedures for servicing the alternator on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 and 2006 models.
STERNDRIVE MCM
- 5.0L V8 MPI Alpha and Bravo
- 350 MAG MPI Alpha and Bravo
- 350 Mag MPI Alpha and Bravo Horizon
- MX 6.2L MPI
- MX 6.2L MPI Horizon
INBOARD AND TOW SPORTS (MIE)
- 350 MAG MPI Inboard
- 350 MAG MPI Horizon Inboard
- MX 6.2 MPI Inboard
- MX 6.2 MPI Horizon Inboard
- 350 MAG MPI Tow Sports
Testing and diagnosis helps determine problems and possible causes. Its important to perform extensive testing and troubleshooting prior to any major tear down or repair work. This ensures that the full extent of the problem is understood beforehand and may prevent any unnecessary repair work. Its recommended you use a factory repair manual when performing repairs on any vehicle, additional safety precautions, or technical data maybe included.
ALTERNATOR REMOVAL
WARNING: Always remove both battery cables from the battery before servicing your engine. Failure to remove cables can lead to shock and ignition of accumulated ignitable fumes or materials.
1. Remove the positive and negative cables from the battery.
2. Remove the lead and ground wires.
3. Remove the excitation wire.
4. Remove the drive belt.
5. Take off the alternator mounting bolts including washers.
6. Take off the alternator.
ALTERNATOR BRACKET REMOVAL
1. Drain the cooling system fluid.
2. Take off the water circulating pump hose.
3. Take off the bracket.
ALTERNATOR BRACKET INSTALLATION
1. Reinstall the alternator bracket.
Torque Specifications: Alternator Mounting Bracket 41 Nm (30 lb-ft)
2. Reinstall the water circulating pump hose and tighten the hose clamps securely.
ALTERNATOR INSTALLATION
1. Reinstall the idler brace.
2. Place the alternator in the alternator mounting bracket.
3. Reinstall the mounting bolts and torque to specifications.
Torque Specifications: Mounting Bolts M8 x 1.25 11 Nm (8 lb-ft)
4. Reinstall the alternator drive belt on the pulleys and adjust the tensioner.
5. Connect the wiring harness to the alternator.
6. Reconnect both the negative and positive cables to the battery.
7. Fill the cooling system with the proper fluid.
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