MerCruiser Cranks but Wont Start or Hard to Start 5 0L MPI 350 MAG MPI MX 6 2

Models these procedures apply to:

Sterndrive (MCM)

5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon

Inboard and Tow Sports (MIE)

350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard, 350 MAG MPI Tow Sports

Year models these procedures apply to:

2001 2002 2003 2004 2005 2006

Important Information

1. Fist figure out what engine system is causing the issue. For an engine to work, basic needs must be present, spark (ignition), fuel and compression for the engine to operate. If one of these three components are not present or not functioning correctly, the engine will not run.
2. If possible, use a diagnostic tool to determine if faults or codes are present. If codes or faults are found, fix the issue before continuing. 
3. Check and see if fuel is reaching the Schrader valve which is located directly behind the throttle body.
4. Extract the spark plugs, ensure the proper heat range, type and the spark plug is being used and is not burned, fouled or oil contaminated. 
5. Perform a compression test on the motor and make sure the motor is mechanically sound. 

Engine cranks over but will not start or starts hard

Causes

1. Flame arrestor possibly clogged or blocked.
2. Fuel pump pressure is excessive.
3. Fuel tank is empty.
4. Fuel shut off valve possibly closed.
5. Vapor lock.
6. Lean fuel system.
7. Gasoline grate to low or stale, sour fuel.
8. Fuel contaminated with water.

Action

1. Clear and clean the flame arrestor.
2. Inspect for the cause of the excessive fuel pressure, repair as necessary.
3. Add fuel to the fuel tank.
4. Turn the fuel shut off valve to open position.
5. See repair manual for vapor lock condition.
6. Clean and clear the fuel system.
7. Drain the fuel from the tank and refill.
8. Use fuel treatment to remedy the contaminated fuel. If the issue continues, drain the gas from the fuel tank and refill the tank.

NOTE: Never attempt to service your MerCruiser without a factory service manual to help guide you through service procedures. 

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Service Manual HITACHI EX60WD 2 WHEELED EXCAVATOR SERVICE MANUAL SET

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MerCruiser Throttle Body Factory Service Reference 5 0 5 7 6 2

The following information covers factory service procedures for servicing the throttle body on MerCruiser inboard engines. Procedures applicable to the 5.0L/5.7L/6.2L MPI gasoline engines for 2001 2002 2003 2004 2005 and 2006 models. 

STERNDRIVE MCM

• 5.0L V8 MPI Alpha and Bravo
• 350 MAG MPI Alpha and Bravo
• MX 6.2L MPI Horizon
• 350 Mag MPI Alpha and Bravo Horizon
• MX 6.2L MPI

INBOARD AND TOW SPORTS (MIE)

• 350 MAG MPI Inboard
• MX 6.2 MPI Horizon Inboard
• 350 MAG MPI Horizon Inboard
• MX 6.2 MPI Inboard
• 350 MAG MPI Tow Sports

Testing and diagnosis helps determine problems and possible causes. Its important to perform extensive testing and troubleshooting prior to any major tear down or repair work. This ensures that the full extent of the problem is understood beforehand and may prevent any unnecessary repair work. Its recommended you use a factory repair manual when performing repairs on any vehicle, additional safety precautions, or technical data maybe included. 

THROTTLE BODY REMOVAL

1. Take off the engine cover and the flame arrestor. 

2. Detach the throttle linkage from the throttle body.

3. Detach the harness connector from the throttle position sensor. 

4. Take off the IAC hose from the throttle body.

5. Take off the throttle body attaching studs.

6. Remove the throttle body.

7. Take off the throttle body sealing ring and discard it. 

IMPORTANT: Place a clean towel over the opening of the intake manifold to prevent items or debris from entering the hole of the engine. 

CLEANING AND INSPECTION

IMPORTANT: Never use any cleaners that contain methyl ethyl ketone. 

IMPORTANT: Avoid getting any cleaners or solvents on the TPS (throttle position sensor).

IMPORTANT: Avoid damaging the throttle body or adapter when removing any gasket material from the throttle body and adapter.

1. Carefully remove any gasket  material from throttle body and adapter, be sure not to damage the sealing surface. 

2. Take off the IAC muffler.

3. Clean all of the throttle body parts thoroughly. Make sure that all of the passages are free of burrs, dirt and debris. 

4. Carefully check the sealing surfaces for damage that may effect the gasket from sealing. 

5. Inspect the throttle body casting for damage or cracks.

6. Check the linkage, throttle plates and other components for wear, damage and foreign material.

INSTALLATION

1. Reinstall a new throttle body sealing ring into the grove in the throttle body.

2. Reinstall the throttle body onto the upper intake manifold and align the dowels. 

3. If your going to be reusing the fasteners, first apply adhesive (Loctite 242, part number 92-809821) to the threads of the throttle body attaching studs. 

4. Reinstall the throttle body attaching studs and torque the studs to 9 Nm 80 lb-in.

5. Reinstall the IAC muffler.

6. Reinstall the throttle cable bracket.

NOTE: Make sure that the stud and nut are threading properly. Torque the throttle cable bracket nut to 19 Nm 168 lb-in.

7. Reinstall the IAC plug to the IAC hose.

8. Reinstall the flame arrestor and torque the flame arrestor retainer bracket nut to 12 Nm 108 lb-in.

9. Reinstall the engine cover.

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