Mercury Mercruiser 454/502 Marine Engine Service Manual

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Professional Marine Engine Documentation

This factory-authorized manual provides the exact same technical specifications and repair procedures used by Mercury Marine technicians. Essential for maintaining these high-performance marine V8 engines in both sterndrive and inboard configurations.

Critical Saltwater Notice

This manual contains special procedures for saltwater operation, including corrosion prevention and anode replacement schedules critical for engine longevity.

Complete Coverage Includes:

Gen VI Engine Rebuild: Step-by-step instructions for 454/502 MPI engines including:

Cylinder head service with marine-specific torque sequences
Piston and connecting rod installation
Marine camshaft timing procedure

Multi-Port Fuel Injection: Complete MPI system service including:

Fuel rail pressure testing
Injector flow rate verification
Throttle body maintenance

Pro Tip: The manual includes special break-in procedures for marine engines that differ from automotive applications.

Closed Cooling Systems: Detailed maintenance of heat exchangers, manifolds and risers with saltwater-specific intervals.

Marine Electrical Systems: Complete wiring diagrams with corrosion-resistant connection methods.

Models Covered:

MCM 454 Mag MPI

MCM 502 Mag MPI

MIE 454 Mag MPI

MIE 8.2L MPI

MCM 7.4L MPI

All 1998-2001 models with serial numbers above specified thresholds.

Key Marine-Specific Specifications

454 CID (7.4L): 330-385 HP @ 4200-4400 RPM | 425-450 lb-ft torque
502 CID (8.2L): 415 HP @ 5000 RPM | 500 lb-ft torque
Compression Ratio: 8.75:1 (marine-optimized for pump gas)
Cooling: Full closed-loop system specs
Fuel: 89 octane minimum requirements

Special Marine Tool Requirements:

The manual includes Mercury's complete list of marine-specific service tools:

Harmonic balancer puller (P/N 91-37241)
Marine timing light with advance
Fuel pressure test kit
Riser temperature gauge
Corrosion-resistant torque wrench

Frequently Asked Questions

Q: Does this cover both Alpha and Bravo sterndrive applications?

A: Yes, includes engine specs for both drive systems with appropriate differences noted.

Q: Are the torque specs different for saltwater vs freshwater?

A: Critical fasteners have saltwater-specific torque values and anti-seize recommendations.

Q: Is the Horizon ignition system included?

A: Yes, complete diagnostics and service for the Horizon electronic ignition.

Professional Marine Repair Knowledge

Don't risk costly engine damage - get the exact specifications used by Mercury technicians!

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Mercury Mercruiser GM V8 Marine Engine Service Manual