Mercruiser 5.0l Mpi Alpha Bravo

Parts Manual
Cat.# 90-8M0049000
Revised 09-11-2020
TABLE OF CONTENTS
Cat.# 90-8M0049000
Service and Support Material 1
Maintenance Kits 5
Starter Motor 9
Alternator and Brackets 11
Gear Lube Monitor 15
Electrical Components Mechanical 17
Electrical Components Digital 21
Distributor and Ignition Components 25
Fuel Supply Module Alpha 27
Fuel Module Components -Bravo 29
Cool Fuel System Bravo 33
Fuel Filter Alpha 35
Throttle Body Mechanical 37
Throttle Body Digital Throttle and Shift 39
Intake Manifold and Fuel Rail 41
Cylinder Head and Rocker Cover 43
Front Cover and Circulating Pump 47
Cylinder Block Camshaft and Crankshaft 51
Pistons and Connecting Rods 55
Oil Pan and Oil Pump 57
Remote Oil Filter Assembly 59
Cylinder Block Flywheel Housing and Rear Main Seal 61
Exhaust Manifold and Elbow 65
Exhaust Risers 67
Thermostat and Housing Single and 3 Point Drain 69
Thermostat and Housing 7 Point Drain 73
Standard Cooling System - ALPHA Single and 3 Point Drain 75
Standard Cooling System -BRAVO Single and 3 Point Drain 77
Standard Cooling System - ALPHA 7 Point Drain 79
Standard Cooling System - BRAVO 7 Point Drain 81
Standard Cooling System Sea Pump Hoses 83
Closed Cooling System ALPHA 85
Closed Cooling System BRAVO 87
Closed Cooling System (BRAVO) Sea Pump Hoses 89
Closed Cooling System (BRAVO) Sea Pump Hoses (SeaCore) 91
Closed Cooling System Heat Exchanger 93
Water Distribution Housing 95
Water Drain Air Manifold and Pump 97
PAGE i
TABLE OF CONTENTS
Sea Water Pump Assembly 99

Steering Components 101
Exhaust System Components 103
Shift Bracket Alpha 105
Shift Bracket Bravo 107
Shift Bracket Digital Throttle Shift 109
Engine Mounts 111
Mercathode Components 113
Jackshaft Main Kit (98634A20) 115
Gasket Set Components (27-861246A05) Engine Overhaul 119
Gasket Set Components (27- 75611A03) Cylinder Head 121
PAGE ii
Cat.# 90-8M0049000
Service and Support Material
v26205245 PARTS MANUAL

PAGE 1
Cat.# 90-8M0049000

Ref # Part Part Number Description Comments Qty Note
Class
- 0090 8M0049000 PARTS MANUAL 5.0, 350, 377 MAG 1
MPI Sterndrive
- 0090 8M0048404 OPERATION MANUAL 350/377 [1A650036] & Below 1
- 0090 8M0050539 OPERATION MANUAL 350/377 [1A650037] & Up 1
- 0090 8M0048402 OPERATION MANUAL 5.0L [1A648622] & Below 1
- 0090 8M0058191 OPERATION MANUAL 4.3/5.0 MPI [1A648623] THRU 1
[2A171549]
- 0090 8M0074349 OPERATION MANUAL 4.3L/5.0L [2A171550 ] & Up 1
MPI
- 0090 864260T00 SERVICE MANUAL #31 1
5.0L/5.7L/6.2L
- 0090 864260T00 SERVICE MANUAL #31 1
- 0090 864573001 SERVICE MANUAL ECM 555 1
Diagnostics, 14 pin, SM 36
- 0000 863660A2 LONGBLOCK ASSEMBLY 5.0L MPI 1 [1]
- 0800 866138A03 LONGBLOCK ASSEMBLY 350 MAG 1 [2]
- 0000 879288A06 LONGBLOCK ASSEMBLY 377 1 [3]
MAG
- 0033 8M2018369 SPARK PLUG (NGK ITR4A15) 8 [4]
- 0027 861246A05 GASKET SET 1
- 0037 863686A04 DECAL SET 5.0L MPI Alpha 1
- 0037 863686A05 DECAL SET 5.0L MPI Bravo 1
- 0037 863686A06 DECAL SET 5.0L Seacore 1
- 0037 863687A06 DECAL SET 350 Mag MPI Alpha 1
- 0037 863687A07 DECAL SET 350 Mag MPI Bravo 1
- 0037 863687A08 DECAL SET 350 Mag Seacore 1
- 0037 863687A10 DECAL SET 377 Mag [1A628534] & Below 1
- 0037 8M0053166 DECAL SET 377 Mag [1A628535] & Up 1
- 0037 863687A09 DECAL SET 377 MAG Seacore [1A628534] & Below 1
- 0037 8M0053165 DECAL SET 377 Mag SeaCore [1A628535] & Up 1
- 0037 864346 DECAL Flush Operation (SEACORE) 1
- 0035 866340Q03 FILTER Oil - Quicksilver Brand 1 [5]
- 0035 866340K01 FILTER Oil - Mercury Brand 1 [5]
- 0035 802893Q01 FILTER Fuel/Water Separating - 1
Quicksilver Brand
- 0035 802893T FILTER Fuel/Water Separating - 1 [6]
Mercury Brand
- 0092 877770K1 COOLANT MPP, 1 Gallon 1 [7]
- 0092 858048Q01 25W40 SD/IB OIL 1 Quart 1 [8]
- 0092 858048K01 25W40 SD/IB OIL MPP, 1 Quart 1 [8]
- 0092 858049Q01 25W40 SD/IB OIL 1 Gallon 1 [9]
- 0092 858049K01 25W40 SD/IB OIL MPP, 1 Gallon 1 [9]
PART NOTES:
[1] - Alternate part numbers:
863660A 2QS
863660R05Reman

PAGE 2
Cat.# 90-8M0049000

PAGE 3
Cat.# 90-8M0049000

866138A03QS
8M0124033Reman
8M0163302QS
879288A06QS
8M0163303QS
8M0058932Bulk Pack
8M2018369QS
866340K01MPP
866340Q02Service Part
866340Q03QS
802893QQS
802893TMPP
807172Service Part
877770K 1MPP
877770Q 1QS
858048K01MPP
858048KC1MPP Canada
858048Q01QS
858048QB1QS Belgium
858048QC1QS Canada
8M0059252QS
8M0059253MPP
858049K01MPP
858049KC1MPP Canada
858049Q01QS
858049QB1QS Belgium
858049QC1QS Canada
8M0061422MPP Spanish

PAGE 4
Cat.# 90-8M0049000
Maintenance Kits
Maintenance Kits

PAGE 5
Cat.# 90-8M0049000
Maintenance Kits
Class
- 0000 8M0147051 MAINTENANCE KIT 4.3L/5.0L/5.7L Alpha 1
MPI (100 Hours)
Mercury Brand
- 0026 830749 SEAL 2
- 0000 8M0147053 MAINTENANCE KIT 5.0L/5.7L/377 1
MAG/8.2L Bravo (100 Hours)
- 0035 8M0093688 FILTER Fuel 1
- 0026 830749 SEAL 2
- 0000 8M0147068 MAINTENANCE KIT 5.0L/5.7L MPI 1
Alpha (300 Hours)
Mercury Brand
- 0026 830749 SEAL 2
- 0033 8M2018369 SPARK PLUG (NGK ITR4A15) 8 [3]
- 0000 8M0109441 THERMOSTAT 71Degree C (160 1 [4]
Degree F)
- 0027 530451 GASKET 1 [5]
- 0027 806871 GASKET 1
- 0057 865615Q04 BELT Serpentine Serpentine 1
- 0000 8M0147069 MAINTENANCE KIT 5.0L/5.7L/377 1
MAG MPI Bravo (300 Hours)
- 0035 8M0093688 FILTER Fuel 1
- 0026 830749 SEAL 2
-- 0033 8M2018369 SPARK PLUG (NGK ITR4A15) 8 [3]
- 0000 8M0109441 THERMOSTAT 71Degree C (160 1 [4]
Degree F)
- 0027 530451 GASKET 1 [5]
- 0027 806871 GASKET 1
- 0057 865615Q03 BELT Serpentine Serpentine 1
- 0047 8M0137219 IMPELLER KIT Heavy Duty 1
PART NOTES:
866340K01MPP
866340Q03QS
802893QQS
802893TMPP
807172Service Part
Maintenance Kits

PAGE 6
Cat.# 90-8M0049000
Maintenance Kits
Maintenance Kits

PAGE 7
Cat.# 90-8M0049000
Maintenance Kits
8M0058932Bulk Pack
8M2018369QS
807252Q 5QS Kit
807252T 5MPP Kit
8M0109441Service Part
53045 1Service Part
53045Q01QS
Maintenance Kits

PAGE 8
Cat.# 90-8M0049000
Starter Motor
10 7
9
11 1 4
12 6
5
9798
Starter Motor

PAGE 9
Cat.# 90-8M0049000
Starter Motor
Class
1 0050 863007A1 STARTER MOTOR ASSEMBLY 1 [1]
2 0000 809463A1 SOLENOID KIT Starter 1
3 0010 8053432 SCREW (.375-16 x 4.33) 2
4 0011 806949 NUT (M8-1.5) 1
5 0011 806949 NUT (M8-1.5) 1
6 0013 26996 LOCKWASHER (#10) Stainless 1
Steel
7 0085 79695 BOOT Insulator - Black 1
8 0088 79023A91 FUSE ASSEMBLY 90 Ampere 1
9 0011 8267119 NUT (.250-28) 1
10 0013 400247 LOCKWASHER (M8) 1
11 NSS NOT SOLD SEPARATE Thru Bolt 3
12 0011 400211 NUT (M5) Stainless Steel 2
PART NOTES:
863007A 1QS
863007R01Reman
Starter Motor

PAGE 10
Cat.# 90-8M0049000
Alternator and Brackets
10
16
12 15
11 14
13
17
18
8
6
7 27
1 26
9 19
2
25 28
3
6 20
5
21
23
4
24 2214
22

PAGE 11
Cat.# 90-8M0049000

Class
1 0000 863077T ALTERNATOR ASSEMBLY Black Non Serviceable 1 [1]
65 Amp With 50mm Pulley
3 0010 40001134 SCREW (M8 x 25) 1
4 0010 828213 SCREW (.312-18 x 1.500) Hex 2
Flange
5 0012 57792 WASHER 2
6 0011 26484 NUT (.312-18) 2
7 0000 863211T01 BRACKET Alternator Mounting 1
8 0010 98261 SCREW (.375-16 x .750) 2
9 0012 20084 WASHER (.328 x .562 x .062) 1
10 0000 865188T01 BRACKET Without Air Actuated Drain 1
10 0000 865188T BRACKET With Air Actuated Drain 1
11 0000 862083T BRACKET Idler Adjustment 1
12 0000 865193 BUSHING 1
13 0011 859135 NUT (.437-20) Brass/Nickel Plated 1
14 0043 8183812 PINION STUD (.437-20) Stainless 1
Steel
15 0000 864625T PULLEY (4.25 Inch Diameter) With Power Steering 1
15 0000 807757T PULLEY ASSEMBLY Idler - Black Compact Hydralic Steering 1
(3.00 Inch Diameter)
16 0010 34353 SCREW (.375-16 x 1.00) 2
17 0000 862082T BRACE Power Steering 1
18 0010 40001188 SCREW (M10 x 20) 1
19 0000 864456T BRACKET Alternator Brace Bravo, Alpha-Closed 1
Cooling
20 0010 34353 SCREW (.375-16 x 1.00) 1
21 0000 862085T BRACE Idler Bracket Bravo, Alpha-Closed 1
Cooling
22 0000 865598 PULLEY Bravo, Alpha-Closed 1
Cooling
23 0000 865193 BUSHING Bravo, Alpha-Closed 1
Cooling
24 0010 56393 SCREW (.437-20 x 1.75) Bravo, Alpha-Closed 1
Cooling
25 0011 859135 NUT (.437-20) Brass/Nickel Plated Bravo, Alpha-Closed 1
Cooling
26 0000 862778 BRACKET Alternator Brace 1
27 0010 34353 SCREW (.375-16 x 1.00) 1
28 0057 865615Q04 BELT Serpentine Standard Cooling, Alpha, 1
With Power Steering
CHS and Non Power
Steering
28 0057 865615Q03 BELT Serpentine Standard Cooling, Bravo, 1
With Power Steering
28 0057 865615Q08 BELT Serpentine Standard Cooling, 1
Bravo, CHS and Non Power Steering
28 0057 865615Q06 BELT Serpentine 1
Alpha/Bravo,Closed Cooling, With
Power Steering

PAGE 12
Cat.# 90-8M0049000
10
16
12 15
11 14
13
17
18
8
6
7 27
1 26
9 19
2
25 28
3
6 20
5
21
23
4
24 2214
22

PAGE 13
Cat.# 90-8M0049000

Class
28 0057 865615Q08 BELT Serpentine Alpha/Bravo, Closed 1
Cooling, CHS and Non
Power Steering
PART NOTES:
863077R01Reman
863077TQS

PAGE 14
Cat.# 90-8M0049000
Gear Lube Monitor
1
4
9 2
6
7
15
7 16
12
11
10
13
14
6
7
8
15
7 16
24371
Gear Lube Monitor

PAGE 15
Cat.# 90-8M0049000
Gear Lube Monitor

Class
1 0000 860065A1 BRACKET KIT Lube Monitor Closed Cooling 1
Reservoir
2 0000 808023T STRAP Reservoir Retainer 1
3 0000 806193A46 LUBE BOTTLE Lube Monitor Closed Cooling 1
4 0036 8067271 CAP Drive Lube Monitor Lube 1
Reservoir
5 0022 808624 CONNECTOR Lube Reservoir 1
6 0022 861163 QUICK CONNECTOR (90 Degree) 1
To Transom
7 0032 1940971 HOSE (54.00 Inches Bulk) (.25 Inch 1
I.D.)
8 0011 8267098 NUT (.250-20) Stainless Steel 1
9 0010 98261 SCREW (.375-16 x .750) 2
10 0000 865175T BRACKET Lube Monitor Reservoir Standard Cooling 1
11 0000 806193A47 RESERVOIR Lube Monitor Standard Cooling 1
12 0036 8067271 CAP Drive Lube Monitor Lube 1
Reservoir
13 0022 85439001 CONNECTOR Male Lube Reservoir 1
14 0010 828552 SCREW (.375-16 x .500) 1
15 0022 865379 FITTING Female 1
16 0022 865191 FITTING Male 1
Gear Lube Monitor

PAGE 16
Cat.# 90-8M0049000
Electrical Components Mechanical
8 6
7
10 5
4
12 9
13
15
11
19
17
18 20 16
20
35
20
13
21
14
26 31 1
23 25 33
24
30 34
27
28 29
2
32
22
22907

PAGE 17
Cat.# 90-8M0049000

Class
1 0000 865480T BRACKET Harness 1
Mounting/Lifting Eye
2 0010 98261 SCREW (.375-16 x .750) 2
3 0077 879194T82 ECM Engine Control Module 5.0L MPI Alpha, Standard 1
Cooling
3 0077 879194T83 ECM Engine Control Module 5.0L MPI Alpha, Closed 1
Cooling
3 0077 879194T84 ECM Engine Control Module 5.0L MPI Bravo, Standard 1
Cooling
3 0077 879194T85 ECM Engine Control Module 5.0L MPI Bravo, Closed 1
Cooling
3 0077 879194T86 ECM Engine Control Module 350 Mag MPI Alpha, 1
Standard Cooling
3 0077 879194T87 ECM Engine Control Module 350 Mag MPI Alpha, 1
Closed Cooling
3 0077 879194T88 ECM Engine Control Module 350 Mag MPI Bravo, 1
Standard Cooling
3 0077 879194T89 ECM Engine Control Module 350 Mag MPI Bravo, 1
Closed Cooling
3 0077 879288T92 ECM Engine Control Module 377 MAG MPI, Standard 1
Cooling
3 0077 879288T93 ECM Engine Control Module 377 MAG MPI, Closed 1
Cooling
4 0010 82130025 SCREW (M6 x 25) 3
5 0012 65567 WASHER (.265 x .750 x .048) 3
Stainless Steel
6 0025 834985 GROMMET 3
7 0023 856954 BUSHING 3
8 0000 863424T BRACKET ECM 1
9 0010 860008 SCREW (.250-20 x .625) Torx 3
10 0084 866058T02 HARNESS ASSEMBLY Alpha 1
10 0084 866056T02 HARNESS ASSEMBLY Bravo 1
11 0086 865205 CLIP Relay Mounting 2
12 0054 804352 CLIP Fuse Block Mounting 1
13 0000 883562 COVER Fuse 1
14 0000 882751 RELAY 3
15 0088 83296915 FUSE Mini - Blue - 15 Ampere 2
15 0088 832969T20 FUSE Mini - Yellow - 20 Ampere 3
16 0000 865483T BRACKET Circuit Breaker and 1
Relays
17 0088 865827T BREAKER Circuit - 50 Ampere Flag [2A171549] & Below 1
Reset
17 0088 11178A01 BREAKER Circuit - 50 Ampere [2A171550 ] & Up 1
Button reset
18 0011 826709106 NUT (#10-32) Stainless Steel [2A171549] & Below 2
18 0011 68219 NUT (#10-32) Stainless Steel [2A171550 ] & Up 2
19 0010 830861 SCREW (#8-32 x .625) [2A171549] & Below 2
19 0010 45862 SCREW (#10-32 x .875) [2A171550 ] & Up 2
21 0016 863439 STUD 1

PAGE 18
Cat.# 90-8M0049000
8 6
7
10 5
4
12 9
13
15
11
19
17
18 20 16
20
35
20
13
21
14
26 31 1
23 25 33
24
30 34
27
28 29
2
32
22
22907

PAGE 19
Cat.# 90-8M0049000

Class
22 0084 865983T01 HARNESS ASSEMBLY Injectors 1
23 0084 865677T02 HARNESS ASSEMBLY Transom 1
24 0084 888416T04 HARNESS ASSEMBLY DTS, Clean 1
Power, 15 Feet Clean Power
25 0000 862646 FUSE Tan - 5 Ampere 1
26 0000 828054 COVER Fuse 1
27 0084 95084A10 CABLE ASSEMBLY (5.00 Inches) Bravo 1
Red
28 0088 79091 FUSE 20 Ampere Bravo 1
Red/Purple Strip
30 0000 881879010 SENSOR Pressure Steering Cooler 1
30 0000 881879T11 SENSOR Pressure (0 - 100 PSI) Oil 1
31 0000 878187 SENSOR ASSEMBLY Knock 2
32 0000 815425T SENDER ASSEMBLY Oil 1
32 0000 37293T SENDER ASSEMBLY Oil Dual Station 1
33 0000 816492A15 ALARM KIT 1
34 0000 864337A1 CONNECTOR Black Jumper Black Wire 1
35 0011 889664 NUT (1.500-18) Black Nylon 1

PAGE 20
Cat.# 90-8M0049000
Electrical Components Digital
10 9 6
7 5
4
9
6
5
12 4
7 3
13 6 5
4
15
14
19 36
17
18 16
20
20
32
20
13
11
21 14
26 31 1
23
25 33
24 30 34
27
28 29
35 2
37
22 45068

PAGE 21
Cat.# 90-8M0049000

Class
1 0000 865480T BRACKET Harness 1
Mounting/Lifting Eye
2 0010 98261 SCREW (.375-16 x .750) 2
3 0000 879194T92 ECM Engine Control Module 5.0L MPI, Standard 1
Cooling
3 0000 879194T93 ECM Engine Control Module 5.0L MPI, Closed Cooling 1
3 0000 879194T94 ECM Engine Control Module 350 MAG., Standard 1
Cooling
3 0000 879194T95 ECM Engine Control Module 350 MAG, Closed Cooling 1
3 0000 879288T96 ECM Engine Control Module 377 MAG, Standard 1
Cooling
3 0000 879288T97 ECM Engine Control Module 377 MAG, Closed Cooling 1
4 0010 82130025 SCREW (M6 x 25) 3
5 0012 65567 WASHER (.265 x .750 x .048) 3
Stainless Steel
6 0025 834985 GROMMET 3
7 0023 856954 BUSHING 3
8 0000 865479T01 BRACKET ECM Mount 1
9 0010 860008 SCREW (.250-20 x .625) Torx 3
10 0084 8M0050326 HARNESS ASSEMBLY Main Digital Throttle and Shift 1
Engine
11 0000 8M0055652 TERMINATOR ASSEMBLY 10 Pin 1
(CAN P and H)
12 0054 804352 CLIP Fuse Block Mounting 1
13 0000 883562 COVER Fuse 1
14 0000 882751 RELAY 5
15 0088 832969T20 FUSE Mini - Yellow - 20 Ampere 3
16 0000 865483T BRACKET Circuit Breaker and 1
Relays
17 0088 865827T BREAKER Circuit - 50 Ampere Flag [2A171549] & Below 1
Reset
17 0088 11178A01 BREAKER Circuit - 50 Ampere [2A171550 ] & Up 1
Button Reset
18 0011 826709106 NUT (#10-32) Stainless Steel [2A171549] & Below 2
18 0011 68219 NUT (#10-32) Stainless Steel [2A171550 ] & Up 2
19 0010 830861 SCREW (#8-32 x .625) [2A171549] & Below 2
19 0010 45862 SCREW (#10-32 x .875) [2A171550 ] & Up 2
21 0016 863439 STUD 1
22 0084 865983T01 HARNESS ASSEMBLY Injectors 1
23 0084 865677T01 HARNESS ASSEMBLY Transom 1
24 0084 888416T04 HARNESS ASSEMBLY DTS, Clean 1
Power, 15 Feet Clean Power
25 0000 862646 FUSE Tan - 5 Ampere 1
26 0000 828054 COVER Fuse 1
Red
28 0088 79091 FUSE 20 Ampere Bravo 1
Red/Purple Strip

PAGE 22
Cat.# 90-8M0049000
10 9 6
7 5
4
9
6
5
12 4
7 3
13 6 5
4
15
14
19 36
17
18 16
20
20
32
20
13
11
21 14
26 31 1
23
25 33
24 30 34
27
28 29
35 2
37
22 45068

PAGE 23
Cat.# 90-8M0049000

Class
30 0000 881879010 SENSOR Pressure Power Steering Cooler 1
30 0000 881879T11 SENSOR Pressure (0 - 100 PSI) Oil 1
32 0011 889664 NUT (1.500-18) Black Nylon 1
33 0000 816492A15 ALARM KIT 1
34 0000 864337A1 CONNECTOR Black Jumper Black Wire 1
35 0084 865774T01 HARNESS ASSEMBLY Trim Pump 1
36 0086 865205 CLIP Relay Mounting 2
37 0000 815425T SENDER ASSEMBLY 1

PAGE 24
Cat.# 90-8M0049000
Distributor and Ignition Components
18
19 13
12
21
14
2
20
3
6 5
4
1
10
22
9
23
16
15
17
11
1
9801

PAGE 25
Cat.# 90-8M0049000

Class
1 0000 884794A02 DISTRIBUTOR ASSEMBLY 1
2 0000 898253T22 CAP Distributor 1 [1]
3 0010 884786 SCREW 2
4 0000 898253013 ROTOR 1 [2]
5 0010 884788 SCREW 2
6 0000 898141 SENSOR Hall Effect Camshaft 1
Position
7 0010 884788 SCREW 2
8 0043 884789 GEAR ASSEMBLY 1
9 0054 88731 CLAMP 1
10 0010 40011149 SCREW (M8 x 25) Stainless Steel 1
11 0027 344863 GASKET 1 [3]
12 0084 863656A1 CABLE KIT Ignition (Spark Plugs 1
and Coil)
13 0084 863657A1 CABLE ASSEMBLY Coil Wire 1
Assembly
14 0033 8M2018369 SPARK PLUG (NGK ITR4A15) 8 [4]
15 0000 54676 RETAINER Two Wire 2
16 0000 32783 RETAINER Three Wire 2
17 0000 32784 RETAINER Four Wire 2
18 0392 863704T COIL Ignition 1
19 0010 657461 SCREW AND LOCKWASHER (.250- 2
20 x .625)
19 0010 69035 SCREW AND LOCKWASHER (.250- (SEACORE) 2
20 x .625) Stainless Steel
20 0000 863663T BRACKET Coil 1
21 0010 98261 SCREW (.375-16 x .750) 2
22 0016 90096A1 STUD ASSEMBLY (#10-32 x 2
Special)
23 0054 72821 RETAINER 2
PART NOTES:
898253T22Service Part
8M0061335Kit
898253013QS
8M0061335Kit
[3] - Component of Engine Overhaul Gasket Set 861246A05
Component of Long Block Assembly (Long Block Part Numbers Listed on Service/Support Material Page)
8M0058932Bulk Pack
8M2018369QS

PAGE 26
Cat.# 90-8M0049000
Fuel Supply Module Alpha
22
19
24
2
25
1
20
13 22
28
10 23
16
18
17
14
15
26
8
5 9 11
12
4
3
21
27 7
6
22806

PAGE 27
Cat.# 90-8M0049000

Class
1 0000 863422T1 BRACKET Fuel Cooler 1
2 0000 807685T INSULATOR Base 1
3 0000 861156A03 PUMP/COOLER KIT Fuel 1
4 0022 807783A1 FITTING ASSEMBLY 90 Degree 1
5 0025 805063 O-RING (.301 x .070) 4
6 0022 808001A1 FITTING ASSEMBLY 1
7 0025 805062 O-RING (.530 x .082) 1
8 0000 865356T COOLER Fuel 1
9 0010 866114 SCREW (.250-28) Special 1
10 0053 861414 RING Retaining 1
11 0000 807979T BRACKET 1
13 0000 861126A1 REGULATOR KIT (43 PSI) 1
14 0035 805406 FILTER 1
15 0025 805531 O-RING (.476 x .075) 1
16 0012 89302 WASHER (.203 x .406 x .040) 2
17 0022 808002A1 FITTING KIT 1
18 0012 36533 WASHER (.328 x .562 x .0312) 1
Copper
19 0010 808005 SCREW (.250-20 x .500) 4
20 0000 269011 BUMPER Rubber 8
21 0000 807930T01 INSULATOR Cover 1
22 0032 8M2005178 LINE Fuel Fuel Cooler To Fuel Rail 1
23 0026 863151 SEAL Quad Ring 1
24 0011 860069 NUT (.375-16) 2
25 0032 80617382 HOSE (58.00 Inches Bulk) Fuel 1
Pressure Regulator To Intake
Manifold
26 0032 8M0045997 LINE Fuel Fuel Pressure Regulator 1
To Fuel Filter
27 0032 8M0046000 LINE Fuel Fuel Filter To Fuel Pump 1
28 0010 852368 SCREW (#10-24 x .750) 2

PAGE 28
Cat.# 90-8M0049000
Fuel Module Components -Bravo
4 20
26
10
25
4
29
9
21 28
22
24
32 33
14
27
13
19
30
11
15
16
12 23
18
17
5 1
8
7 31
3
44814
2

PAGE 29
Cat.# 90-8M0049000

Class
- 0000 8M0047215 MODULE KIT Fuel Pump, Complete 1
- 0000 8M0047215 MODULE KIT Fuel Pump, Complete 1
With Drain Port
1 0000 8M0047216 HOUSING Fuel Module With Drain 1
Port
2 0022 8M2010476 FITTING (3/8-18) 2
3 0022 806608A02 PLUG ASSEMBLY (.500-13) Blue 1 [1]
Housing With Drain Port Only
4 0010 892684 SCREW 8
5 0000 892670A01 CHECK VALVE KIT 1
6 NSS NOT SOLD SEPARATE Check 1
Valve
7 NSS NOT SOLD SEPARATE Plug 1
8 NSS NOT SOLD SEPARATE Seal 1
9 0000 892677 COVER Fuel Module Housing 1
10 0000 892681 REGULATOR 1
11 0000 866170A01 PUMP ASSEMBLY Fuel - Low 1
Pressure
12 NSS NOT SOLD SEPARATE Seal 1 [2]
14 NSS NOT SOLD SEPARATE Isolator, 1 [2]
Lift Pump
15 0000 866169T01 PUMP ASSEMBLY Fuel High 1
Pressure
16 NSS NOT SOLD SEPARATE Isolator 1 [2]
17 0035 8M2018790 FILTER Pump Suction 1
18 0054 8M2018792 CLIP 1
20 0084 8M0056175 HARNESS ASSEMBLY 1
21 NSS NOT SOLD SEPARATE Retainer 1
22 NSS NOT SOLD SEPARATE Screw 1
23 0035 892665 FILTER Fuel 1
24 0035 892687A02 CARTRIDGE ASSEMBLY Fuel 1
Filter
25 NSS NOT SOLD SEPARATE Cap, 1
Fuel Filter Cartridge
26 NSS NOT SOLD SEPARATE Screw 3
28 0035 866171A01 FILTER 1 [3]
30 NSS NOT SOLD SEPARATE Cup, 1
Fuel Filter Cartridge
31 0022 88517 FITTING Reducing 1
32 0026 892683 SEAL 1 [2]
33 0010 866114 SCREW (.250-28) Special 1

PAGE 30
Cat.# 90-8M0049000
4 20
26
10
25
4
29
9
21 28
22
24
32 33
14
27
13
19
30
11
15
16
12 23
18
17
5 1
8
7 31
3
44814
2

PAGE 31
Cat.# 90-8M0049000

PART NOTES:
806608A02Service Part
806608Q01QS
[2] - Component of Seal Kit 892683A01
[3] - Supersedes to 8M0093688 Which Now Includes Cap Seal and Filter Seal

PAGE 32
Cat.# 90-8M0049000
Cool Fuel System Bravo
7
9 8
10
12
11 13
15
8 1
2
6
14
16
3
5
4 44819

PAGE 33
Cat.# 90-8M0049000

Class
1 0000 864650A13 MODULE KIT Fuel Pump, Complete 1
1 0000 8M0047215 MODULE KIT Fuel Pump, Complete 1
With Drain Port
2 0022 8M2010476 FITTING (3/8-18) 2
Housing With Drain Port Only
4 0054 815504228 CLAMP Worm Gear 1
5 0054 815504206 CLAMP Worm Gear 2
6 0010 40001195 SCREW (M10 x 30) 2
7 0000 864459 BRACKET 1
8 0010 4010720 SCREW (M8 x 20) 4
9 0010 4010820 SCREW (M10 x 20) Hex Flange - 1
Stainless Steel
10 0032 80617382 HOSE (58.00 Inches Bulk) 1
11 0032 8M2005177 LINE Cooler to Rail 350/377 1
12 NSS NOT SOLD SEPARATE Insulator 1
Sleeve
13 0026 863151 SEAL Quad Ring 1
14 0010 866114 SCREW (.250-28) Special 1
15 0000 864458 BRACKET 1
16 0022 865317T02 HOSE ASSEMBLY 2 Bib Orifice 1
Meter
16 0022 865208T02 HOSE ASSEMBLY 3 Bib Orifice 1
Meter
PART NOTES:
806608Q01QS

PAGE 34
Cat.# 90-8M0049000
Fuel Filter Alpha
9
13
5
1
12
6 8
11
7
10 3
2
11
12
1355
Fuel Filter Alpha

PAGE 35
Cat.# 90-8M0049000
Fuel Filter Alpha

Class
1 0000 89876A3 BASE ASSEMBLY Fuel Filter With 1
Water Seperator
2 0022 816133 FITTING 1
3 0022 32561 PLUG Pipe - Allen Head (.250-18) 1
4 0035 802893Q01 FILTER Fuel/Water Separating - 1
Quicksilver Brand
4 0035 802893T FILTER Fuel/Water Separating - 1 [1]
Mercury Brand
5 0022 33821 CONNECTOR 1
6 0022 808003 CONNECTOR 1
7 0022 865907 FITTING (3/8-18) Inlet 1
8 0000 88641 INSULATOR Back 1
9 0000 807918T BRACKET Fuel Filter Base 1
10 0011 82670811 NUT (.312-24) 2
11 0032 8M0046000 LINE Fuel Fuel Pump to Filter 1
12 0032 8M0045997 LINE Fuel Fuel Regulator to Filter 1
13 0011 860069 NUT (.375-16) 2
PART NOTES:
802893QQS
802893TMPP
807172Service Part
Fuel Filter Alpha

PAGE 36
Cat.# 90-8M0049000
Throttle Body Mechanical
24
23
22
21
32
30 28
20
31
29
26
27
25
17
19
32
33
31 18
29 16
32
34
10 9 7
11
35 1
3
2 5
4
13 12 8
6
14 15
33537

PAGE 37
Cat.# 90-8M0049000

Class
1 0000 888770T THROTTLE BODY ASSEMBLY 1
2 0000 853678T SENSOR TPS 1
3 NSS NOT SOLD SEPARATE O-RING 1
4 NSS NOT SOLD SEPARATE SCREW 2
KIT, TPS
5 NSS NOT SOLD SEPARATE O-RING 2
6 0027 885172 GASKET Throttle Body 1
7 0000 866295A02 IAC ADAPTER KIT 1
8 NSS NOT SOLD SEPARATE Gasket 1
9 0025 863006 O-RING (10.82 x 1.78) 1
10 0025 808547 O-RING 1
11 NSS NOT SOLD SEPARATE Screw- 4
Drive
12 0035 8M2001030 FILTER 1
13 0010 4008612 SCREW (M4 x 12) 2
14 0000 862998 VALVE Idle Air 1
15 0010 4008820 SCREW (M6 x 20) 2
16 0000 863647T BRACKET 1
18 0016 885171 STUD 3
19 0016 864338 STUD Special 3
20 0000 863416T FLAME ARRESTOR 1
21 0000 863423 BRACKET Cover Mount 1
23 0000 879288T67 COVER Silver
24 0011 863701 KNOB Engine Cover 1
25 0032 1589424 HOSE (16.50 Inches Bulk) Breather 1
26 0000 863420T BRACKET Throttle Anchor 1
27 0016 863439 STUD 1
29 0016 97477A3 STUD KIT Throttle Anchor 2
29 0016 866641A01 STUD KIT Throttle Anchor (SEACORE) 2
30 0023 31866 SPACER (.256 x .313 x .625) 2
30 0023 11284 SPACER (.62 Diameter) 1
31 0012 20533 WASHER 2
32 0011 8267139 NUT (.250-28) 3
32 0011 826709109 NUT (.250-28) Stainless Steel (SEACORE) 3
33 NSS NOT SOLD SEPARATE Spacer 1
34 0000 863417 BRACKET Throttle 1
35 0011 8267138 NUT (.25-20) 1
35 0011 826709108 NUT (.250-20) Stainless Steel (SEACORE) 1

PAGE 38
Cat.# 90-8M0049000
Throttle Body Digital Throttle and Shift
2
3
10
11
11
12
13
33536

PAGE 39
Cat.# 90-8M0049000

Class
1 0000 879288T67 COVER Silver Engine 1
2 0011 863701 KNOB 1
3 0012 86400 WASHER 1
4 0011 8267138 NUT (.25-20) 1
5 0000 866206T FLAME ARRESTOR 1
6 0016 866204 STUD 1
7 0026 866232 SEAL Flame Arrestor 1
8 0010 4008855 SCREW (M6 x 55) 4
9 0000 866205 MOUNT Flame Arrestor 1
10 0000 866592A04 THROTTLE BODY ASSEMBLY 1
11 0010 4008825 SCREW (M6 x 25) 3
12 0000 862538001 ADAPTER Throttle Body 1
13 0027 863215 GASKET 1

PAGE 40
Cat.# 90-8M0049000
Intake Manifold and Fuel Rail
25
20 19
18
13
11
10 12 14
16
21 21
11
15 22
21 8
17 26 9
7
23 2
1
3
24 22911

PAGE 41
Cat.# 90-8M0049000

Class
1 0000 885164001 MANIFOLD Intake Lower 1
2 0022 12524 PLUG (.375-18 x .475) Brass 1
3 0027 807473A1 GASKET SET Intake Manifold 1 [1]
4 0010 808010 SCREW (.312-18 x 1.375) 8
5 0000 885167 MANIFOLD Intake Upper 1
6 0027 885168 GASKET Intake Manifold 1
7 0010 885166 SCREW 13
8 0000 885165 SENSOR Manifold Air Pressure and 1
Temperature
9 0025 881733 SEAL 2
10 NSS NOT SOLD SEPARATE Bracket Component of 885164 1
11 0010 885180 SCREW 4
12 0000 885173 FUEL RAIL ASSEMBLY 1
13 0000 885174 REGULATOR Fuel Pressure 1
14 0000 885175 CLIP Retaining 1
15 0000 879312003 INJECTOR 8
16 0000 885177 RETAINER Injector 1
17 0025 8M0046869 O-RING KIT 1
18 0000 885178 VALVE Fuel Pressure Service 1
19 0000 885179 CAP Fuel Pressure Sevice Valve 1
20 0010 885180 SCREW 4
21 0032 80617382 HOSE (58.00 Inches Bulk) Cut to 2
Appropriate Length
22 0022 806689 FITTING Tee 1
23 0022 37372 PLUG Pipe (.500) 1
23 0022 806242 CONNECTOR Barb Closed Cooling 1
24 0022 866157 PLUG EGR Port 1
25 0022 8623601 PLUG Fuel Rail Block Off 1
26 0022 863432T FITTING 90 Degree Vent 1
PART NOTES:

PAGE 42
Cat.# 90-8M0049000
Cylinder Head and Rocker Cover
2 8 10
11
3
6 7
5
5
1
4
1
18
17
4
15
21 12 16
20
19
27 14
13
23 26
22
29
30 31
25 28
24
19354

PAGE 43
Cat.# 90-8M0049000

Class
1 0000 809995 COVER Rocker With Oil Fill Hole 2 [1]
1 0000 8M0086350 COVER Rocker Without Oil Fill Hole 1 [1]
2 0036 18710002 CAP Oil Fill 1
3 0010 17344 SCREW 8 [1]
4 0027 17467 GASKET Rocker Cover 2 [1]
5 0025 52188 GROMMET 2
6 0000 97850 ELBOW 90 Degree 1
7 0032 86197763 HOSE (33.00 Inches Bulk) 1
8 0021 861476 VALVE PCV 1
9 0032 1589424 HOSE (16.50 Inches Bulk) Breather 1
10 0054 815504206 CLAMP Worm Gear 2
11 0000 807688T TUBE Oil Fill 1
12 0000 173391 PUSH ROD 16
13 0000 8243171 VALVE Exhaust Standard 8 [1]
13 0000 8243181 VALVE Exhaust (.030) Oversize AR
14 0000 802555 VALVE Intake 5.0L Standard 8 [1]
14 0000 809992 VALVE Intake 350 Standard 8 [1]
14 0000 8M2010902 VALVE Intake 377 Standard 8 [1]
15 0026 976641 SEAL Intake 8 [1]
15 0026 804507 SEAL Exhaust 8 [1]
16 0024 483471 SPRING 16 [1]
17 0000 483481 CAP 16 [1]
18 0028 547971 KEY 32 [1]
19 0000 35329 ARM KIT Rocker 16 [1]
20 0000 35331 BALL Rocker Arm 16 [1]
21 0011 34516 NUT 16 [1]
22 0938 802556T CYLINDER HEAD ASSEMBLY 5.0L (Bare) 2 [1]
22 0938 803860T CYLINDER HEAD ASSEMBLY 350 (Bare) 2 [2]
22 0900 879172A32 CYLINDER HEAD ASSEMBLY 377 (Loaded - Includes 2 [1]
references 13-18, 23-24)
23 0016 34522 STUD (.003) Oversized AR [1]
23 0016 34521 STUD (.013) Oversized AR [1]
24 0027 756111 GASKET 2 [1]
25 0010 11968 SCREW (.437-14 x 1.750) 16 [1]
26 0010 119671 SCREW (.437-14 x 3.00) 4 [1]
27 0010 11966 SCREW (.437-14 x 3.750) 14
29 0011 82670912 NUT (.375-16) Stainless Steel 5.0L 2
30 0016 863414 STUD Knock Sensor 5.0L 2
31 0010 865982007 SCREW (.375-16 x 1.25) Hex Flange 350 Mag / 377 Mag 2
Knock Sensor
- 0800 866138A03 LONGBLOCK ASSEMBLY 350 MAG-MPI 1 [4]
- 0000 879288A06 LONGBLOCK ASSEMBLY 377 MAG 1 [5]
- 0027 861246A05 GASKET SET Engine Overhaul 1
- 0027 75611A03 GASKET SET Cylinder Head 1

PAGE 44
Cat.# 90-8M0049000
2 8 10
11
3
6 7
5
5
1
4
1
18
17
4
15
21 12 16
20
19
27 14
13
23 26
22
29
30 31
25 28
24
19354

PAGE 45
Cat.# 90-8M0049000

PART NOTES:
[1] - Component of Long Block Assembly (Long Block Part Numbers Listed on Service/Support Material Page)
803860TQS
8M0115137Kit
863660A 2QS
863660R05Reman
866138A03QS
8M0124033Reman
8M0163302QS
879288A06QS
8M0163303QS

PAGE 46
Cat.# 90-8M0049000
Front Cover and Circulating Pump
4
2
3
3
1
8 6
26 20
5 21
22
24
18
10 23
9 18
11 25
19
18
13
14
17
15 16 12
27
9806

PAGE 47
Cat.# 90-8M0049000

Class
1 0000 8503991 PUMP ASSEMBLY Water 2 [1]
2 0022 428611 FITTING Pipe - Brass (.750-14) Standard Cooling 0 [2]
3 0027 34897 GASKET Water Pump 2 [2]
4 0022 860346 FITTING Elbow (90 Degree) (.750) Closed Cooling 1
90 Degrees
5 0016 35342 STUD (.312-24/.375-16 x 2.5625) 2 [2]
6 0010 32132 SCREW (.375-16 x 1.750) 1 [2]
6 0010 47688 SCREW (.375-16 x 2.750) 1 [2]
7 0000 807729T PULLEY Water Pump Standard Cooling 1
7 0000 865047T PULLEY Water Pump Closed Cooling 1 [2]
8 0010 47277 SCREW (.312-24 x .750) 4 [2]
8 0010 866656 SCREW (.312-24 x .750) Stainless (SEACORE) 4
Steel
9 0000 864297T01 SENSOR ASSEMBLY Crankshaft 0 [2]
Position
10 0025 885192 O-RING 1 [2]
11 0010 884018001 SCREW 1 [2]
12 0000 807730T PULLEY Crankshaft 1
13 0010 34352 SCREW (.375-24 x .875) 3
14 0000 863397 HARMONIC BALANCER 1 [2]
15 0010 32515 SCREW (.437-20 x 2.50) 1 [2]
16 0013 39131 LOCKWASHER (.437) 1 [2]
17 0012 71458 WASHER 1 [2]
18 0000 863396001 TIMING COVER ASSEMBLY 1 [2]
Screws, Grommets, Oil Seal, and
Gasket are Not Sold Seperately
19 0000 863398 RELUCTOR WHEEL 1 [2]
20 0000 845941 RETAINER Camshaft 1 [2]
21 0010 845943 SCREW (.250-20 x .500) 2 [2]
22 0000 17161T CHAIN Timing 1 [2]
23 0043 8116591 SPROCKET Camshaft 1 [2]
24 0010 845942 SCREW (.312-18 x .750) 3 [2]
25 0043 17160 SPROCKET Crankshaft 1 [2]
26 0019 816565 PLUG Cup (.468) 1 [2]
With Power Steering
CHS and Non Power
Steering
With Power Steering
CHS and Non Power
Steering
Cooling, With Power
Steering
Cooling, CHS and Non
Power Steering

PAGE 48
Cat.# 90-8M0049000
4
2
3
3
1
8 6
26 20
5 21
22
24
18
10 23
9 18
11 25
19
18
13
14
17
15 16 12
27
9806

PAGE 49
Cat.# 90-8M0049000

Class
PART NOTES:
850399 1QS
850399R04Reman

PAGE 50
Cat.# 90-8M0049000
Cylinder Block Camshaft and Crankshaft
14
13
15
10 16
19 18
11 17
8
1 2
12
1
4
5
5
5
5
5
6 9807

PAGE 51
Cat.# 90-8M0049000

Class
1 0023 818465 BEARING SET 5 Pair Standard 5.0L/350 1 [1]
1 0023 818466 BEARING SET 5 Pair (.001) 5.0L/350 AR [1]
Undersized
Undersized
Undersized
1 0031 849396 BEARING SET Standard - 5 Pair 377 1 [1]
Standard
1 0031 849395 BEARING SET (.001 Oversize) 5 377 AR [1]
Pair (.001) Oversized
1 0031 849394 BEARING SET (.001 Undersize) 5 377 AR [1]
Pair (.001) Undersized
2 0017 43504 PIN Dowel 2 [1]
3 NA NOT AVAILABLE 5.0L/350 1 [1]
3 0429 863323T1 CRANKSHAFT 377 1 [1]
4 0028 34466 KEY Crankshaft 5.0L/350 2 [1]
4 0028 862594 KEY Crankshaft Crankshaft 377 1 [1]
5 NSS NOT SOLD SEPARATE Cap, 0 [1]
Crankshaft Bearing
6 0010 8625671 SCREW Carnkshaft Bearing Cap 10 [1]
7 0016 850090 STUD (.437-14/.375-16 x 3.360) 5 [1]
Crankshaft Bearing Cap
8 0023 85674 BEARING SET 1 [1]
9 0000 17341T GUIDE Lifter 8 [1]
10 0000 17340T1 LIFTER Roller 16 [1]
11 0431 811658 CAMSHAFT 5.0L 11 [1]
11 0431 866022T CAMSHAFT 350 Mag 1 [1]
11 0431 862562T1 CAMSHAFT 377 Mag 1 [1]
12 0017 843378 PIN Dowel 1 [1]
13 0000 811662 RETAINER Lifter Guide 1 [1]
14 0010 34500 SCREW (.312-18 x .625) 3 [1]
15 0022 864669 FITTING 1
16 0000 881879T11 SENSOR Pressure (0 - 100 PSI) 1
17 0000 815425T SENDER ASSEMBLY 1
Steel
19 0011 68219 NUT (#10-32) Stainless Steel 1
- 0800 866138A03 LONGBLOCK ASSEMBLY 350 Mag 1 [3]
- 0000 879288A06 LONGBLOCK ASSEMBLY 377 Mag 1 [4]
- 0092 809825 RTV SILICONE (3 Ounce Tube) Where Applicable 1
Metallic Blue
PART NOTES:
863660A 2QS
863660R05Reman

PAGE 52
Cat.# 90-8M0049000
14
13
15
10 16
19 18
11 17
8
1 2
12
1
4
5
5
5
5
5
6 9807

PAGE 53
Cat.# 90-8M0049000

866138A03QS
8M0124033Reman
8M0163302QS
879288A06QS
8M0163303QS

PAGE 54
Cat.# 90-8M0049000
Pistons and Connecting Rods
4 3
5 9809

PAGE 55
Cat.# 90-8M0049000

Class
1 0735 802557T PISTON ASSEMBLY Standard 5.0L 8 [1]
1 0735 802558T PISTON ASSEMBLY .030 Oversize 5.0L AR
1 0735 835001T PISTON ASSEMBLY Standard 350 MAG 8 [1]
1 0735 835002T PISTON ASSEMBLY (.5MM) 350 MAG AR
Oversize
1 0735 879194T68 PISTON ASSEMBLY Standard 377 MAG 8 [1]
2 0039 802559 RING SET Piston, Standard 5.0L 8 [1]
2 0039 808570 RING SET Piston, (.030) Oversize 5.0L AR
2 0039 8018611 RING SET Piston, Standard 350 MAG 8 [1]
2 0039 835000 RING SET Piston, (.5mm) Oversize 350 MAG AR
2 0039 864176A1 RING SET Piston, Standard 377 MAG 8 [1]
3 0614 8164T CONNECTING ROD ASSEMBLY 350 MAG 8 [1]
3 0614 862587A3 CONNECTING ROD ASSEMBLY 377 MAG 8 [1]
4 0010 85802 SCREW (.375-24 x Special) 16
Connecting Rod
5 0011 37493 NUT (.375-24) 350 MAG 16
5 0011 862573 NUT 377 MAG 16
6 0023 85701 BEARING Connecting Rod, 350 MAG 8 [1]
Standard
6 0023 85702 BEARING Connecting Rod, (.001) 350 MAG AR
Undersize
Undersize
Undersize
Undersize
6 0000 849391T BEARING SET 8 Pair Standard, 377 MAG 1 [1]
Connecting Rod
6 0031 849392 BEARING SET (.001 Oversize) 8 377 MAG 1
Pair Connecting Rod
6 0031 849393 BEARING SET (.001 Undersize) 8 377 MAG 1
Pair Connecting Rod
PART NOTES:

PAGE 56
Cat.# 90-8M0049000
Oil Pan and Oil Pump
19
4
5 7
1
18 3
6
20
21 12
2
10
11
16 22 14
17
15
13 43872

PAGE 57
Cat.# 90-8M0049000

Class
1 0000 809907002 PUMP ASSEMBLY Oil 1 [1]
2 0010 17346 SCREW Oil Pump 1 [1]
3 0000 809909 SCREEN Oil Pump Pick Up 1 [1]
4 0000 36184 SHAFT 1 [1]
5 0023 36183 RETAINER 1 [1]
6 0000 986021 DEFLECTOR Oil 1 [1]
7 0017 843378 PIN Dowel Alignment, Oil Pump 1 [1]
8 0011 845602 NUT (.375-16) 5 [1]
9 0000 809910 PAN Oil 1 [1]
10 0027 138651 GASKET Oil Pan 1 [1]
11 0027 49955 GASKET Drain Screw 1 [1]
12 0012 27339 WASHER 1
13 0010 14070 SCREW (.250-20 x .625) 14 [1]
14 0016 11989 STUD (.312-18 x 1.6718) 2 [1]
15 0000 14257 REINFORCEMENT Port 1 [1]
16 0000 14256 REINFORCEMENT Starboard 1 [1]
17 0011 11971 NUT (.312-18) 4 [1]
18 0000 862704A4 TUBE Dipstick [2A032739] & Below 1 [1]
18 0000 8M0058920 TUBE ASSEMBLY Dipstick [2A032740] & Up 2 [1]
19 0000 861942T9 DIPSTICK Oil Level [2A032739] & Below 1 [1]
19 0000 8M0058919 DIPSTICK Oil Level [2A032740] & Up 1 [1]
20 0054 805625 CLIP Dipstick Tube 1 [1]
21 0010 35366 SCREW 1 [1]
22 0010 809911001 SCREW KIT Drain 1
PART NOTES:

PAGE 58
Cat.# 90-8M0049000
Remote Oil Filter Assembly
4 11
12
10
3
2
13
1
8
9826

PAGE 59
Cat.# 90-8M0049000

Class
1 0000 863732T1 BRACKET Oil Filter 1
2 0022 863485 FITTING 1
3 0010 98261 SCREW (.375-16 x .750) 2
3 0010 866640 SCREW (.375-16 x .750) Stainless (SEACORE) 2
Steel
4 0035 866340Q03 FILTER Oil - Quicksilver Brand 1 [1]
4 0035 866340K01 FILTER Oil - Mercury Brand 1 [1]
5 0032 864924 HOSE Oil To Adaptor Alpha/Bravo 1
6 0032 864925 HOSE Oil From Adaptor Alpha/Bravo 1
7 0000 818400A1 ADAPTER 1
8 0026 42077 SEAL 1 [2]
9 0022 806121 FITTING 1
10 0027 91892 GASKET 1 [2]
11 0000 71920 VALVE ASSEMBLY Filter 1
12 0010 54786 SCREW (.312-18 x 1.250) 2
13 0012 20553 WASHER (.406 x .734 x .063) 2
13 0012 34931 WASHER (.406 x .734 x .063) (SEACORE) 2
Stainless Steel
PART NOTES:
866340K01MPP
866340Q03QS

PAGE 60
Cat.# 90-8M0049000
Cylinder Block Flywheel Housing and Rear Main Seal
2
3
4
5
6
8 7
14
10
11
12
9
16 13
31
32
19 27 33
26
15 40
35
17 18 34
25
39
37
38
20
24
28
21
30
29
36
23
22
9830

PAGE 61
Cat.# 90-8M0049000

Class
1 0017 843379 PIN Dowel (.6206/.6211 x 1.20) 2 [1]
Flywheel Housing Location
2 0019 34270 EXPANSION PLUG (1.625) Engine 8 [1]
Core Hole
3 0022 48340 PLUG (.250-18 x .41) Oil Galley 4 [1]
4 0022 72640 PLUG Expansion, Camshaft 1 [1]
Bearing Hole
5 0016 14827 STUD (.250-20 x 2.180) 2 [1]
6 0027 881715 GASKET Crankshaft Oil Seal 1 [2]
Housing
7 0000 852940 HOUSING ASSEMBLY With Studs 1 [1]
Crankshaft Oil Seal
8 0026 852941 SEAL Cranskshaft Oil 1 [2]
9 0016 11989 STUD (.312-18 x 1.6718) 2 [1]
10 0011 8167301 NUT 1 [1]
11 0010 14242 BOLT (.250-20 x .875) 2 [1]
12 0010 14243 BOLT (.250-20 x 1.750) 1 [1]
13 0011 11971 NUT (.312-18) 2 [1]
14 0017 14263 PIN Dowel Oil Seal Housing 1 [1]
Location
15 0000 807260A2 COVER KIT Flywheel 1
NS 0011 807296 NUT (.250-20) 2
16 0010 76596 SCREW (.250-20 x 1.250) 2
16 0010 86885 SCREW (.250-20 x 1.500) Stainless (SEACORE) 2
Steel Not Included With Item 15
17 0222 9520001 FLYWHEEL 1 [1]
18 0017 43504 PIN Dowel Flywheel 2 [1]
19 0010 845757 SCREW (.437-20 x 1.00) 6 [1]
20 0000 18643A5 COUPLING ASSEMBLY Alpha 1
NS 0022 74036 FITTING Grease Alpha 1
21 0000 18644 BUMPER Rubber Alpha 3
22 0010 14883 SCREW (.375-16 x 1.12) Alpha 3
23 0012 13510 WASHER Alpha 3
24 0000 861523A9 COUPLER ASSEMBLY Engine - Bravo and All Jacksahft 1
Short Aluminum Hub Models
24 0000 861523A11 COUPLER ASSEMBLY Engine Bravo, Steel Hub for Work OPT
Application
25 0022 49099 FITTING Bravo 2
26 0010 863480 SCREW (.375-16 x 1.125) Bravo 6
27 0012 20572 WASHER (.390 x .750 x .093) Bravo 6
28 0000 865657A03 HOUSING ASSEMBLY Flywheel Alpha/Bravo 1
29 0000 865329A02 MOUNT KIT Rubber Alpha/Bravo 1
30 0023 99322 SPACER 2
31 0010 97934 SCREW (.500-20 x 5.370) Special 2
32 0012 35777 WASHER (.5156 x 1.375 x .125) 2
Aluminum
33 0023 99299 SPACER (.520 x .870 x .630) 2
34 0013 35048 LOCKWASHER (.375) 2
35 0016 64066 STUD (.375-16 x 2.750) Special 2

PAGE 62
Cat.# 90-8M0049000
2
3
4
5
6
8 7
14
10
11
12
9
16 13
31
32
19 27 33
26
15 40
35
17 18 34
25
39
37
38
20
24
28
21
30
29
36
23
22
9830

PAGE 63
Cat.# 90-8M0049000

Class
36 0011 863332 NUT (.500-20) Aluminum 2
37 0012 20572 WASHER (.390 x .750 x .093) 1
38 0010 68101 SCREW (.375-16 x 1.375) 3
38 0010 32132 SCREW (.375-16 x 1.750) 1
38 0010 8M2015899 SCREW (.375-16 x 1.37) Stainless (SEACORE) 4
Steel
39 0011 32219 NUT (.375-16) 1
39 0011 82671112 NUT (.375-16) (SEACORE) 1
40 0084 62826A6 CABLE ASSEMBLY Ground (13.00 2
Inches) Black
PART NOTES:

PAGE 64
Cat.# 90-8M0049000
Exhaust Manifold and Elbow
13 15
18
22
16
19
14
17
12
3
21
5
4 20
8
7 9
10 2 1
11
6
13270

PAGE 65
Cat.# 90-8M0049000

Class
1 0000 865735A02 MANIFOLD ASSEMBLY Exhaust 2
2 0022 428611 FITTING Pipe - Brass (.750-14) 4
3 0022 390721 PLUG Pipe (.125-27) Brass 2
4 0019 864689 PLUG Expansion Expansion 3
5 0027 33395 GASKET Manifold 2 [1]
6 0000 8M2000229 SCREW (.375-16 x 4.75) 8
7 0022 866725 FITTING Straight (.750-14) Closed Cooling 2
8 0022 863786A1 FITTING ASSEMBLY Drain Standard Cooling 2
9 0025 864701 O-RING (1.112 x .103) 1
10 0030 863129 BALL Check 1
11 0000 862994T FITTING 1
12 0027 864850A02 GASKET Elbow, Resitrictor Standard Cooling 2
12 0027 864549A02 GASKET Elbow, Block Off Closed Cooling 2
13 0000 864591T02 ELBOW ASSEMBLY 2
14 0019 864689 PLUG Expansion Expansion 4
15 0022 73379 PLUG (.250-18) AR
17 0022 866725 FITTING Straight (.750-14) 1
17 0022 865159 FITTING 45 Degree 1
18 0010 865982057 SCREW (.375-16 x 7.50) Exhaust 8
Elbow
20 0022 12524 PLUG (.375-18 x .475) Brass 2
22 0000 864263 BRACKET Flushing Attachment 1
PART NOTES:

PAGE 66
Cat.# 90-8M0049000
Exhaust Risers
1 11
18
7 17
19
20
9
5 14
10
6
15
3
2 12
16
4 13
5 14
6 15
41244
Exhaust Risers

PAGE 67
Cat.# 90-8M0049000
Exhaust Risers
Class
1 0000 865995A01 RISER EXTENSION KIT 1.7 Inch Standard Cooling 1
1 0000 865996A01 RISER EXTENSION KIT 1.7 Inch Closed Cooling 1
1 0000 864929A3 RISER EXTENSION KIT 3 Inch Standard Cooling 1
1 0000 864929A4 RISER EXTENSION KIT 3 Inch Closed Cooling 1
2 NSS NOT SOLD SEPARATE 1.7 Inch 2
or 3 Inch Riser
3 0019 864689 PLUG Expansion 1.7 Inch Riser 2
5 0027 864850A02 GASKET Restrictor 2
5 0027 864549A02 GASKET Block Off 2
6 0027 864547A02 GASKET Full Flow 2
7 0010 865982071 SCREW (.375-16 x 9.250) (1.7 Inch Riser Kit) 8
7 0010 865982077 SCREW (.375-16 x 10.500) (3 Inch Riser Kit) 8
8 0010 860008 SCREW (.250-20 x .625) Torx 1
9 0000 863714T01 BRACKET 1
10 0010 864378 SCREW (.250-20 x .375) Torx 1
11 0000 866208A02 RISER EXTENSION KIT 4.7 Inch Standard Cooling 1
11 0000 866208A03 RISER EXTENSION KIT 4.7 Inch Closed Cooling 1
11 0000 864908A1 RISER EXTENSION KIT 6 Inch Standard Cooling 1
11 0000 864908A2 RISER EXTENSION KIT 6 Inch Closed Cooling 1
12 NSS NOT SOLD SEPARATE 6 Inch or 2
4.7 Inch Riser
14 0027 864850A02 GASKET Restrictor 2
14 0027 864549A02 GASKET Block Off 2
15 0027 864547A02 GASKET Full Flow 2
16 0010 865982005 SCREW (.375-16 x 1.00) 6 Inch Riser 8
17 0010 865982092 SCREW (.375-16 x 12.380) 4.7 Inch Riser 8
17 0010 865982057 SCREW (.375-16 x 7.50) 6 Inch - Not included in OPT
Riser Kit.
18 0010 860008 SCREW (.250-20 x .625) Torx 6
19 0000 863715T01 BRACKET 2
20 0010 864378 SCREW (.250-20 x .375) Torx 1
Exhaust Risers

PAGE 68
Cat.# 90-8M0049000
Thermostat and Housing Single and 3 Point Drain
11
12
2
2
7
6
5 1
10
14
13 2
3
26 19
23 15
22
21
25
24 27
18
17
16
20
40665

PAGE 69
Cat.# 90-8M0049000

Class
1 0000 863457A2 HOUSING ASSEMBLY Thermostat 1
2 0022 32803 PLUG Pipe (.375-18) Brass 3
3 0027 806871 GASKET Thermostat Housing 1
4 0027 530451 GASKET Lower Thermostat 1 [1]
Housing
5 0000 806490T SENDER Water Temperature 1
5 0000 49734 SENDER Water Temperature Dual Station OPT
Steel
8 0000 807252T2 THERMOSTAT 71DegreeC (160 1 [2]
Degree F)
9 0023 806922 SLEEVE Thermostat 1
10 0000 805218T SENSOR 1
11 0010 4010775 SCREW (M8 x 75) 2
12 0000 12552 LIFTING EYE 1
14 0025 8M2000926 SEAL 1
15 0000 864398T1 HOUSING ASSEMBLY Thermostat Mechanical Throttle and 1
Shift
15 0000 864398T04 HOUSING ASSEMBLY Thermostat Digital Throttle and Shift 1
16 0027 530451 GASKET Thermostat Housing 1 [1]
17 0022 32803 PLUG Pipe (.375-18) Brass 2
18 0025 8071341 SEAL Thermostat 1
20 0000 805218T SENSOR 1
21 0000 806490T SENDER Temperature 1
21 0000 49734 SENDER Water Temperature Dual Station OPT
Steel
24 0000 864493 THERMOSTAT 77°C (170°F) 1
25 0000 807075A1 COVER Thermostat Housing 1
26 0022 818390 DRAIN COCK 1
18 x .875) With Lockwasher
PART NOTES:
53045 1Service Part
53045Q01QS
807252Q 5QS Kit
807252T 2Service Part
807252T 5MPP Kit

PAGE 70
Cat.# 90-8M0049000
11
12
2
2
7
6
5 1
10
14
13 2
3
26 19
23 15
22
21
25
24 27
18
17
16
20
40665

PAGE 71
Cat.# 90-8M0049000

806608Q01QS

PAGE 72
Cat.# 90-8M0049000
Thermostat and Housing 7 Point Drain
11
12
15
14
18 13
16
14
15
16
5
4
3
17
1
8 2
10
1719

PAGE 73
Cat.# 90-8M0049000

Class
1 0000 864592T1 HOUSING Thermostat Thermostat 1
2 0022 32803 PLUG Pipe (.375-18) Brass 1
3 0000 806490T SENDER Water Temperature 1
3 0000 49734 SENDER Water Temperature (Dual Station) OPT
Steel
6 0000 805218T SENSOR 1
7 0027 806871 GASKET Thermostat Housing 1
8 0000 807252T2 THERMOSTAT 71DegreeC (160 1 [1]
Degree F)
9 0023 806922 SLEEVE Thermostat 1
10 0027 530451 GASKET Lower Thermostat 1 [2]
Housing
11 0010 81742780 SCREW (M8 x 80) 2
12 0000 12552 LIFTING EYE 1
13 0022 98477A2 VALVE ASSEMBLY 1
14 0030 98475 BALL Nylon Check 2
15 0024 75533 SPRING 2
16 0012 89302 WASHER (.203 x .406 x .040) 2
17 0010 98476 SCREW (#10-32 x 6.00) 1
PART NOTES:
807252Q 5QS Kit
807252T 2Service Part
807252T 5MPP Kit

53045 1Service Part

53045Q01QS

PAGE 74
Cat.# 90-8M0049000
Standard Cooling System - ALPHA Single and 3 Point Drain
A 17
7
26
25
26
1
23 24
25
4 6 13 26
10
2
25
24 27
25 20
27 26 3
24
15 24 26
10 25
26
26
12 22 25
19 5
26
24 24
9 25
26
8
11
26 14
26
26
18
21
16
10115

PAGE 75
Cat.# 90-8M0049000

Class
1 0032 863489 HOSE Power Steering Cooler to 1
Check Valve
2 0021 864206A1 CHECK VALVE ASSEMBLY 1
3 0032 863623 HOSE Check Valve to Fuel Cooler 1
4 0032 863456A1 HOSE ASSEMBLY Thermostat 1
Housing to Circulating Pump
5 0032 863458 HOSE Thermostat Housing to Port 1
Manifold
6 0032 863459 HOSE Thermostat Housing to 1
Starboard Manifold
7 0032 807661 HOSE Transom Assembly to Power Alpha 1
Steering Cooler
8 0032 863670 HOSE Fuel Cooler to Water 1
Distribution Housing
9 0022 864621A1 FITTING ASSEMBLY Lower 1
Distribution
10 0032 8623175 HOSE Cylinder Block Drain to Port Cut to 23 Inches, 2
Distribution Fitting Starboard 17 Inches
11 0032 863490 HOSE Water Drain Accumulator to 1
Distribution Fitting
12 0032 863491 HOSE Distribution Fitting to 1
"Y" Fitting
13 0032 4285069 HOSE (44.00 Inches Bulk) Cut to 22 Inch Length 1
Starboard Manifold to Distribution
Fitting
14 0032 4285069 HOSE (44.00 Inches Bulk) Port Cut to 31 Inch Length 1
Manifold to Distribution Fitting
15 0054 815504232 CLAMP Worm Gear (2.50 Diameter) AR
16 0022 862603 FITTING Male Quick Connector, 2
Threaded
17 0000 863841T TUBE Water Brass Compact Hydraulic 1
Steering
18 0022 862225 FITTING Pushlock 4
19 0032 863465 HOSE Drain Accumulator to Tee 1
Fitting
20 0022 863464A1 FITTING ASSEMBLY Alpha Only 1
NS 0023 864327 BUSHING Orifice Alpha Only 1
NS 0025 864353 O-RING Alpha Only 1
21 0025 627021 O-RING (.301 x .070) 2
22 0032 864560 HOSE Tee Fitting to Port Elbow Non Riser, 1.7 inch and 3 1
Inch Riser
22 0032 864965 HOSE Tee Fitting to Port Elbow 4.7 Inch and 6 Inch Riser 1
23 0032 864561 HOSE Tee Fitting to Starboard Non Riser, 1.7 inch and 3 1
Elbow Inch Riser
23 0032 864966 HOSE Tee Fitting to Starboard 4.7 Inch and 6 Inch Riser 1
Elbow
24 0054 815504212 CLAMP Worm Gear 2
26 0054 815504228 CLAMP Worm Gear 2
27 0054 815504232 CLAMP Worm Gear (2.50 Diameter) 1

PAGE 76
Cat.# 90-8M0049000
Standard Cooling System -BRAVO Single and 3 Point Drain
17
3 14
25
24 24 15
23 26
26
26
25
13
6 1
26
10
4
25
24
27 25 20
24
16 24
25 24
26 10
22 3
26 24
12 25
19
26 5
2
9 25
26
11 7
26
26
26
18
21
44670

PAGE 77
Cat.# 90-8M0049000

Class
Accumulator Housing
2 0022 862993 FITTING Y, (2) 1-1/4 In. Hose Barbs / 1
(1) 3/4 In. Hose Barb
3 0032 4285069 HOSE (44.00 Inches Bulk) Exhaust Port, Cut to 9.00 Inches 1
Manifold to Y Fitting
3 0032 4285069 HOSE (44.00 Inches Bulk) Exhaust Starboard, Cut to 3.5 1
Manifold to Orifice Fitting Inches
4 0032 863456A1 HOSE ASSEMBLY Thermostat 1
Housing to Circulating Pump
Manifold
Starboard Manifold
7 0032 866331 HOSE Y Fitting to Accumulator 1
8 0022 862603 FITTING Male Quick Connector, 2
Threaded - Engine Block
9 0022 864989A01 FITTING ASSEMBLY Lower 1
Distribution
10 0032 8623175 HOSE Cylinder Block Drain to Port Cut to 23 Inches, 2
Distribution Fitting Starboard 17 Inches
11 0032 863490 HOSE Water Drain Accumulator to 1
12 0032 865394 HOSE 1
13 0032 865337 HOSE Sea Pump to Water Orifice 3 Point Manual Drain 1
13 0032 865234 HOSE Sea Pump to Water Orifice Single Point Air Actuated 1
Drain
14 NA NOT AVAILABLE Orifice Meter (See Cool Fuel System - 1
Assembly Bravo for Service Part
Number)
15 0032 865235 HOSE Water Orifice to Power 1
Steering Cooler
17 0000 863841T TUBE Water Brass Compact Hydraulic 1
Steering
18 0022 862225 FITTING Pushlock - Block Drian 4
Hose
19 0032 863465 HOSE Drain Accumulator to Tee 1
Fitting
20 0022 863464 FITTING Tee Bravo Only 1
21 0025 627021 O-RING (.301 x .070) 2
22 0032 864560 HOSE Tee Fitting to Port Elbow Non Riser, 1.7 Inch and 3 1
Inch Riser
22 0032 864965 HOSE Tee Fitting to Port Elbow 4.7 Inch and 6 Inch Riser 1
23 0032 864561 HOSE Tee Fitting to Starboard Non Riser, 1.7 Inch and 3 1
Elbow Inch Riser
23 0032 864966 HOSE Tee Fitting to Starboard 4.7 Inch and 6 Inch Riser 1
Elbow
24 0054 815504212 CLAMP Worm Gear 2
26 0054 815504228 CLAMP Worm Gear 2

PAGE 78
Cat.# 90-8M0049000
Standard Cooling System - ALPHA 7 Point Drain
A 9
10
21
11
21
20 15
6 1
17
7 16
20
5 20
20
22
21
18
21
22 17
14 16
1918 11
17 16 4 21 20
21
15
18
16 13 21 17
12 8
17 21 16
2 20
21 17
16
3
10134

PAGE 79
Cat.# 90-8M0049000

Class
1 0032 8600891 HOSE Molded Power Steering to 1
Fuel Cooler
2 0032 866331 HOSE Fuel Cooler to Drain Fitting Cut to Length 1
3 0032 864578 HOSE Drain Fitting to Check Valve 1
4 0032 864579 HOSE Check Valve to Thermostat 1
Housing
5 0032 864703A1 HOSE Circulating Pump to Drain 1
Elbow
6 0032 864979 HOSE Starboard Exhaust Elbow to 1
Thermostat Housing
Starboard Manifold
Manifold
9 0000 863841T TUBE Water Brass Compact Hydralic Steering 1
10 0032 807661 HOSE Transom Assembly to Power 1
Steering Cooler
11 0022 866725 FITTING Straight (.750-14) Barb 1
12 0000 861505 FITTING Drain Tee 1
13 0021 862271A1 CHECK VALVE 1
14 0032 864435 HOSE Port Exhaust Elbow to 1
Thermostat Housing
15 0022 862210A01 ELBOW KIT Drain 1
17 0025 8M2000926 SEAL 9
18 0022 860088 BUSHING 4
19 0022 46982 FITTING (90 Degree) 1
21 0054 815504228 CLAMP Worm Gear 1
22 0054 8M2001490 CLAMP Worm Gear 4
PART NOTES:
806608Q01QS

PAGE 80
Cat.# 90-8M0049000
Standard Cooling System - BRAVO 7 Point Drain
10
2 13
21
9
21
4
21
20 15
6
17
7 16
20
5 20
1
20
22
18
21
11 22 17
14 16
1918 4
17 16 20
15
21 17
12 8
21 16
2 20
3 17
16
44669

PAGE 81
Cat.# 90-8M0049000

Class
Drain Fitting
Steering Cooler
3 0032 865409 HOSE Drain Fitting to Thermostat 1
Housing
4 0022 866725 FITTING Straight (.750-14) Barb 1
5 0032 864703A1 HOSE Circulating Pump to Drain 1
Elbow
6 0032 864979 HOSE Starboard Exhaust Elbow to 1
Thermostat Housing
Starboard Manifold
Manifold
9 0032 865337 HOSE Sea Water Pump to Water 1
Orifice
10 NA NOT AVAILABLE Orifice Meter (See Cool Fuel System - 1
Assembly Bravo page for service part
number
11 0022 866729 FITTING (.250 x .250 NPTF) 1
12 0000 861505 FITTING Drain Tee 1
14 0032 864435 HOSE Port Exhaust Elbow to 1
Thermostat Housing
15 0022 862210A01 ELBOW KIT Drain 2
17 0025 8M2000926 SEAL 9
18 0022 860088 BUSHING 4
19 0022 46982 FITTING (90 Degree) 1
21 0054 815504228 CLAMP Worm Gear 11
PART NOTES:
806608Q01QS

PAGE 82
Cat.# 90-8M0049000
Standard Cooling System Sea Pump Hoses
2
3
1
5
3
3
44449

PAGE 83
Cat.# 90-8M0049000

Class
1 0022 865324 QUICK CONNECT 2
3 0054 815504222 CLAMP Worm Gear (1.98 DIameter) 4
4 0032 865672079 HOSE (96.00 Inches Bulk) (Cut to 18.5 Inches) 1
Design I
4 0032 1743534 HOSE (14.5 Inches) Design II 1
5 0032 865672079 HOSE (96.00 Inches Bulk) Cut to 13 Inches) Design I 1
5 0032 865672079 HOSE (96.00 Inches Bulk) (Cut to 12.5 Inches) 1
Design II

PAGE 84
Cat.# 90-8M0049000
Closed Cooling System ALPHA
17 24
15
13 18
17
17 18
23
6 1
12
17
8
17 18
17
22
23 2
20 17 16 19
3
19
4
17 7 18 18
16
17
20
14
11
21 17
17
5
10 9
19 18
34199

PAGE 85
Cat.# 90-8M0049000

Class
1 0032 863489 HOSE Power Steering to Check 1
Valve
2 0021 864206A1 CHECK VALVE ASSEMBLY 1
3 0032 863623 HOSE Check Valve to Fuel Cooler 1
4 0032 864551 HOSE Intake Bypass to Circulating 1
Pump
5 0032 864431 HOSE Distribution Fitting to Heat 1
Exchanger
6 0032 864539 HOSE Thermostat Housing to Starboard, Non- Riser 1
Upper Manifold
6 0032 864956 HOSE Thermostat Housing to Starboard (1.7 Inch, 3 1
Upper Manifold Inch, 4.7 Inch and 6 Inch
Riser)
7 0032 864552 HOSE Thermostat Housing to Port, Non-Riser 1
Upper Manifold
7 0032 864954 HOSE Thermostat Housing to Port (1.7 Inch, 3 Inch, 4.7 1
Upper Manifold Inch and 6 Inch Riser)
8 0032 864509 HOSE Thermostat Housing to Starboard 1
Lower Manifold
Lower Manifold
10 0032 863670 HOSE Fuel Cooler to Accumulator 1
Housing
11 0032 864506 HOSE Heat Exchanger to 1
Thermostat Housing
Thermostat Housing
13 0032 8M2005027 HOSE Heat Exchanger to (Non Riser, 1.7 Inch and 3 1
Starboard Elbow Inch Riser)
13 0032 864955 HOSE Heat Exchanger to (4.7 Inch and 6 Inch Riser) 1
Starboard Elbow
14 0032 864726 HOSE Heat Exchanger to Port (Non Riser, 1.7 Inch and 3 1
Elbow Inch Riser)
14 0032 864953 HOSE Heat Exchanger to Port (4.7 Inch and 6 Inch Riser) 1
Elbow
15 0032 863611 HOSE Sea Pump to Power Steering 1
Cooler
16 0054 815504212 CLAMP Worm Gear 1
18 0054 815504228 CLAMP Worm Gear 1
Circulating Pump
22 0054 815504228 CLAMP Worm Gear 1
23 0032 865672079 HOSE (96.00 Inches Bulk) Sea 1
Water Pump to Water Pick Up

PAGE 86
Cat.# 90-8M0049000
Closed Cooling System BRAVO
17 10
13 15 18
17 17 2
18
6 3 1
12
17
8
17
17
20 17 16
19
4
16 17 7
17
20
14
11
21 17
17
5
9
19 18
34184

PAGE 87
Cat.# 90-8M0049000

Class
Accumulator Housing
2 0000 863841T TUBE Water Brass (Compact Hydraulic 1
Steering)
3 0032 865234 HOSE Sea Water Pump to Water
Orifice
4 0032 864551 HOSE Intake Bypass to Circulating 1
Pump
5 0032 864431 HOSE Distribution Fitting to Heat 1
Exchanger
6 0032 864539 HOSE Thermostat Housing to (Starboard) (Non Riser) 1
Upper Manifold
6 0032 864956 HOSE Thermostat Housing to (Starboard)(1.7 Inch, 3 1
Upper Manifold Inch, 4.7 Inch and 6 Inch
Riser)
7 0032 864552 HOSE Thermostat Housing to (Port) (Non Riser) 1
Upper Manifold
7 0032 864954 HOSE Thermostat Housing to (Port)(1.7 Inch, 3 Inch, 4.7 1
Upper Manifold Inch and 6 Inch Riser)
8 0032 864509 HOSE Thermostat Housing to (Starboard) 1
Lower Manifold
9 0032 864508 HOSE Thermostat Housing to (Port) 1
Lower Manifold
10 NA NOT AVAILABLE Orifice Meter (See 'Cool Fuel System - 1
Assembly Bravo' for Service Part
Number)
Thermostat Housing
Thermostat Housing
13 0032 8M2005027 HOSE Heat Exchanger to (Non Riser, 1.7 Inch and 3 1
Starboard Elbow Inch Riser)
13 0032 864955 HOSE Heat Exchanger to (4.7 Inch and 6 Inch Riser) 1
Starboard Elbow
14 0032 864726 HOSE Heat Exchanger to Port (Non Riser, 1.7 Inch and 3 1
Elbow Inch Riser)
14 0032 864953 HOSE Heat Exchanger to Port (4.7 Inch and 6 Inch Riser) 1
Elbow
Steering Cooler
16 0054 815504212 CLAMP Worm Gear 1
18 0054 815504228 CLAMP Worm Gear 1
Circulating Pump

PAGE 88
Cat.# 90-8M0049000
Closed Cooling System (BRAVO) Sea Pump Hoses
2 8
1 1
4
7
5
4 4
4 4
6
4
3
44447

PAGE 89
Cat.# 90-8M0049000

Class
3 0022 864727 FITTING Y, (3) 1-1/4 In. OD Hose (If Required) 1
Barbs
4 0054 815504222 CLAMP Worm Gear (1.98 DIameter) AR
5 0032 865672079 HOSE (96.00 Inches Bulk) Design I (Cut to 23.5 1
Inches) 5.0/350/377
5 0032 865672079 HOSE (96.00 Inches Bulk) Design I (Cut to 20 Inches) 1
4.3L
5 0032 865672079 HOSE (96.00 Inches Bulk) Design II (Cut to 15 1
Inches) 5.0/350/377
5 0032 865672079 HOSE (96.00 Inches Bulk) Design II (Cut to 10 1
Inches) 4.3
6 0032 865672013 HOSE (4.00 Inches) Design I 1
6 0032 865672079 HOSE (96.00 Inches Bulk) Design II (Cut to Fit) 1
7 0032 865672079 HOSE (96.00 Inches Bulk) Design I (Cut to Fit) 1
8 0000 865470 HOUSING Inlet 1

PAGE 90
Cat.# 90-8M0049000
Closed Cooling System (BRAVO) Sea Pump Hoses (SeaCore)
Design I
9
4 1
4
5 8
4
7 2 4
4 1
14
15
16
17
4 18
6
4
4
3
17
Design II
4
9
1
4
4 11 14
15
4 10
13 16
1 17
4
12
4 18
3
17
44448

PAGE 91
Cat.# 90-8M0049000

Class
2 0022 865362 QUICK CONNECT Design I 1
3 0022 864727 FITTING Y, (3) 1-1/4 In. OD Hose (If Required) 1
Barbs
4 0054 815504222 CLAMP Worm Gear (1.98 DIameter) AR
5.0/350/377
4.3L
6 0032 865672013 HOSE (4.00 Inches) Design I 1
7 0022 862993 FITTING Y, (2) 1-1/4 In. Hose Barbs / Design I 1
(1) 3/4 In. Hose Barb
8 0032 865672079 HOSE (96.00 Inches Bulk) Design I (Cut to Fit) 1
10 0032 865672079 HOSE (96.00 Inches Bulk) Design II (Cut to 13.5 1
Inches) 5.0/350/377
10 0032 865672079 HOSE (96.00 Inches Bulk) Design II (Cut to 9 Inches) 1
4.3
12 0032 865672079 HOSE (96.00 Inches Bulk) Design II (Cut to Fit) 1
13 0022 8M4501756 FITTING Design II 1
14 0000 861427 CAP 1
15 0022 861405 FITTING 1
16 0022 861406 SOCKET 1
17 0054 815504212 CLAMP Worm Gear 2
18 0032 86438765 HOSE (34 Inches) 1

PAGE 92
Cat.# 90-8M0049000
Closed Cooling System Heat Exchanger
16
15 17
14
6
8
7
5
3 2
9 10
4
11
13
34186
12

PAGE 93
Cat.# 90-8M0049000

Class
1 0000 864395T01 HEAT EXCHANGER Closed 1
Cooling
2 0000 864708 COVER End, Heat Exchanger 2
3 0025 818679 O-RING 4
4 0010 94247 SCREW (.375-16 x .750) Stainless 2
Steel
5 0027 866152 SEAL 1
7 0025 8M2000926 SEAL 1
8 0036 8148791 CAP Pressure 1
9 0000 18431 PAD Heat Exchanger 1
10 0054 815504396 CLAMP Worm Gear Heat 1
Exchanger
11 0000 864494T BRACKET Cooler 1
12 0010 34353 SCREW (.375-16 x 1.00) 3
13 0010 805559 SCREW (.375-16 x .875) Stainless 1
Steel
14 0000 71587A10 RECOVERY KIT Coolant 1
15 0000 71587A11 BOTTLE Plastic Coolant Recovery 1
Kit
16 0000 72058 CAP Coolant Recovery Bottle 1
17 0032 1983389 HOSE (Included with Coolant 1
Recovery Kit)
PART NOTES:
806608Q01QS

PAGE 94
Cat.# 90-8M0049000
Water Distribution Housing
17
12
8 5
9 16
13 1
4
10
14
15
3
2
11
1440

PAGE 95
Cat.# 90-8M0049000

Class
1 0000 863631T1 HOUSING Water Distribution Manual Drain 1
1 0000 863444T1 HOUSING Water Distribution Rod Actuated 1
1 0000 863802T2 HOUSING Water Distribution Air Actuated, Closed Cool 1
1 0000 863444T2 HOUSING Water Distribution Air Actuated, Standard 1
Cool
3 0025 8M2000926 SEAL 1
4 0010 8175051 SCREW (.250-20 x .625) 3
5 0000 863839 COVER Rod Actuated 1
6 0000 863865 COVER Manual Drain 1
7 0000 863449T BRACKET Water Distribution 1
Housing
8 0010 34353 SCREW (.375-16 x 1.00) 1
9 0016 805357 STUD (.375-16 x 2.130) 1
10 0000 863451T BRACKET Water Drain Actuator 1
11 0010 34353 SCREW (.375-16 x 1.00) 2
12 0000 863381A1 DRAIN ROD ASSEMBLY 1
13 0011 32219 NUT (.375-16) 1
14 0022 863499 FITTING Gray Air Valve Component of Air Actuated 1
Housing Only
15 0022 863467 FITTING Orange Air Valve Component of Air Actuated 1
Housing Only
16 0013 35048 LOCKWASHER (.375) 1
17 0053 863741 E-RING 1
PART NOTES:
806608Q01QS

PAGE 96
Cat.# 90-8M0049000
Water Drain Air Manifold and Pump
8
9
1 3
2360

PAGE 97
Cat.# 90-8M0049000

Class
1 0000 863057 PUMP Bracket Assembly 1
2 0000 8634741 BRACKET Air Pump Bravo Standard Cooling 1
2 0000 8634742 BRACKET Air Pump Bravo Closed Cooling 1
3 0010 40011106 SCREW (M5 x 13) Stainless Steel Bravo Standard Cooling 1
4 0000 863053T MANIFOLD ASSEMBLY Air 1
5 0019 883503 CAP Service Point 1
6 0010 40007112 SCREW (M5 x 40) 2
7 0012 4002314 WASHER 2
8 0032 8630552 HOSE (40.00 Inches Bulk) Green 2
Cut to 32 Inch Length
9 0032 8630542 HOSE (40.00 Inches Bulk) Grey Cut 2
to 32 Inch Lenght
NS 0032 8630561 HOSE (42.00 Inches Bulk) Black Cut 2
to 28 Inch Length

PAGE 98
Cat.# 90-8M0049000
Sea Water Pump Assembly
10 11
9
19
23
15 25 20
16
24 22
21
14
13 17
12
3 6
2
8
1 4
18
51175

PAGE 99
Cat.# 90-8M0049000

Class
- 0046 862914T10 PUMP KIT Sea Water Without Air Fittings 1
- 0046 862914T11 PUMP KIT Sea Water With Air Fittings 1
1 0046 862914A13 HOUSING ASSEMBLY Impeller 1
2 0047 862232A2 IMPELLER 1
3 0000 8M2021987 O-RING Formed Also included 1
with Reference 8 and 9
- 0000 8M0050018 DRIVESHAFT ASSEMBLY KIT 1
4 0026 8M2001645 SEAL Oil 1
5 0000 862235A1 DRIVESHAFT ASSEMBLY 1
6 NSS NOT SOLD SEPARATE 1
SPACER
7 0026 862040 SEAL Lip 1
8 NSS NOT SOLD SEPARATE SNAP 1
RING
9 0000 863674A05 COVER KIT Impeller Housing With Air Fittings 1
10 0000 862776A01 COVER KIT Impeller Housing Without Air Fittings 1
11 0000 8M2014176 PLATE Wear 1
13 0025 8M2000926 SEAL 2
14 0010 4000328 SCREW (M6 x 16) 6
15 0022 863718 FITTING Gray - Straight Male Air (.1562) Component of 46- 1
862914T11
16 0022 863719 FITTING Orange - Straight Male Air (.1875) Component of 46- 1
862914T11
17 0010 4000331 SCREW (M6 x 30) 1
18 0000 862351T PULLEY 1
19 0016 863853 STUD 2
20 0011 82671112 NUT (.375-16) 2
21 0010 32132 SCREW (.375-16 x 1.750) 1
22 0013 35048 LOCKWASHER (.375) 1
23 0010 4000331 SCREW (M6 x 30) 2
24 0000 865143T01 BRACKET Sea Water Pump 1
25 0012 38622 WASHER (.391 x 1.00 x .125) 1
PART NOTES:
806608Q01QS

PAGE 100
Cat.# 90-8M0049000
Steering Components
14
16
15
1 2
5 7
13
12
6
11
10
4
12
12
8
13285
Steering Components

PAGE 101
Cat.# 90-8M0049000
Steering Components
Class
1 0000 16792A39 PUMP ASSEMBLY Power Steering 1
2 0016 41877 STUD (M10) 2
3 0036 95805 CAP 1
4 0000 861578 PULLEY 1
5 0000 862082T BRACE Power Steering 1
6 0010 40001188 SCREW (M10 x 20) 2
7 0011 90517 NUT (M10) 2
7 0011 8M2000545 NUT (M10) Stainless Steel (SEACORE) 2
8 0032 866685 HOSE Female Quick Connect 1
(Fittings on Both Ends)
8 0032 866509 HOSE Pressure (Fittings on Both (SEACORE) 1
Ends)
8 0032 866689 HOSE Female Quick Connect Jackshaft Models 1
9 0025 89879 O-RING (.301 x .064) 1
10 0032 865390015 HOSE Male Quick Connect (Fitting 1
on One End)
10 0032 865390134 HOSE Male Quick Connect (Fitting Jackshaft Models 1
on One End)
11 0032 5251914 HOSE (53.00 Inches Bulk) Pump to 1
Oil Cooler (37 Inch)
12 0054 815504105 CLAMP Worm Gear (11-18 mm) 3
Hose
13 0023 905201 SPACER (.750 x .250) 1
14 0000 863820T1 COOLER Power Steering 1
15 0010 816585 SCREW (.312-18 x .875) 1
16 0000 881879010 SENSOR 1
NS 0019 8079921 COVER Hose Clamp End (.25 Inside Diameter) AR
NS 0019 8079923 COVER Hose Clamp End (.375 Inside Diameter) 1
NS 0000 77054 TIE STRAP (14.50 Inches) 1
Steering Components

PAGE 102
Cat.# 90-8M0049000
Exhaust System Components
1
2
5
7 8
6 11
13
12
10 1488

PAGE 103
Cat.# 90-8M0049000

Class
1 0032 44348001 TUBE Exhaust Exhaust 2
2 0054 815504272 CLAMP Worm Gear 8
3 0000 865951A01 ELBOW KIT Intermediate Non-Riser 1
3 0000 866003A01 ELBOW KIT Intermediate (1.7 Inch Riser) 1
3 0000 866004A01 ELBOW KIT Intermediate (3 Inch Riser) 1
3 0000 866209A01 ELBOW KIT Intermediate (4.7 Inch Riser) 1
3 0000 866005A01 ELBOW KIT Intermediate (6 Inch Riser) 1
4 0054 815504272 CLAMP Worm Gear 8
5 0032 14358001 TUBE Exhaust 2
6 0000 807130A4 PIPE Exhaust 1
7 0000 807166A1 SHUTTER ASSEMBLY Water 2
8 0025 807167 GROMMET 4
9 0010 58640 SCREW (.375-16 x 1.25) 4
10 0013 41471 LOCKWASHER (.375) 4
NS 0019 8079923 COVER Hose Clamp AR
11 0000 861776A2 PLATE KIT Through Transome 1
Exhaust
12 0010 98794 SCREW (.375-16 x 1.00) Through Transom Exhaust 4
13 0013 41471 LOCKWASHER (.375) Through Transom Exhaust 4

PAGE 104
Cat.# 90-8M0049000
Shift Bracket Alpha
23
6 10
4 2
20 18 7
8
5 9
19 3
21 16
14 15 22
11 17
12 12
13
10
2582
Shift Bracket Alpha

PAGE 105
Cat.# 90-8M0049000
Shift Bracket Alpha

Class
1 0000 807962A15 BRACKET ASSEMBLY Shift 1
2 0000 865149A02 STUD With Cotter Pin 1
3 0000 865433A02 LEVER ASSEMBLY Actuator, With 1
Cotter Pin
4 0024 864907T SPRING 1
5 0010 865148 SHOULDER SCREW (.312-18 x 1
1.843) Stainless Steel
6 0018 328571 COTTER PIN 1
7 0024 98880 SPRING 1
8 0012 56720 WASHER (.330 x .750 x .060) 1
Stainless Steel
9 0012 35462 WASHER (.2656 x .625 x .0625) 1
Stainless Steel
10 0018 210711 COTTER PIN 2
11 0000 13898T06 LEVER ASSEMBLY Shift 1
12 0012 35462 WASHER (.2656 x .625 x .0625) 3
Stainless Steel
13 0016 865393A02 STUD KIT (.250-28 x 1.90) With 1
Cotter Pin
14 0011 63341 TEE NUT 1
15 0017 814001 PIN Clevis 1
16 0018 210711 COTTER PIN 1
17 0010 865148 SHOULDER SCREW (.312-18 x 1
18 0087 808009T10 SWITCH ASSEMBLY Shift Interupt 1
19 0010 865147 SCREW (#6-32 x .750) Stainless 2
Steel
20 0087 808009T11 SWITCH ASSEMBLY Gear 1
Indicator
Steel
22 0000 813995A1 GUIDE ASSEMBLY Spring 1
20 x .625)
Shift Bracket Alpha

PAGE 106
Cat.# 90-8M0049000
Shift Bracket Bravo
2 10
17 7
8
3 4 9
18 8
5
19
16
12 15
10
14
13 9
20
11
9 2581
Shift Bracket Bravo

PAGE 107
Cat.# 90-8M0049000
Shift Bracket Bravo

Class
1 0000 807962A15 BRACKET ASSEMBLY Shift 1
2 0016 865154A02 STUD KIT (.250-20/.250-28 x 2.120) 1
With Cotter Pin
3 0000 865434A02 RETAINER KIT Shift Cable, With 1
Cotter Pin
4 0023 98828 SPACER 1
5 0010 53167 SCREW (.312-18 x .880) 1
6 0018 328571 COTTER PIN 1
7 0024 98880 SPRING 1
8 0012 56720 WASHER (.330 x .750 x .060) 1
Stainless Steel
9 0012 35462 WASHER (.2656 x .625 x .0625) 3
Stainless Steel
10 0018 210711 COTTER PIN 2
11 0016 865393A02 STUD KIT (.250-28 x 1.90) With 1
Cotter Pin
12 0011 63341 TEE NUT 1
13 0000 863911A12 LEVER ASSEMBLY Shift 1
14 0010 865148 SHOULDER SCREW (.312-18 x 1
15 0017 68402 PIN (.250 x 1.13) Clevis 1
16 0018 210711 COTTER PIN 1
20 x .625)
17 0010 69035 SCREW AND LOCKWASHER (.250- (SEACORE) 3
20 x .625) Stainless Steel
18 0087 808009T11 SWITCH ASSEMBLY Gear 1
Indicator
Steel
20 0091 12427 TOOL Shift Adjust 1
Shift Bracket Bravo

PAGE 108
Cat.# 90-8M0049000
Shift Bracket Digital Throttle Shift
1
16
14
7 12
11
14
5 14
12 15
4 10
15
13
3 9
2 8
6
18
19 17
16171

PAGE 109
Cat.# 90-8M0049000

Class
1 0000 879194T46 SHIFT ACTUATOR 1
2 0000 865481 BRACKET Shift Plate 1
3 0000 864616 RETAINER Shift Cable 1
4 0023 98828 SPACER 1
5 0018 328571 COTTER PIN 1
6 0023 863133 SPACER Actuator 1
7 0000 8631341 LEVER Shift Arm 1
8 0023 863132 SPACER Shift Arm 1
10 0016 864361 STUD 1
11 0016 96112 STUD (.250-28 x 2.00) Throttle 1
Cable Anchor
12 0011 8267119 NUT (.250-28) 3
13 0011 46335 NUT (.375-24) 1
14 0012 35462 WASHER (.2656 x .625 x .0625) 5
Stainless Steel
15 0012 34931 WASHER (.406 x .734 x .063) 2
Stainless Steel
17 0087 889514A01 SWITCH 1
18 0010 865076 SCREW (6-32 x 1.25) 2
19 0023 864386 SPACER Switch 1

PAGE 110
Cat.# 90-8M0049000
Engine Mounts
7
1
3
6
9
5
1739
Engine Mounts

PAGE 111
Cat.# 90-8M0049000
Engine Mounts
Class
1 0000 79550A1 BRACKET Mount 2
2 0010 68101 SCREW (.375-16 x 1.375) 2
3 0016 805357 STUD (.375-16 x 2.130) 4
4 0000 66284A2 BASE ASSEMBLY 2
4 0000 866711T01 BASE ASSEMBLY (SEACORE) 2
5 0011 20739 NUT (.750-16) Jam 2
5 0011 18304 NUT Jam (SEACORE) 2
6 0014 12657 TAB WASHER Tab 2
7 0013 68102 LOCKWASHER (.750) 2
7 0013 33164 LOCKWASHER Stainless (.750) (SEACORE) 2
8 0011 20739 NUT (.750-16) Jam 2
8 0011 866710 NUT (.750-16) Stainless Steel Jam (SEACORE) 2
9 0011 860069 NUT (.375-16) 2
Engine Mounts

PAGE 112
Cat.# 90-8M0049000
Mercathode Components
5
8
1 2
4
3
12
13
11 14
10 13
11
59537

PAGE 113
Cat.# 90-8M0049000
Class
1 0000 98869A17 ELECTRODE ASSEMBLY With Quick Connectors 1
2 0084 865181T01 HARNESS ASSEMBLY Mercathode 1
3 0013 26992 LOCKWASHER (.250) Stainless 2
Steel
4 0012 29245 WASHER (.281 x .500 x .060) 2
Stainless Steel
5 0000 42600A09 MERCATHODE ASSEMBLY 1
7 0084 88543A3 CABLE ASSEMBLY 1
8 0010 62568 SCREW (#10-16 x .375) 1
10 0088 79091 FUSE 20 Ampere 1
11 0084 95084A9 CABLE ASSEMBLY (91.00 Inches) 1
Red/Purple Strip
11 0084 95084A10 CABLE ASSEMBLY (5.00 Inches) 1
Red
12 0010 69067 SCREW (.250-20 x 1.375) 2
13 0084 8M0060271 CABLE ASSEMBLY 1
14 0000 862646 FUSE Tan - 5 Ampere 1

PAGE 114
Cat.# 90-8M0049000
Jackshaft Main Kit (98634A20)
31
32
29
64
22
25
24
30
6
8
23
13 9 2 1
12
11 26
3 27 28
10 18 21
17
16
20
19
4 60
15
14 7 5
52
6
45 8
46 42
47 49 53
39 41
40 50 51 54
47 55
48
56
7
33 44 57
43 67 63
34
35
36
37
38 67 58 59
66 61
47106
65 62

PAGE 115
Cat.# 90-8M0049000

Class
- 0000 98634A20 EXTENSION KIT Jackshaft Kit 1
1 0000 93911A4 HOUSING ASSEMBLY Shaft 1
Extension Support
2 0022 74036 FITTING Grease (Use with greased bearing) 1
2 0010 8M2015913 PLUG (.250-28 x .320) (Use with non-greased 1
bearing)
3 0010 47651 SCREW (.437-14 x 1.50) 6
4 0000 93918A1 SHIELD Lower 1
5 0010 96995 SCREW (.375-16 x .880) 3
6 0000 93919A1 SHIELD Upper 2
8 0010 96995 SCREW (.375-16 x .880) 8
9 0000 93923A1 MOUNT ASSEMBLY Flywheel 2
Housing
10 0000 814263A1 BASE ASSEMBLY Mount 2
Assembly
11 0011 816331 NUT (.750-16) Jam 2
12 0014 12657 TAB WASHER 2
13 0011 859126 NUT (.750-16) 2
14 0000 93906A2 SHAFT Output 1
15 0025 29845 O-RING (.924 x .103) 2
17 0030 879194A03 GIMBAL BEARING KIT 1
18 0053 841897T RING Retaining 1
19 0010 47651 SCREW (.437-14 x 1.50) 4
20 0013 32993 LOCKWASHER (.437) 4
21 0000 814309A1 HOUSING ASSEMBLY 1
22 0019 12304 PLUG Timing Window 1
23 0023 49126 BUSHING Pilot V8 1
23 0030 863864 BEARING Pilot 496 1
24 0010 68101 SCREW (.375-16 x 1.375) 1
24 0010 34353 SCREW (.375-16 x 1.00) 1
24 0010 47688 SCREW (.375-16 x 2.750) 2
25 0013 35048 LOCKWASHER (.375) 4
26 0000 939201 PLATE Cover 1
27 0010 92913 SCREW (.437-14 x .750) 2
28 0013 32993 LOCKWASHER (.437) 2
29 0000 818718A3 COVER KIT Flywheel Inspection 1
30 0027 86015 GASKET Flywheel Inspection 1
Cover
31 0010 98253 SCREW (.250-20 x .500) 7
32 0013 26992 LOCKWASHER (.250) Stainless 7
Steel
33 0000 817416A4 HOUSING ASSEMBLY Bearing 1
34 0030 93944A2 BEARING SET Ball Includes Part Number 36 1
35 0023 817417T SPACER 1
36 0030 93944A2 BEARING SET Ball Includes Part Number 34 1

PAGE 116
Cat.# 90-8M0049000
31
32
29
64
22
25
24
30
6
8
23
13 9 2 1
12
11 26
3 27 28
10 18 21
17
16
20
19
4 60
15
14 7 5
52
6
45 8
46 42
47 49 53
39 41
40 50 51 54
47 55
48
56
7
33 44 57
43 67 63
34
35
36
37
38 67 58 59
66 61
47106
65 62

PAGE 117
Cat.# 90-8M0049000

Class
39 0026 93924 SEAL Oil 1
40 NSS NOT SOLD SEPARATE Input 1
Shaft
41 0019 93921 EXPANSION PLUG 1
42 0022 74036 FITTING Grease 2
43 0000 93918A1 SHIELD Lower 1
44 0010 76926 SCREW (.375-16 x .875) 3
45 0010 57053 SCREW (.500-20 x 4.500) 2
46 0012 35777 WASHER (.5156 x 1.375 x .125) 2
Aluminum
47 0012 42307 WASHER Spherical 4
48 0011 898832 NUT (.500-20) 2
49 0000 860065A1 BRACKET KIT 1
50 0000 808023T STRAP 1
51 0032 865389139 HOSE Female Quick Connect 1
52 0032 865390134 HOSE Male Quick Connect 1
(Fittings on One End)
55 0054 815504222 CLAMP Worm Gear (1.98 3
DIameter)
56 0032 8M0062666 HOSE (96.00 Inches Bulk) (Cut to 13 Inches) 1
58 0022 865415 FITTING PS Return 1
59 0022 865414001 FITTING PS Pressure 1
60 0000 861523A18 COUPLER ASSEMBLY Engine - 1
Short Steel Hub
61 0000 78458A1 TUBE 1
62 0000 41063A1 BRACKET ASSEMBLY 1
63 0000 861776A2 PLATE KIT 1
64 0084 41575A10 HARNESS ASSEMBLY Alpha 1
64 0084 41575A11 HARNESS ASSEMBLY Bravo 1
65 0000 862268T1 TUBE 1
66 0000 862268T2 TUBE 1
67 0000 41802 SEAL Rubber 1

PAGE 118
Cat.# 90-8M0049000
Gasket Set Components (27-861246A05) Engine Overhaul

PAGE 119
Cat.# 90-8M0049000

Class
- 0027 138651 GASKET Oil Pan 1
- 0027 756111 GASKET Cylinder Head 2
- 0027 33395 GASKET Exhaust Manifold 2
- 0027 17467 GASKET Rocker Cover 2
- 0027 866027 GASKET Carburated Models Only 1
- 0027 8079821 GASKET 1
- 0027 806640 GASKET 1
- 0027 861246 GASKET 1
- 0027 91892 GASKET Oil Filter Not Applicable in All 1
Models
- 0027 34897 GASKET Water Pump 2
- 0027 881715 GASKET Crankshaft Oil Seal 1
Housing
- 0027 530451 GASKET Lower Thermostat 1 [1]
Housing
- 0027 806871 GASKET Thermostat Housing 1
- 0027 344863 GASKET Distributor 1
- 0027 34898 GASKET 1
- 0027 49955 GASKET Drain 2
- 0026 42077 SEAL Oil Filter Not Applicable in All 2
Models
- 0026 976641 SEAL Intake valve 8
- 0026 804507 SEAL Exhaust Valve 8
- 0025 8071341 SEAL Thermostat 1
- 0025 32509 O-RING (.489 x .070) 5
- 0025 805063 O-RING (.301 x .070) 6
- 0025 805062 O-RING (.530 x .082) 1
- 0026 806655 SEAL 1
- 0026 806706 SEAL 1
- 0026 852941 SEAL Crankshaft Oil 1
- 0027 807473A1 GASKET SET Intake Manifold 1
PART NOTES:
53045 1Service Part
53045Q01QS

PAGE 120
Cat.# 90-8M0049000
Gasket Set Components (27- 75611A03) Cylinder Head

PAGE 121
Cat.# 90-8M0049000

Class
- 0027 75611A03 GASKET SET Cylinder Head 1
- 0027 17467 GASKET Rocker Cover 2
- 0027 8M2000819 GASKET Exhaust Manifold 2
- 0027 344863 GASKET Distributor 1
- 0027 530451 GASKET Thermostat Housing 1 [1]
- 0027 756111 GASKET Cylinder Head 2
- NSS NOT SOLD SEPARATE GASKET, 2
Intake Manifold
PART NOTES:
53045 1Service Part
53045Q01QS

PAGE 122
PARTS INDEX
Part No. Description Pg. Ref.no Part No. Description Pg. Ref.no
11178A01 BREAKER Circuit - 50 Ampere Button reset 18 17 11178A01 BREAKER Circuit - 50 Ampere Button Reset 22 17
11284 SPACER (.62 Diameter) 38 30 11966 SCREW (.437-14 x 3.750) 44 27
119671 SCREW (.437-14 x 3.00) 44 26 11968 SCREW (.437-14 x 1.750) 44 25
11971 NUT (.312-18) 58 17 11971 NUT (.312-18) 62 13
11989 STUD (.312-18 x 1.6718) 58 14 11989 STUD (.312-18 x 1.6718) 62 9
12304 PLUG Timing Window 116 22 12427 TOOL Shift Adjust 108 20
12524 PLUG (.375-18 x .475) Brass 42 2 12524 PLUG (.375-18 x .475) Brass 66 20
12552 LIFTING EYE 70 12 12552 LIFTING EYE 74 12
12657 TAB WASHER Tab 112 6 12657 TAB WASHER 116 12
13510 WASHER 62 23 138651 GASKET Oil Pan 58 10
138651 GASKET Oil Pan 120 - 13898T06 LEVER ASSEMBLY Shift 106 11
14070 SCREW (.250-20 x .625) 58 13 14242 BOLT (.250-20 x .875) 62 11
14243 BOLT (.250-20 x 1.750) 62 12 14256 REINFORCEMENT Starboard 58 16
14257 REINFORCEMENT Port 58 15 14263 PIN Dowel Oil Seal Housing Location 62 14
14358001 TUBE Exhaust 104 5 14827 STUD (.250-20 x 2.180) 62 5
14883 SCREW (.375-16 x 1.12) 62 22 1589424 HOSE (16.50 Inches Bulk) Breather 38 25
1589424 HOSE (16.50 Inches Bulk) Breather 44 9 16604 FITTING Straight (.125-27) 66 19
16792A39 PUMP ASSEMBLY Power Steering 102 1 17160 SPROCKET Crankshaft 48 25
17161T CHAIN Timing 48 22 173391 PUSH ROD 44 12
17340T1 LIFTER Roller 52 10 17341T GUIDE Lifter 52 9
17344 SCREW 44 3 17346 SCREW Oil Pump 58 2
1743534 HOSE (14.5 Inches) 84 4 1743534 HOSE (14.5 Inches) 90 7
1743534 HOSE (14.5 Inches) 92 11 17467 GASKET Rocker Cover 44 4
17467 GASKET Rocker Cover 120 - 17467 GASKET Rocker Cover 122 -
18304 NUT Jam 112 5 18431 PAD Heat Exchanger 94 9
18643A5 COUPLING ASSEMBLY 62 20 18644 BUMPER Rubber 62 21
18710002 CAP Oil Fill 44 2 1940971 HOSE (54.00 Inches Bulk) (.25 Inch I.D.) 16 7
1983389 HOSE (Included with Coolant Recovery Kit) 94 17 20084 WASHER (.328 x .562 x .062) 12 9
20533 WASHER 38 31 20553 WASHER (.406 x .734 x .063) 60 13
20572 WASHER (.390 x .750 x .093) 62 27 20572 WASHER (.390 x .750 x .093) 64 37
20739 NUT (.750-16) Jam 112 5 20739 NUT (.750-16) Jam 112 8
210711 COTTER PIN 106 10 210711 COTTER PIN 106 16
26484 NUT (.312-18) 12 6 269011 BUMPER Rubber 28 20
26992 LOCKWASHER (.250) Stainless Steel 114 3 26992 LOCKWASHER (.250) Stainless Steel 116 32
26996 LOCKWASHER (#10) Stainless Steel 10 6 26996 LOCKWASHER (#10) Stainless Steel 52 18
26996 LOCKWASHER (#10) Stainless Steel 70 6 26996 LOCKWASHER (#10) Stainless Steel 70 22
26996 LOCKWASHER (#10) Stainless Steel 74 4 27339 WASHER 58 12
29198 SCREW AND LOCKWASHER (.312-18 x .875) 70 27 29245 WASHER (.281 x .500 x .060) Stainless Steel 114 4
With Lockwasher
29598 NUT (.250-28) Stainless Steel 28 12 29845 O-RING (.924 x .103) 116 15
31866 SPACER (.256 x .313 x .625) 38 30 32132 SCREW (.375-16 x 1.750) 48 6
32132 SCREW (.375-16 x 1.750) 64 38 32132 SCREW (.375-16 x 1.750) 100 21
32219 NUT (.375-16) 64 39 32219 NUT (.375-16) 96 13
32509 O-RING (.489 x .070) 120 - 32515 SCREW (.437-20 x 2.50) 48 15
32561 PLUG Pipe - Allen Head (.250-18) 36 3 32783 RETAINER Three Wire 26 16
32784 RETAINER Four Wire 26 17 32803 PLUG Pipe (.375-18) Brass 70 2
32803 PLUG Pipe (.375-18) Brass 70 17 32803 PLUG Pipe (.375-18) Brass 74 2
328571 COTTER PIN 110 5 32993 LOCKWASHER (.437) 116 20
32993 LOCKWASHER (.437) 116 28 33164 LOCKWASHER Stainless (.750) 112 7
33395 GASKET Manifold 66 5 33395 GASKET Exhaust Manifold 120 -
33821 CONNECTOR 36 5 34270 EXPANSION PLUG (1.625) Engine Core Hole 62 2
34352 SCREW (.375-24 x .875) 48 13 34353 SCREW (.375-16 x 1.00) 12 16
34353 SCREW (.375-16 x 1.00) 12 20 34353 SCREW (.375-16 x 1.00) 12 27
34353 SCREW (.375-16 x 1.00) 94 12 34353 SCREW (.375-16 x 1.00) 96 8
34353 SCREW (.375-16 x 1.00) 96 11 34353 SCREW (.375-16 x 1.00) 116 24
34466 KEY Crankshaft 52 4 344863 GASKET 26 11
344863 GASKET Distributor 120 - 344863 GASKET Distributor 122 -
34500 SCREW (.312-18 x .625) 52 14 34516 NUT 44 21
34521 STUD 44 23 34522 STUD 44 23
PARTS MANUAL
PAGE 123
PARTS INDEX
34897 GASKET Water Pump 48 3 34897 GASKET Water Pump 120 -
34898 GASKET 120 - 34931 WASHER (.406 x .734 x .063) Stainless Steel 60 13
34931 WASHER (.406 x .734 x .063) Stainless Steel 110 15 35048 LOCKWASHER (.375) 62 34
35048 LOCKWASHER (.375) 96 16 35048 LOCKWASHER (.375) 100 22
35048 LOCKWASHER (.375) 116 25 35329 ARM KIT Rocker 44 19
35331 BALL Rocker Arm 44 20 35342 STUD (.312-24/.375-16 x 2.5625) 48 5
35366 SCREW 58 21 35462 WASHER (.2656 x .625 x .0625) Stainless Steel 106 9
35462 WASHER (.2656 x .625 x .0625) Stainless Steel 106 12 35462 WASHER (.2656 x .625 x .0625) Stainless Steel 108 9
35462 WASHER (.2656 x .625 x .0625) Stainless Steel 110 14 35777 WASHER (.5156 x 1.375 x .125) Aluminum 62 32
35777 WASHER (.5156 x 1.375 x .125) Aluminum 118 46 36183 RETAINER 58 5
36184 SHAFT 58 4 36533 WASHER (.328 x .562 x .0312) Copper 28 18
37293T SENDER ASSEMBLY Oil 20 32 37372 PLUG Pipe (.500) 42 23
37493 NUT (.375-24) 56 5 38622 WASHER (.391 x 1.00 x .125) 100 25
390721 PLUG Pipe (.125-27) Brass 66 3 39131 LOCKWASHER (.437) 48 16
40001134 SCREW (M8 x 25) 12 3 40001188 SCREW (M10 x 20) 12 18
40001188 SCREW (M10 x 20) 102 6 40001195 SCREW (M10 x 30) 34 6
4000328 SCREW (M6 x 16) 100 14 4000331 SCREW (M6 x 30) 100 17
4000331 SCREW (M6 x 30) 100 23 40007112 SCREW (M5 x 40) 98 6
40011106 SCREW (M5 x 13) Stainless Steel 98 3 40011149 SCREW (M8 x 25) Stainless Steel 26 10
40011151 SCREW (M8 x 35) Stainless Steel 70 19 40011151 SCREW (M8 x 35) Stainless Steel 110 9
40011155 SCREW (M8 x 55) Stainless Steel 110 16 400211 NUT (M5) Stainless Steel 10 12
400212 NUT (M6) Stainless Steel 12 2 4002314 WASHER 98 7
400247 LOCKWASHER (M8) 10 10 4008612 SCREW (M4 x 12) 38 13
4008820 SCREW (M6 x 20) 38 15 4008825 SCREW (M6 x 25) 40 11
4008855 SCREW (M6 x 55) 40 8 4010516 SCREW (M5 x 16) Stainless Steel 114 9
4010720 SCREW (M8 x 20) 34 8 4010775 SCREW (M8 x 75) 70 11
4010820 SCREW (M10 x 20) Hex Flange - Stainless Steel 34 9 401366 NUT (M6) Stainless Steel 18 20
401366 NUT (M6) Stainless Steel 22 20 401366 NUT (M6) Stainless Steel 38 17
401366 NUT (M6) Stainless Steel 38 28 401386 NUT (M6) Stainless Steel 38 22
41063A1 BRACKET ASSEMBLY 118 62 41471 LOCKWASHER (.375) 104 10
41471 LOCKWASHER (.375) 104 13 41575A10 HARNESS ASSEMBLY 118 64
41575A11 HARNESS ASSEMBLY 118 64 41802 SEAL Rubber 118 67
41877 STUD (M10) 102 2 42077 SEAL 60 8
42077 SEAL Oil Filter 120 - 42307 WASHER Spherical 118 47
42600A09 MERCATHODE ASSEMBLY 114 5 4285069 HOSE (44.00 Inches Bulk) Starboard Manifold to 76 13
4285069 HOSE (44.00 Inches Bulk) Port Manifold to 76 14 4285069 HOSE (44.00 Inches Bulk) Exhaust Manifold to Y 78 3
Distribution Fitting Fitting
4285069 HOSE (44.00 Inches Bulk) Exhaust Manifold to 78 3 428611 FITTING Pipe - Brass (.750-14) 48 2
Orifice Fitting
428611 FITTING Pipe - Brass (.750-14) 66 2 428611 FITTING Pipe - Brass (.750-14) 66 16
428611 FITTING Pipe - Brass (.750-14) 68 4 428611 FITTING Pipe - Brass (.750-14) 68 13
43504 PIN Dowel 52 2 43504 PIN Dowel Flywheel 62 18
44348001 TUBE Exhaust Exhaust 104 1 45862 SCREW (#10-32 x .875) 18 19
45862 SCREW (#10-32 x .875) 22 19 46335 NUT (.375-24) 110 13
46982 FITTING (90 Degree) 80 19 46982 FITTING (90 Degree) 82 19
47277 SCREW (.312-24 x .750) 48 8 47651 SCREW (.437-14 x 1.50) 116 3
47651 SCREW (.437-14 x 1.50) 116 19 47688 SCREW (.375-16 x 2.750) 48 6
47688 SCREW (.375-16 x 2.750) 116 24 48340 PLUG (.250-18 x .41) Oil Galley 62 3
483471 SPRING 44 16 483481 CAP 44 17
49099 FITTING 62 25 49126 BUSHING Pilot 116 23
49734 SENDER Water Temperature 70 5 49734 SENDER Water Temperature 70 21
49734 SENDER Water Temperature 74 3 49955 GASKET Drain Screw 58 11
49955 GASKET Drain 120 - 52188 GROMMET 44 5
5251914 HOSE (53.00 Inches Bulk) Pump to Oil Cooler (37 102 11 530451 GASKET 6 -
Inch)
530451 GASKET 6 - 530451 GASKET Lower Thermostat Housing 70 4
530451 GASKET Thermostat Housing 70 16 530451 GASKET Lower Thermostat Housing 74 10
530451 GASKET Lower Thermostat Housing 120 - 530451 GASKET Thermostat Housing 122 -
53167 SCREW (.312-18 x .880) 108 5 54676 RETAINER Two Wire 26 15
54786 SCREW (.312-18 x 1.250) 60 12 547971 KEY 44 18
56393 SCREW (.437-20 x 1.75) 12 24 56720 WASHER (.330 x .750 x .060) Stainless Steel 106 8
PARTS MANUAL
PAGE 124
PARTS INDEX
56720 WASHER (.330 x .750 x .060) Stainless Steel 108 8 57053 SCREW (.500-20 x 4.500) 118 45
57792 WASHER 12 5 58640 SCREW (.375-16 x 1.25) 104 9
62568 SCREW (#10-16 x .375) 114 8 627021 O-RING (.301 x .070) 76 21
627021 O-RING (.301 x .070) 78 21 62826A6 CABLE ASSEMBLY Ground (13.00 Inches) Black 64 40
63341 TEE NUT 106 14 63341 TEE NUT 108 12
64066 STUD (.375-16 x 2.750) Special 62 35 65567 WASHER (.265 x .750 x .048) Stainless Steel 18 5
65567 WASHER (.265 x .750 x .048) Stainless Steel 22 5 657461 SCREW AND LOCKWASHER (.250-20 x .625) 26 19
657461 SCREW AND LOCKWASHER (.250-20 x .625) 106 23 657461 SCREW AND LOCKWASHER (.250-20 x .625) 108 17
66284A2 BASE ASSEMBLY 112 4 68101 SCREW (.375-16 x 1.375) 64 38
68101 SCREW (.375-16 x 1.375) 112 2 68101 SCREW (.375-16 x 1.375) 116 24
68102 LOCKWASHER (.750) 112 7 68219 NUT (#10-32) Stainless Steel 18 18
68219 NUT (#10-32) Stainless Steel 22 18 68219 NUT (#10-32) Stainless Steel 52 19
68402 PIN (.250 x 1.13) Clevis 108 15 69035 SCREW AND LOCKWASHER (.250-20 x .625) 26 19
Stainless Steel
69035 SCREW AND LOCKWASHER (.250-20 x .625) 108 17 69067 SCREW (.250-20 x 1.375) 114 12
Stainless Steel
71458 WASHER 48 17 71587A10 RECOVERY KIT Coolant 94 14
71587A11 BOTTLE Plastic Coolant Recovery Kit 94 15 71920 VALVE ASSEMBLY Filter 60 11
72058 CAP Coolant Recovery Bottle 94 16 72640 PLUG Expansion, Camshaft Bearing Hole 62 4
72821 RETAINER 26 23 73379 PLUG (.250-18) 66 15
74036 FITTING Grease 62 NS 74036 FITTING Grease 116 2
74036 FITTING Grease 118 42 75533 SPRING 74 15
756111 GASKET 44 24 756111 GASKET Cylinder Head 120 -
756111 GASKET Cylinder Head 122 - 75611A03 GASKET SET Cylinder Head 44 -
75611A03 GASKET SET Cylinder Head 122 - 76596 SCREW (.250-20 x 1.250) 62 16
76926 SCREW (.375-16 x .875) 118 44 77054 TIE STRAP (14.50 Inches) 102 NS
78458A1 TUBE 118 61 79023A91 FUSE ASSEMBLY 90 Ampere 10 8
79091 FUSE 20 Ampere 20 28 79091 FUSE 20 Ampere 22 28
79091 FUSE 20 Ampere 114 10 79550A1 BRACKET Mount 112 1
79695 BOOT Insulator - Black 10 7 8018611 RING SET Piston, Standard 56 2
802555 VALVE Intake 44 14 802556T CYLINDER HEAD ASSEMBLY 44 22
802557T PISTON ASSEMBLY Standard 56 1 802558T PISTON ASSEMBLY .030 Oversize 56 1
802559 RING SET Piston, Standard 56 2 802893Q01 FILTER Fuel/Water Separating - Quicksilver Brand 2 -
802893Q01 FILTER Fuel/Water Separating - Quicksilver Brand 36 4 802893T FILTER Fuel/Water Separating - Mercury Brand 2 -
802893T FILTER Fuel/Water Separating - Mercury Brand 6 - 802893T FILTER Fuel/Water Separating - Mercury Brand 6 -
802893T FILTER Fuel/Water Separating - Mercury Brand 36 4 803860T CYLINDER HEAD ASSEMBLY 44 22
804352 CLIP Fuse Block Mounting 18 12 804352 CLIP Fuse Block Mounting 22 12
804507 SEAL Exhaust 44 15 804507 SEAL Exhaust Valve 120 -
805062 O-RING (.530 x .082) 28 7 805062 O-RING (.530 x .082) 120 -
805063 O-RING (.301 x .070) 28 5 805063 O-RING (.301 x .070) 120 -
805218T SENSOR 70 10 805218T SENSOR 70 20
805218T SENSOR 74 6 8053432 SCREW (.375-16 x 4.33) 10 3
805357 STUD (.375-16 x 2.130) 96 9 805357 STUD (.375-16 x 2.130) 112 3
805406 FILTER 28 14 805531 O-RING (.476 x .075) 28 15
805559 SCREW (.375-16 x .875) Stainless Steel 94 13 805625 CLIP Dipstick Tube 58 20
806121 FITTING 60 9 80617382 HOSE (58.00 Inches Bulk) Fuel Pressure Regulator 28 25
To Intake Manifold
80617382 HOSE (58.00 Inches Bulk) 34 10 80617382 HOSE (58.00 Inches Bulk) Cut to Appropriate 42 21
Length
806193A46 LUBE BOTTLE Lube Monitor 16 3 806193A47 RESERVOIR Lube Monitor 16 11
806242 CONNECTOR Barb 42 23 806490T SENDER Water Temperature 70 5
806490T SENDER Temperature 70 21 806490T SENDER Water Temperature 74 3
806608A02 PLUG ASSEMBLY (.500-13) Blue Housing With 30 3 806608A02 PLUG ASSEMBLY (.500-13) Blue Housing With 34 3
Drain Port Only Drain Port Only
806608A02 PLUG ASSEMBLY (.500-13) Blue 70 13 806608A02 PLUG ASSEMBLY (.500-13) Blue 80 16
806640 GASKET 120 - 806655 SEAL 120 -
806689 FITTING Tee 42 22 806706 SEAL 120 -
8067271 CAP Drive Lube Monitor Lube Reservoir 16 4 8067271 CAP Drive Lube Monitor Lube Reservoir 16 12
806871 GASKET 6 - 806871 GASKET 6 -
PARTS MANUAL
PAGE 125
PARTS INDEX
806871 GASKET Thermostat Housing 70 3 806871 GASKET Thermostat Housing 74 7
806871 GASKET Thermostat Housing 120 - 806922 SLEEVE Thermostat 70 9
806922 SLEEVE Thermostat 74 9 806949 NUT (M8-1.5) 10 4
806949 NUT (M8-1.5) 10 5 807075A1 COVER Thermostat Housing 70 25
807130A4 PIPE Exhaust 104 6 8071341 SEAL Thermostat 70 18
8071341 SEAL Thermostat 120 - 807166A1 SHUTTER ASSEMBLY Water 104 7
807167 GROMMET 104 8 807252T2 THERMOSTAT 71DegreeC (160 Degree F) 70 8
807252T2 THERMOSTAT 71DegreeC (160 Degree F) 74 8 807260A2 COVER KIT Flywheel 62 15
807296 NUT (.250-20) 62 NS 807473A1 GASKET SET Intake Manifold 42 3
807473A1 GASKET SET Intake Manifold 120 - 807661 HOSE Transom Assembly to Power Steering 76 7
Cooler
807661 HOSE Transom Assembly to Power Steering 80 10 807685T INSULATOR Base 28 2
Cooler
807688T TUBE Oil Fill 44 11 807729T PULLEY Water Pump 48 7
807730T PULLEY Crankshaft 48 12 807757T PULLEY ASSEMBLY Idler - Black (3.00 Inch 12 15
Diameter)
807783A1 FITTING ASSEMBLY 90 Degree 28 4 807918T BRACKET Fuel Filter Base 36 9
807930T01 INSULATOR Cover 28 21 807962A15 BRACKET ASSEMBLY Shift 106 1
807962A15 BRACKET ASSEMBLY Shift 108 1 807979T BRACKET 28 11
8079821 GASKET 120 - 8079921 COVER Hose Clamp End 102 NS
8079923 COVER Hose Clamp End 102 NS 8079923 COVER Hose Clamp 104 NS
808001A1 FITTING ASSEMBLY 28 6 808002A1 FITTING KIT 28 17
808003 CONNECTOR 36 6 808005 SCREW (.250-20 x .500) 28 19
808009T10 SWITCH ASSEMBLY Shift Interupt 106 18 808009T11 SWITCH ASSEMBLY Gear Indicator 106 20
808009T11 SWITCH ASSEMBLY Gear Indicator 108 18 808010 SCREW (.312-18 x 1.375) 42 4
808023T STRAP Reservoir Retainer 16 2 808023T STRAP 118 50
808547 O-RING 38 10 808570 RING SET Piston, (.030) Oversize 56 2
808624 CONNECTOR Lube Reservoir 16 5 809463A1 SOLENOID KIT Starter 10 2
809825 RTV SILICONE (3 Ounce Tube) Metallic Blue 52 - 809907002 PUMP ASSEMBLY Oil 58 1
809909 SCREEN Oil Pump Pick Up 58 3 809910 PAN Oil 58 9
809911001 SCREW KIT Drain 58 22 809992 VALVE Intake 44 14
809995 COVER Rocker With Oil Fill Hole 44 1 811658 CAMSHAFT 52 11
8116591 SPROCKET Camshaft 48 23 811662 RETAINER Lifter Guide 52 13
813995A1 GUIDE ASSEMBLY Spring 106 22 814001 PIN Clevis 106 15
814263A1 BASE ASSEMBLY Mount Assembly 116 10 814309A1 HOUSING ASSEMBLY 116 21
8148791 CAP Pressure 94 8 815425T SENDER ASSEMBLY Oil 20 32
815425T SENDER ASSEMBLY 24 37 815425T SENDER ASSEMBLY 52 17
815504105 CLAMP Worm Gear (11-18 mm) Hose 102 12 815504206 CLAMP Worm Gear 34 5
815504206 CLAMP Worm Gear 44 10 815504212 CLAMP Worm Gear 76 24
815504216 CLAMP Worm Gear (1.56 Diameter) 76 25 815504216 CLAMP Worm Gear (1.56 Diameter) 78 25
815504222 CLAMP Worm Gear (1.98 DIameter) 84 3 815504222 CLAMP Worm Gear (1.98 DIameter) 90 4
815504222 CLAMP Worm Gear (1.98 DIameter) 92 4 815504222 CLAMP Worm Gear (1.98 DIameter) 118 55
815504396 CLAMP Worm Gear Heat Exchanger 94 10 816133 FITTING 36 2
816331 NUT (.750-16) Jam 116 11 816492A15 ALARM KIT 20 33
816492A15 ALARM KIT 24 33 8164T CONNECTING ROD ASSEMBLY 56 3
816565 PLUG Cup (.468) 48 26 816585 SCREW (.312-18 x .875) 102 15
8167301 NUT 62 10 817416A4 HOUSING ASSEMBLY Bearing 116 33
817417T SPACER 116 35 81742780 SCREW (M8 x 80) 74 11
8175051 SCREW (.250-20 x .625) 96 4 8183812 PINION STUD (.437-20) Stainless Steel 12 14
818390 DRAIN COCK 70 26 818400A1 ADAPTER 60 7
PARTS MANUAL
PAGE 126
PARTS INDEX
818465 BEARING SET 5 Pair Standard 52 1 818466 BEARING SET 5 Pair (.001) Undersized 52 1
818467 BEARING SET 5 Pair (.010) Undersized 52 1 818468 BEARING SET 5 Pair (.020) Undersized 52 1
818679 O-RING 94 3 818718A3 COVER KIT Flywheel Inspection 116 29
82130025 SCREW (M6 x 25) 18 4 82130025 SCREW (M6 x 25) 22 4
8243171 VALVE Exhaust 44 13 8243181 VALVE Exhaust 44 13
82670811 NUT (.312-24) 36 10 826709106 NUT (#10-32) Stainless Steel 18 18
826709108 NUT (.250-20) Stainless Steel 38 35 826709109 NUT (.250-28) Stainless Steel 38 32
82670912 NUT (.375-16) Stainless Steel 44 29 82670912 NUT (.375-16) Stainless Steel 116 7
8267098 NUT (.250-20) Stainless Steel 16 8 82671112 NUT (.375-16) 64 39
82671112 NUT (.375-16) 100 20 8267119 NUT (.250-28) 10 9
8267119 NUT (.250-28) 110 12 8267138 NUT (.25-20) 38 35
8267138 NUT (.25-20) 40 4 8267139 NUT (.250-28) 38 32
828054 COVER Fuse 20 26 828054 COVER Fuse 22 26
828213 SCREW (.312-18 x 1.500) Hex Flange 12 4 828552 SCREW (.375-16 x .500) 16 14
830749 SEAL 6 - 830749 SEAL 6 -
830749 SEAL 6 - 830749 SEAL 6 -
830861 SCREW (#8-32 x .625) 18 19 830861 SCREW (#8-32 x .625) 22 19
83296915 FUSE Mini - Blue - 15 Ampere 18 15 832969T20 FUSE Mini - Yellow - 20 Ampere 18 15
832969T20 FUSE Mini - Yellow - 20 Ampere 22 15 834985 GROMMET 18 6
834985 GROMMET 22 6 835000 RING SET Piston, (.5mm) Oversize 56 2
835001T PISTON ASSEMBLY Standard 56 1 835002T PISTON ASSEMBLY (.5MM) Oversize 56 1
841897T RING Retaining 116 18 843378 PIN Dowel 52 12
843378 PIN Dowel Alignment, Oil Pump 58 7 843379 PIN Dowel (.6206/.6211 x 1.20) Flywheel Housing 62 1
Location
845602 NUT (.375-16) 58 8 845757 SCREW (.437-20 x 1.00) 62 19
845941 RETAINER Camshaft 48 20 845942 SCREW (.312-18 x .750) 48 24
845943 SCREW (.250-20 x .500) 48 21 849391T BEARING SET 8 Pair Standard, Connecting Rod 56 6
849392 BEARING SET (.001 Oversize) 8 Pair Connecting 56 6 849393 BEARING SET (.001 Undersize) 8 Pair Connecting 56 6
Rod Rod
849394 BEARING SET (.001 Undersize) 5 Pair (.001) 52 1 849395 BEARING SET (.001 Oversize) 5 Pair (.001) 52 1
Undersized Oversized
849396 BEARING SET Standard - 5 Pair Standard 52 1 850090 STUD (.437-14/.375-16 x 3.360) Crankshaft 52 7
Bearing Cap
8503991 PUMP ASSEMBLY Water 48 1 852368 SCREW (#10-24 x .750) 28 28
852940 HOUSING ASSEMBLY With Studs Crankshaft Oil 62 7 852941 SEAL Cranskshaft Oil 62 8
Seal
852941 SEAL Crankshaft Oil 120 - 853678T SENSOR TPS 38 2
85439001 CONNECTOR Male Lube Reservoir 16 13 85674 BEARING SET 52 8
856954 BUSHING 18 7 856954 BUSHING 22 7
85701 BEARING Connecting Rod, Standard 56 6 85702 BEARING Connecting Rod, (.001) Undersize 56 6
85703 BEARING Connecting Rod, (.002) Undersize 56 6 85704 BEARING Connecting Rod, (.010) Undersize 56 6
85705 BEARING Connecting Rod, (.020) Undersize 56 6 85802 SCREW (.375-24 x Special) Connecting Rod 56 4
858048K01 25W40 SD/IB OIL MPP, 1 Quart 2 - 858048Q01 25W40 SD/IB OIL 1 Quart 2 -
858049K01 25W40 SD/IB OIL MPP, 1 Gallon 2 - 858049Q01 25W40 SD/IB OIL 1 Gallon 2 -
859126 NUT (.750-16) 116 13 859135 NUT (.437-20) Brass/Nickel Plated 12 13
859135 NUT (.437-20) Brass/Nickel Plated 12 25 860008 SCREW (.250-20 x .625) Torx 18 9
860008 SCREW (.250-20 x .625) Torx 22 9 860008 SCREW (.250-20 x .625) Torx 68 8
860008 SCREW (.250-20 x .625) Torx 68 18 860065A1 BRACKET KIT Lube Monitor Reservoir 16 1
860065A1 BRACKET KIT 118 49 860069 NUT (.375-16) 28 24
860069 NUT (.375-16) 36 13 860069 NUT (.375-16) 112 9
860088 BUSHING 80 18 860088 BUSHING 82 18
8600891 HOSE Molded Power Steering to Fuel Cooler 80 1 86015 GASKET Flywheel Inspection Cover 116 30
860346 FITTING Elbow (90 Degree) (.750) 90 Degrees 48 4 861126A1 REGULATOR KIT (43 PSI) 28 13
861156A03 PUMP/COOLER KIT Fuel 28 3 861163 QUICK CONNECTOR (90 Degree) To Transom 16 6
861246 GASKET 120 - 861246A05 GASKET SET 2 -
861246A05 GASKET SET Engine Overhaul 44 - 861246A05 GASKET SET Engine Overhaul 50 -
861246A05 GASKET SET Engine Overhaul 58 - 861246A05 GASKET SET Engine Overhaul 120 -
861405 FITTING 92 15 861406 SOCKET 92 16
861414 RING Retaining 28 10 861427 CAP 92 14
861476 VALVE PCV 44 8 861505 FITTING Drain Tee 80 12
861505 FITTING Drain Tee 82 12 861523A11 COUPLER ASSEMBLY Engine 62 24
PARTS MANUAL
PAGE 127
PARTS INDEX
861523A18 COUPLER ASSEMBLY Engine - Short Steel Hub 118 60 861523A9 COUPLER ASSEMBLY Engine - Short Aluminum 62 24
Hub
861578 PULLEY 102 4 861776A2 PLATE KIT 104 11
861776A2 PLATE KIT 118 63 861942T9 DIPSTICK Oil Level 58 19
86197763 HOSE (33.00 Inches Bulk) 44 7 862040 SEAL Lip 100 7
862082T BRACE Power Steering 12 17 862082T BRACE Power Steering 102 5
862083T BRACKET Idler Adjustment 12 11 862085T BRACE Idler Bracket 12 21
862210A01 ELBOW KIT Drain 80 15 862210A01 ELBOW KIT Drain 82 15
862225 FITTING Pushlock 76 18 862225 FITTING Pushlock - Block Drian Hose 78 18
862232A2 IMPELLER 100 2 862235A1 DRIVESHAFT ASSEMBLY 100 5
862268T1 TUBE 118 65 862268T2 TUBE 118 66
862271A1 CHECK VALVE 80 13 8623175 HOSE Cylinder Block Drain to Distribution Fitting 76 10
8623175 HOSE Cylinder Block Drain to Distribution Fitting 78 10 862351T PULLEY 100 18
8623601 PLUG Fuel Rail Block Off 42 25 862538001 ADAPTER Throttle Body 40 12
862562T1 CAMSHAFT 52 11 8625671 SCREW Carnkshaft Bearing Cap 52 6
862573 NUT 56 5 862587A3 CONNECTING ROD ASSEMBLY 56 3
862594 KEY Crankshaft Crankshaft 52 4 862603 FITTING Male Quick Connector, Threaded 76 16
862603 FITTING Male Quick Connector, Threaded - 78 8 862646 FUSE Tan - 5 Ampere 20 25
Engine Block
862646 FUSE Tan - 5 Ampere 22 25 862646 FUSE Tan - 5 Ampere 114 14
862704A4 TUBE Dipstick 58 18 862776A01 COVER KIT Impeller Housing 100 10
862778 BRACKET Alternator Brace 12 26 862914A13 HOUSING ASSEMBLY Impeller 100 1
862914T10 PUMP KIT Sea Water 100 - 862914T11 PUMP KIT Sea Water 100 -
862993 FITTING Y, (2) 1-1/4 In. Hose Barbs / (1) 3/4 In. 78 2 862993 FITTING Y, (2) 1-1/4 In. Hose Barbs / (1) 3/4 In. 92 7
Hose Barb Hose Barb
862994T FITTING 66 11 862998 VALVE Idle Air 38 14
863006 O-RING (10.82 x 1.78) 38 9 863007A1 STARTER MOTOR ASSEMBLY 10 1
863053T MANIFOLD ASSEMBLY Air 98 4 8630542 HOSE (40.00 Inches Bulk) Grey Cut to 32 Inch 98 9
Lenght
8630552 HOSE (40.00 Inches Bulk) Green Cut to 32 Inch 98 8 8630561 HOSE (42.00 Inches Bulk) Black Cut to 28 Inch 98 NS
Length Length
863057 PUMP Bracket Assembly 98 1 863077T ALTERNATOR ASSEMBLY Black 65 Amp With 12 1
50mm Pulley
863129 BALL Check 66 10 863132 SPACER Shift Arm 110 8
863133 SPACER Actuator 110 6 8631341 LEVER Shift Arm 110 7
863151 SEAL Quad Ring 28 23 863151 SEAL Quad Ring 34 13
863211T01 BRACKET Alternator Mounting 12 7 863215 GASKET 40 13
863323T1 CRANKSHAFT 52 3 863332 NUT (.500-20) Aluminum 64 36
863381A1 DRAIN ROD ASSEMBLY 96 12 863396001 TIMING COVER ASSEMBLY Screws, Grommets, 48 18
Oil Seal, and Gasket are Not Sold Seperately
863397 HARMONIC BALANCER 48 14 863398 RELUCTOR WHEEL 48 19
863414 STUD Knock Sensor 44 30 863416T FLAME ARRESTOR 38 20
863417 BRACKET Throttle 38 34 863420T BRACKET Throttle Anchor 38 26
863422T1 BRACKET Fuel Cooler 28 1 863423 BRACKET Cover Mount 38 21
863424T BRACKET ECM 18 8 863432T FITTING 90 Degree Vent 42 26
863439 STUD 18 21 863439 STUD 22 21
863439 STUD 38 27 863444T1 HOUSING Water Distribution 96 1
863444T2 HOUSING Water Distribution 96 1 863449T BRACKET Water Distribution Housing 96 7
863451T BRACKET Water Drain Actuator 96 10 863456A1 HOSE ASSEMBLY Thermostat Housing to 76 4
Circulating Pump
863456A1 HOSE ASSEMBLY Thermostat Housing to 78 4 863457A2 HOUSING ASSEMBLY Thermostat 70 1
Circulating Pump
863458 HOSE Thermostat Housing to Port Manifold 76 5 863458 HOSE Thermostat Housing to Port Manifold 78 5
863458 HOSE Thermostat Housing to Port Manifold 80 8 863458 HOSE Thermostat Housing to Port Manifold 82 8
863459 HOSE Thermostat Housing to Starboard Manifold 76 6 863459 HOSE Thermostat Housing to Starboard Manifold 78 6
863459 HOSE Thermostat Housing to Starboard Manifold 80 7 863459 HOSE Thermostat Housing to Starboard Manifold 82 7
863464 FITTING Tee 78 20 863464A1 FITTING ASSEMBLY 76 20
863465 HOSE Drain Accumulator to Tee Fitting 76 19 863465 HOSE Drain Accumulator to Tee Fitting 78 19
863467 FITTING Orange Air Valve 96 15 8634741 BRACKET Air Pump 98 2
8634742 BRACKET Air Pump 98 2 863480 SCREW (.375-16 x 1.125) 62 26
863485 FITTING 60 2 863489 HOSE Power Steering Cooler to Check Valve 76 1
863489 HOSE Power Steering to Check Valve 86 1 863490 HOSE Water Drain Accumulator to Distribution 76 11
Fitting
863490 HOSE Water Drain Accumulator to Distribution 78 11 863491 HOSE Distribution Fitting to "Y" Fitting 76 12
Fitting
PARTS MANUAL
PAGE 128
PARTS INDEX
863499 FITTING Gray Air Valve 96 14 863611 HOSE Sea Pump to Power Steering Cooler 86 15
863623 HOSE Check Valve to Fuel Cooler 76 3 863623 HOSE Check Valve to Fuel Cooler 86 3
863631T1 HOUSING Water Distribution 96 1 863647T BRACKET 38 16
863656A1 CABLE KIT Ignition (Spark Plugs and Coil) 26 12 863657A1 CABLE ASSEMBLY Coil Wire Assembly 26 13
863660A2 LONGBLOCK ASSEMBLY 2 - 863660A2 LONGBLOCK ASSEMBLY 44 -
863660A2 LONGBLOCK ASSEMBLY 52 - 863663T BRACKET Coil 26 20
863670 HOSE Fuel Cooler to Water Distribution Housing 76 8 863670 HOSE Fuel Cooler to Accumulator Housing 86 10
863674A05 COVER KIT Impeller Housing 100 9 863686A04 DECAL SET 5.0L MPI Alpha 2 -
863686A05 DECAL SET 5.0L MPI Bravo 2 - 863686A06 DECAL SET 5.0L Seacore 2 -
863687A06 DECAL SET 350 Mag MPI Alpha 2 - 863687A07 DECAL SET 350 Mag MPI Bravo 2 -
863687A08 DECAL SET 350 Mag Seacore 2 - 863687A09 DECAL SET 377 MAG Seacore 2 -
863687A10 DECAL SET 377 Mag 2 - 863701 KNOB Engine Cover 38 24
863701 KNOB 40 2 863704T COIL Ignition 26 18
863714T01 BRACKET 68 9 863715T01 BRACKET 68 19
863718 FITTING Gray - Straight Male Air 100 15 863719 FITTING Orange - Straight Male Air 100 16
863732T1 BRACKET Oil Filter 60 1 863741 E-RING 96 17
863786A1 FITTING ASSEMBLY Drain 66 8 863802T2 HOUSING Water Distribution 96 1
863820T1 COOLER Power Steering 102 14 863839 COVER 96 5
863841T TUBE Water Brass 76 17 863841T TUBE Water Brass 78 17
863853 STUD 100 19 863864 BEARING Pilot 116 23
863865 COVER 96 6 863911A12 LEVER ASSEMBLY Shift 108 13
86400 WASHER 40 3 864176A1 RING SET Piston, Standard 56 2
864206A1 CHECK VALVE ASSEMBLY 76 2 864206A1 CHECK VALVE ASSEMBLY 86 2
864260T00 SERVICE MANUAL #31 5.0L/5.7L/6.2L 2 - 864260T00 SERVICE MANUAL #31 2 -
864263 BRACKET Flushing Attachment 66 22 864297T01 SENSOR ASSEMBLY Crankshaft Position 48 9
864327 BUSHING Orifice 76 NS 864337A1 CONNECTOR Black Jumper 20 34
864337A1 CONNECTOR Black Jumper 24 34 864338 STUD Special 38 19
864346 DECAL Flush Operation 2 - 864353 O-RING 76 NS
864361 STUD 110 10 864378 SCREW (.250-20 x .375) Torx 68 10
864378 SCREW (.250-20 x .375) Torx 68 20 864386 SPACER Switch 110 19
86438765 HOSE (34 Inches) 92 18 864395T01 HEAT EXCHANGER Closed Cooling 94 1
864398T04 HOUSING ASSEMBLY Thermostat 70 15 864398T1 HOUSING ASSEMBLY Thermostat 70 15
864431 HOSE Distribution Fitting to Heat Exchanger 86 5 864431 HOSE Distribution Fitting to Heat Exchanger 88 5
864435 HOSE Port Exhaust Elbow to Thermostat Housing 80 14 864435 HOSE Port Exhaust Elbow to Thermostat Housing 82 14
864456T BRACKET Alternator Brace 12 19 864458 BRACKET 34 15
864459 BRACKET 34 7 864493 THERMOSTAT 77°C (170°F) 70 24
864494T BRACKET Cooler 94 11 864506 HOSE Heat Exchanger to Thermostat Housing 86 11
864506 HOSE Heat Exchanger to Thermostat Housing 88 11 864507 HOSE Heat Exchanger to Thermostat Housing 86 12
864507 HOSE Heat Exchanger to Thermostat Housing 88 12 864508 HOSE Thermostat Housing to Lower Manifold 86 9
864508 HOSE Thermostat Housing to Lower Manifold 88 9 864509 HOSE Thermostat Housing to Lower Manifold 86 8
864509 HOSE Thermostat Housing to Lower Manifold 88 8 864539 HOSE Thermostat Housing to Upper Manifold 86 6
864539 HOSE Thermostat Housing to Upper Manifold 88 6 864547A02 GASKET Full Flow 68 6
864547A02 GASKET Full Flow 68 15 864549A02 GASKET Elbow, Block Off 66 12
864549A02 GASKET Block Off 68 5 864549A02 GASKET Block Off 68 14
864551 HOSE Intake Bypass to Circulating Pump 86 4 864551 HOSE Intake Bypass to Circulating Pump 88 4
864552 HOSE Thermostat Housing to Upper Manifold 86 7 864552 HOSE Thermostat Housing to Upper Manifold 88 7
864560 HOSE Tee Fitting to Port Elbow 76 22 864560 HOSE Tee Fitting to Port Elbow 78 22
864561 HOSE Tee Fitting to Starboard Elbow 76 23 864561 HOSE Tee Fitting to Starboard Elbow 78 23
864573001 SERVICE MANUAL ECM 555 Diagnostics, 14 pin, 2 - 864578 HOSE Drain Fitting to Check Valve 80 3
SM 36
864579 HOSE Check Valve to Thermostat Housing 80 4 864591T02 ELBOW ASSEMBLY 66 13
864592T1 HOUSING Thermostat Thermostat 74 1 864616 RETAINER Shift Cable 110 3
864621A1 FITTING ASSEMBLY Lower Distribution 76 9 864625T PULLEY (4.25 Inch Diameter) 12 15
864650A13 MODULE KIT Fuel Pump, Complete 34 1 864669 FITTING 52 15
864689 PLUG Expansion Expansion 66 4 864689 PLUG Expansion Expansion 66 14
864689 PLUG Expansion 68 3 864701 O-RING (1.112 x .103) 66 9
864703A1 HOSE Circulating Pump to Drain Elbow 80 5 864703A1 HOSE Circulating Pump to Drain Elbow 82 5
864708 COVER End, Heat Exchanger 94 2 864726 HOSE Heat Exchanger to Port Elbow 86 14
864726 HOSE Heat Exchanger to Port Elbow 88 14 864727 FITTING Y, (3) 1-1/4 In. OD Hose Barbs 90 3
PARTS MANUAL
PAGE 129
PARTS INDEX
864727 FITTING Y, (3) 1-1/4 In. OD Hose Barbs 92 3 864850A02 GASKET Elbow, Resitrictor 66 12
864850A02 GASKET Restrictor 68 5 864850A02 GASKET Restrictor 68 14
864886 HOSE Heat Exchanger to Circulating Pump 86 21 864886 HOSE Heat Exchanger to Circulating Pump 88 21
864907T SPRING 106 4 864908A1 RISER EXTENSION KIT 6 Inch 68 11
864908A2 RISER EXTENSION KIT 6 Inch 68 11 864924 HOSE Oil To Adaptor 60 5
864925 HOSE Oil From Adaptor 60 6 864929A3 RISER EXTENSION KIT 3 Inch 68 1
864929A4 RISER EXTENSION KIT 3 Inch 68 1 864953 HOSE Heat Exchanger to Port Elbow 86 14
864953 HOSE Heat Exchanger to Port Elbow 88 14 864954 HOSE Thermostat Housing to Upper Manifold 86 7
864954 HOSE Thermostat Housing to Upper Manifold 88 7 864955 HOSE Heat Exchanger to Starboard Elbow 86 13
864955 HOSE Heat Exchanger to Starboard Elbow 88 13 864956 HOSE Thermostat Housing to Upper Manifold 86 6
864956 HOSE Thermostat Housing to Upper Manifold 88 6 864965 HOSE Tee Fitting to Port Elbow 76 22
864965 HOSE Tee Fitting to Port Elbow 78 22 864966 HOSE Tee Fitting to Starboard Elbow 76 23
864966 HOSE Tee Fitting to Starboard Elbow 78 23 864979 HOSE Starboard Exhaust Elbow to Thermostat 80 6
Housing
864979 HOSE Starboard Exhaust Elbow to Thermostat 82 6 864989A01 FITTING ASSEMBLY Lower Distribution 78 9
Housing
865047T PULLEY Water Pump 48 7 865076 SCREW (6-32 x 1.25) 110 18
865143T01 BRACKET Sea Water Pump 100 24 865147 SCREW (#6-32 x .750) Stainless Steel 106 19
865147 SCREW (#6-32 x .750) Stainless Steel 106 21 865147 SCREW (#6-32 x .750) Stainless Steel 108 19
865148 SHOULDER SCREW (.312-18 x 1.843) Stainless 106 5 865148 SHOULDER SCREW (.312-18 x 1.843) Stainless 106 17
Steel Steel
865148 SHOULDER SCREW (.312-18 x 1.843) Stainless 108 14 865149A02 STUD With Cotter Pin 106 2
Steel
865154A02 STUD KIT (.250-20/.250-28 x 2.120) With Cotter 108 2 865159 FITTING 45 Degree 66 17
Pin
865175T BRACKET Lube Monitor Reservoir 16 10 865181T01 HARNESS ASSEMBLY Mercathode 114 2
865188T BRACKET 12 10 865188T01 BRACKET 12 10
865191 FITTING Male 16 16 865193 BUSHING 12 12
865193 BUSHING 12 23 865205 CLIP Relay Mounting 18 11
865205 CLIP Relay Mounting 24 36 865208T02 HOSE ASSEMBLY 3 Bib Orifice Meter 34 16
865234 HOSE Sea Pump to Water Orifice 78 13 865234 HOSE Sea Water Pump to Water Orifice 88 3
865235 HOSE Water Orifice to Power Steering Cooler 78 15 865235 HOSE Water Orifice to Power Steering Cooler 82 2
865235 HOSE Water Orifice to Power Steering Cooler 88 15 865247 HOSE Power Steering Cooler to Accumulator 88 1
Housing
865255 HOSE Power Steering Cooler to Accumulator 78 1 865317T02 HOSE ASSEMBLY 2 Bib Orifice Meter 34 16
Housing
865324 QUICK CONNECT 84 1 865324 QUICK CONNECT 90 1
865329A02 MOUNT KIT Rubber 62 29 865337 HOSE Sea Pump to Water Orifice 78 13
865337 HOSE Sea Water Pump to Water Orifice 82 9 865356T COOLER Fuel 28 8
865379 FITTING Female 16 15 865389139 HOSE Female Quick Connect (Fittings on Both 118 51
Ends)
865390015 HOSE Male Quick Connect (Fitting on One End) 102 10 865390134 HOSE Male Quick Connect (Fitting on One End) 102 10
865390134 HOSE Male Quick Connect (Fittings on One End) 118 52 865393A02 STUD KIT (.250-28 x 1.90) With Cotter Pin 106 13
865393A02 STUD KIT (.250-28 x 1.90) With Cotter Pin 108 11 865394 HOSE 78 12
865409 HOSE Drain Fitting to Thermostat Housing 82 3 865414001 FITTING PS Pressure 118 59
865415 FITTING PS Return 118 58 865433A02 LEVER ASSEMBLY Actuator, With Cotter Pin 106 3
865434A02 RETAINER KIT Shift Cable, With Cotter Pin 108 3 865470 HOUSING Inlet 90 8
865470 HOUSING Inlet 92 9 865470 HOUSING Inlet 118 53
865479T01 BRACKET ECM Mount 22 8 865480T BRACKET Harness Mounting/Lifting Eye 18 1
865480T BRACKET Harness Mounting/Lifting Eye 22 1 865481 BRACKET Shift Plate 110 2
865483T BRACKET Circuit Breaker and Relays 18 16 865483T BRACKET Circuit Breaker and Relays 22 16
865598 PULLEY 12 22 865615Q03 BELT Serpentine Serpentine 6 -
865615Q03 BELT Serpentine 12 28 865615Q03 BELT Serpentine 48 27
865615Q04 BELT Serpentine Serpentine 6 - 865615Q04 BELT Serpentine 12 28
865615Q04 BELT Serpentine 48 27 865615Q06 BELT Serpentine Alpha/Bravo,Closed Cooling, With 12 28
Power Steering
865615Q06 BELT Serpentine 48 27 865615Q08 BELT Serpentine Standard Cooling, Bravo, CHS 12 28
and Non Power Steering
865615Q09 BELT Serpentine 48 27 865657A03 HOUSING ASSEMBLY Flywheel 62 28
865672013 HOSE (4.00 Inches) 90 6 865672013 HOSE (4.00 Inches) 92 6
PARTS MANUAL
PAGE 130
PARTS INDEX
865672079 HOSE (96.00 Inches Bulk) 84 4 865672079 HOSE (96.00 Inches Bulk) 84 5
865672079 HOSE (96.00 Inches Bulk) 84 5 865672079 HOSE (96.00 Inches Bulk) Sea Water Pump to 86 23
Water Pick Up
865674 HOSE Power Steering Cooler to Drain Fitting 82 1 865677T01 HARNESS ASSEMBLY Transom 22 23
865677T02 HARNESS ASSEMBLY Transom 20 23 865735A02 MANIFOLD ASSEMBLY Exhaust 66 1
865774T01 HARNESS ASSEMBLY Trim Pump 24 35 865827T BREAKER Circuit - 50 Ampere Flag Reset 18 17
865827T BREAKER Circuit - 50 Ampere Flag Reset 22 17 865907 FITTING (3/8-18) Inlet 36 7
865951A01 ELBOW KIT Intermediate 104 3 865982005 SCREW (.375-16 x 1.00) 68 16
865982007 SCREW (.375-16 x 1.25) Hex Flange Knock Sensor 44 31 865982057 SCREW (.375-16 x 7.50) Exhaust Elbow 66 18
865982057 SCREW (.375-16 x 7.50) 68 17 865982071 SCREW (.375-16 x 9.250) 68 7
865982077 SCREW (.375-16 x 10.500) 68 7 865982092 SCREW (.375-16 x 12.380) 68 17
865983T01 HARNESS ASSEMBLY Injectors 20 22 865983T01 HARNESS ASSEMBLY Injectors 22 22
865995A01 RISER EXTENSION KIT 1.7 Inch 68 1 865996A01 RISER EXTENSION KIT 1.7 Inch 68 1
866003A01 ELBOW KIT Intermediate 104 3 866004A01 ELBOW KIT Intermediate 104 3
866005A01 ELBOW KIT Intermediate 104 3 866022T CAMSHAFT 52 11
866027 GASKET 120 - 866056T02 HARNESS ASSEMBLY 18 10
866058T02 HARNESS ASSEMBLY 18 10 866114 SCREW (.250-28) Special 28 9
866114 SCREW (.250-28) Special 30 33 866114 SCREW (.250-28) Special 34 14
866138A03 LONGBLOCK ASSEMBLY 2 - 866138A03 LONGBLOCK ASSEMBLY 44 -
866138A03 LONGBLOCK ASSEMBLY 52 - 866152 SEAL 94 5
866157 PLUG EGR Port 42 24 866169T01 PUMP ASSEMBLY Fuel High Pressure 30 15
866170A01 PUMP ASSEMBLY Fuel - Low Pressure 30 11 866171A01 FILTER 30 28
866204 STUD 40 6 866205 MOUNT Flame Arrestor 40 9
866206T FLAME ARRESTOR 40 5 866208A02 RISER EXTENSION KIT 4.7 Inch 68 11
866208A03 RISER EXTENSION KIT 4.7 Inch 68 11 866209A01 ELBOW KIT Intermediate 104 3
866232 SEAL Flame Arrestor 40 7 866295A02 IAC ADAPTER KIT 38 7
866331 HOSE Y Fitting to Accumulator 78 7 866331 HOSE Fuel Cooler to Drain Fitting 80 2
866340K01 FILTER Oil - Mercury Brand 2 - 866340K01 FILTER Oil - Mercury Brand 6 -
866340K01 FILTER Oil - Mercury Brand 6 - 866340K01 FILTER Oil - Mercury Brand 6 -
866340K01 FILTER Oil - Mercury Brand 6 - 866340K01 FILTER Oil - Mercury Brand 60 4
866340Q03 FILTER Oil - Quicksilver Brand 2 - 866340Q03 FILTER Oil - Quicksilver Brand 60 4
866509 HOSE Pressure (Fittings on Both Ends) 102 8 866592A04 THROTTLE BODY ASSEMBLY 40 10
866640 SCREW (.375-16 x .750) Stainless Steel 60 3 866641A01 STUD KIT Throttle Anchor 38 29
866656 SCREW (.312-24 x .750) Stainless Steel 48 8 866685 HOSE Female Quick Connect (Fittings on Both 102 8
Ends)
866689 HOSE Female Quick Connect (Fittings on Both 102 8 866710 NUT (.750-16) Stainless Steel Jam 112 8
Ends)
866711T01 BASE ASSEMBLY 112 4 866725 FITTING Straight (.750-14) 66 7
866725 FITTING Straight (.750-14) 66 17 866725 FITTING Straight (.750-14) 66 21
866725 FITTING Straight (.750-14) Barb 80 11 866725 FITTING Straight (.750-14) Barb 82 4
866729 FITTING (.250 x .250 NPTF) 82 11 86885 SCREW (.250-20 x 1.500) Stainless Steel Not 62 16
Included With Item 15
877770K1 COOLANT MPP, 1 Gallon 2 - 878187 SENSOR ASSEMBLY Knock 20 31
878187 SENSOR ASSEMBLY Knock 24 31 878187 SENSOR ASSEMBLY Knock 44 28
879172A32 CYLINDER HEAD ASSEMBLY 44 22 879194A03 GIMBAL BEARING KIT 116 17
879194T46 SHIFT ACTUATOR 110 1 879194T68 PISTON ASSEMBLY Standard 56 1
879194T82 ECM Engine Control Module 18 3 879194T83 ECM Engine Control Module 18 3
879288A06 LONGBLOCK ASSEMBLY 377 MAG 2 - 879288A06 LONGBLOCK ASSEMBLY 44 -
879288A06 LONGBLOCK ASSEMBLY 52 - 879288T67 COVER Silver 38 23
879288T67 COVER Silver Engine 40 1 879288T92 ECM Engine Control Module 18 3
PARTS MANUAL
PAGE 131
PARTS INDEX
879288T97 ECM Engine Control Module 22 3 879312003 INJECTOR 42 15
881715 GASKET Crankshaft Oil Seal Housing 62 6 881715 GASKET Crankshaft Oil Seal Housing 120 -
881733 SEAL 42 9 881879010 SENSOR Pressure 20 30
881879010 SENSOR Pressure 24 30 881879010 SENSOR 102 16
881879T11 SENSOR Pressure (0 - 100 PSI) Oil 20 30 881879T11 SENSOR Pressure (0 - 100 PSI) Oil 24 30
881879T11 SENSOR Pressure (0 - 100 PSI) 52 16 882751 RELAY 18 14
882751 RELAY 22 14 883503 CAP Service Point 98 5
883562 COVER Fuse 18 13 883562 COVER Fuse 22 13
884018001 SCREW 48 11 884786 SCREW 26 3
884788 SCREW 26 5 884788 SCREW 26 7
884789 GEAR ASSEMBLY 26 8 884794A02 DISTRIBUTOR ASSEMBLY 26 1
885164001 MANIFOLD Intake Lower 42 1 885165 SENSOR Manifold Air Pressure and Temperature 42 8
885166 SCREW 42 7 885167 MANIFOLD Intake Upper 42 5
885168 GASKET Intake Manifold 42 6 88517 FITTING Reducing 30 31
885171 STUD 38 18 885172 GASKET Throttle Body 38 6
885173 FUEL RAIL ASSEMBLY 42 12 885174 REGULATOR Fuel Pressure 42 13
885175 CLIP Retaining 42 14 885177 RETAINER Injector 42 16
885178 VALVE Fuel Pressure Service 42 18 885179 CAP Fuel Pressure Sevice Valve 42 19
885180 SCREW 42 11 885180 SCREW 42 20
885192 O-RING 48 10 88543A3 CABLE ASSEMBLY 114 7
88641 INSULATOR Back 36 8 88731 CLAMP 26 9
888416T04 HARNESS ASSEMBLY DTS, Clean Power, 15 Feet 20 24 888416T04 HARNESS ASSEMBLY DTS, Clean Power, 15 Feet 22 24
Clean Power Clean Power
888770T THROTTLE BODY ASSEMBLY 38 1 889514A01 SWITCH 110 17
889664 NUT (1.500-18) Black Nylon 20 35 889664 NUT (1.500-18) Black Nylon 24 32
892665 FILTER Fuel 30 23 892670A01 CHECK VALVE KIT 30 5
892677 COVER Fuel Module Housing 30 9 892681 REGULATOR 30 10
892683 SEAL 30 32 892684 SCREW 30 4
892687A02 CARTRIDGE ASSEMBLY Fuel Filter 30 24 89302 WASHER (.203 x .406 x .040) 28 16
89302 WASHER (.203 x .406 x .040) 74 16 898141 SENSOR Hall Effect Camshaft Position 26 6
898253013 ROTOR 26 4 898253T22 CAP Distributor 26 2
89876A3 BASE ASSEMBLY Fuel Filter With Water 36 1 89879 O-RING (.301 x .064) 102 9
Seperator
898832 NUT (.500-20) 118 48 8M0045997 LINE Fuel Fuel Pressure Regulator To Fuel Filter 28 26
8M0045997 LINE Fuel Fuel Regulator to Filter 36 12 8M0046000 LINE Fuel Fuel Filter To Fuel Pump 28 27
8M0046000 LINE Fuel Fuel Pump to Filter 36 11 8M0046869 O-RING KIT 42 17
8M0047215 MODULE KIT Fuel Pump, Complete 30 - 8M0047215 MODULE KIT Fuel Pump, Complete With Drain 30 -
Port
8M0047215 MODULE KIT Fuel Pump, Complete With Drain 34 1 8M0047216 HOUSING Fuel Module With Drain Port 30 1
Port
8M0048402 OPERATION MANUAL 5.0L 2 - 8M0048404 OPERATION MANUAL 350/377 2 -
8M0049000 PARTS MANUAL 5.0, 350, 377 MAG MPI Sterndrive 2 - 8M0050018 DRIVESHAFT ASSEMBLY KIT 100 -
8M0050326 HARNESS ASSEMBLY Main Engine 22 10 8M0050539 OPERATION MANUAL 350/377 2 -
8M0053165 DECAL SET 377 Mag SeaCore 2 - 8M0053166 DECAL SET 377 Mag 2 -
8M0055652 TERMINATOR ASSEMBLY 10 Pin (CAN P and H) 22 11 8M0056175 HARNESS ASSEMBLY 30 20
8M0058191 OPERATION MANUAL 4.3/5.0 MPI 2 - 8M0058919 DIPSTICK Oil Level 58 19
8M0058920 TUBE ASSEMBLY Dipstick 58 18 8M0060271 CABLE ASSEMBLY 114 13
8M0062666 HOSE (96.00 Inches Bulk) 118 56 8M0074349 OPERATION MANUAL 4.3L/5.0L MPI 2 -
8M0086350 COVER Rocker Without Oil Fill Hole 44 1 8M0093688 FILTER Fuel 6 -
8M0093688 FILTER Fuel 6 - 8M0109441 THERMOSTAT 71Degree C (160 Degree F) 6 -
8M0109441 THERMOSTAT 71Degree C (160 Degree F) 6 - 8M0137219 IMPELLER KIT Heavy Duty 6 -
8M0147051 MAINTENANCE KIT 4.3L/5.0L/5.7L MPI (100 6 - 8M0147053 MAINTENANCE KIT 5.0L/5.7L/377 MAG/8.2L Bravo 6 -
Hours) (100 Hours)
8M0147068 MAINTENANCE KIT 5.0L/5.7L MPI Alpha (300 6 - 8M0147069 MAINTENANCE KIT 5.0L/5.7L/377 MAG MPI Bravo 6 -
Hours) (300 Hours)
8M2000229 SCREW (.375-16 x 4.75) 66 6 8M2000545 NUT (M10) Stainless Steel 102 7
8M2000819 GASKET Exhaust Manifold 122 - 8M2000926 SEAL 70 14
8M2000926 SEAL 80 17 8M2000926 SEAL 82 17
8M2000926 SEAL 94 7 8M2000926 SEAL 96 3
8M2000926 SEAL 100 13 8M2001030 FILTER 38 12
8M2001490 CLAMP Worm Gear 80 22 8M2001490 CLAMP Worm Gear 82 22
8M2001490 CLAMP Worm Gear 86 19 8M2001490 CLAMP Worm Gear 88 19
8M2001645 SEAL Oil 100 4 8M2005027 HOSE Heat Exchanger to Starboard Elbow 86 13
PARTS MANUAL
PAGE 132
PARTS INDEX
8M2005027 HOSE Heat Exchanger to Starboard Elbow 88 13 8M2005177 LINE Cooler to Rail 34 11
8M2005178 LINE Fuel Fuel Cooler To Fuel Rail 28 22 8M2010476 FITTING (3/8-18) 30 2
8M2010476 FITTING (3/8-18) 34 2 8M2010902 VALVE Intake 44 14
8M2014176 PLATE Wear 100 11 8M2015899 SCREW (.375-16 x 1.37) Stainless Steel 64 38
8M2015913 PLUG (.250-28 x .320) 116 2 8M2018369 SPARK PLUG (NGK ITR4A15) 2 -
8M2018369 SPARK PLUG (NGK ITR4A15) 6 - 8M2018369 SPARK PLUG (NGK ITR4A15) 6 --
8M2018369 SPARK PLUG (NGK ITR4A15) 26 14 8M2018790 FILTER Pump Suction 30 17
8M2018792 CLIP 30 18 8M2021987 O-RING Formed Also included with Reference 8 100 3
and 9
8M4501756 FITTING 92 13 90096A1 STUD ASSEMBLY (#10-32 x Special) 26 22
90517 NUT (M10) 102 7 905201 SPACER (.750 x .250) 102 13
91892 GASKET 60 10 91892 GASKET Oil Filter 120 -
92913 SCREW (.437-14 x .750) 116 27 93906A2 SHAFT Output 116 14
93911A4 HOUSING ASSEMBLY Shaft Extension Support 116 1 93914 RING Retaining 118 37
93915 RING Retaining 118 38 93918A1 SHIELD Lower 116 4
93918A1 SHIELD Lower 118 43 93919A1 SHIELD Upper 116 6
939201 PLATE Cover 116 26 93921 EXPANSION PLUG 118 41
93923A1 MOUNT ASSEMBLY Flywheel Housing 116 9 93924 SEAL Oil 118 39
93944A2 BEARING SET Ball 116 34 93944A2 BEARING SET Ball 116 36
94104 RING Retaining 116 16 94247 SCREW (.375-16 x .750) Stainless Steel 94 4
95084A10 CABLE ASSEMBLY (5.00 Inches) Red 20 27 95084A10 CABLE ASSEMBLY (5.00 Inches) Red 22 27
95084A10 CABLE ASSEMBLY (5.00 Inches) Red 114 11 95084A9 CABLE ASSEMBLY (91.00 Inches) Red/Purple Strip 20 29
95084A9 CABLE ASSEMBLY (91.00 Inches) Red/Purple Strip 22 29 95084A9 CABLE ASSEMBLY (91.00 Inches) Red/Purple Strip 114 11
9520001 FLYWHEEL 62 17 95805 CAP 102 3
96112 STUD (.250-28 x 2.00) Throttle Cable Anchor 110 11 96995 SCREW (.375-16 x .880) 116 5
96995 SCREW (.375-16 x .880) 116 8 97477A3 STUD KIT Throttle Anchor 38 29
976641 SEAL Intake 44 15 976641 SEAL Intake valve 120 -
97850 ELBOW 90 Degree 44 6 97934 SCREW (.500-20 x 5.370) Special 62 31
98253 SCREW (.250-20 x .500) 116 31 98261 SCREW (.375-16 x .750) 12 8
98261 SCREW (.375-16 x .750) 16 9 98261 SCREW (.375-16 x .750) 18 2
98261 SCREW (.375-16 x .750) 22 2 98261 SCREW (.375-16 x .750) 26 21
98261 SCREW (.375-16 x .750) 60 3 98475 BALL Nylon Check 74 14
98476 SCREW (#10-32 x 6.00) 74 17 98477A2 VALVE ASSEMBLY 74 13
986021 DEFLECTOR Oil 58 6 98634A20 EXTENSION KIT Jackshaft Kit 116 -
98794 SCREW (.375-16 x 1.00) 104 12 98828 SPACER 108 4
98828 SPACER 110 4 98869A17 ELECTRODE ASSEMBLY 114 1
98880 SPRING 106 7 98880 SPRING 108 7
99299 SPACER (.520 x .870 x .630) 62 33 99322 SPACER 62 30
NA NOT AVAILABLE 52 3 NA NOT AVAILABLE Orifice Meter Assembly 78 14
NA NOT AVAILABLE Orifice Meter Assembly 82 10 NA NOT AVAILABLE Orifice Meter Assembly 88 10
NSS NOT SOLD SEPARATE Thru Bolt 10 11 NSS NOT SOLD SEPARATE Check Valve 30 6
NSS NOT SOLD SEPARATE Plug 30 7 NSS NOT SOLD SEPARATE Seal 30 8
NSS NOT SOLD SEPARATE Seal 30 12 NSS NOT SOLD SEPARATE Seal 30 13
NSS NOT SOLD SEPARATE Isolator, Lift Pump 30 14 NSS NOT SOLD SEPARATE Isolator 30 16
NSS NOT SOLD SEPARATE Seal 30 19 NSS NOT SOLD SEPARATE Retainer 30 21
NSS NOT SOLD SEPARATE Screw 30 22 NSS NOT SOLD SEPARATE Cap, Fuel Filter Cartridge 30 25
NSS NOT SOLD SEPARATE Screw 30 26 NSS NOT SOLD SEPARATE Seal 30 27
NSS NOT SOLD SEPARATE Seal 30 29 NSS NOT SOLD SEPARATE Cup, Fuel Filter Cartridge 30 30
NSS NOT SOLD SEPARATE Insulator Sleeve 34 12 NSS NOT SOLD SEPARATE O-RING 38 3
NSS NOT SOLD SEPARATE SCREW KIT, TPS 38 4 NSS NOT SOLD SEPARATE O-RING 38 5
NSS NOT SOLD SEPARATE Gasket 38 8 NSS NOT SOLD SEPARATE Screw-Drive 38 11
NSS NOT SOLD SEPARATE Spacer 38 33 NSS NOT SOLD SEPARATE Bracket 42 10
NSS NOT SOLD SEPARATE Cap, Crankshaft Bearing 52 5 NSS NOT SOLD SEPARATE 1.7 Inch or 3 Inch Riser 68 2
NSS NOT SOLD SEPARATE 6 Inch or 4.7 Inch Riser 68 12 NSS NOT SOLD SEPARATE SPACER 100 6
NSS NOT SOLD SEPARATE SNAP RING 100 8 NSS NOT SOLD SEPARATE Input Shaft 118 40
NSS NOT SOLD SEPARATE GASKET, Intake Manifold 122 -
PARTS MANUAL
PAGE 133

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