PDF Service manual for 4.5L

[TomB985]

Good morning, everyone.

I’m picking up a 2019 Monterey with a 4.5L Merc 250 later this morning. It has 1,100 hours and has been fleet-maintained, so I expect it to be in good running order. All of my experience has been with a 4.3L TKS, so I’m trying to wrap my head around the 4.5L. I have a neurological condition that makes paper manuals difficult to use, so I’m hoping to find a source for a PDF or electronic copy of the service manuals for this one. Does anyone have any suggestions on where I can find one? I don’t mind paying, but I can’t find electronic copies anywhere.

This boat was run by a fleet operator since new. They changed the oil and gear lube every 100 hours, and replaced the impeller and spark plugs every 200 hours. It got a new outdrive at the end of 2021 and the engine looks immaculate. My plan is to get it wet this week, run it out, and see how it performs. Does anyone have any suggestions on things to check over?

I came here after buying my 2011 4.3L TKS new almost twelve years ago, and I’ve learned a ton from this community over the years. It’s a shame Don is no longer with us; he helped me through my stupid questions more than a few times!

 

[TomB985]

No replies, must be a tough crowd tonight.

Sounds like I might be stuck with paper manuals?

I spent all of yesterday going through the boat, and it seems to be in fantastic shape. It has more cosmetic blemishes than most 4-year-old boats, but the mechanical bits seem great. I was impressed to see they filled it with antifreeze last winter, which is a step beyond what I’ve ever done. Oil and drive lube look fresh, fluid levels are good, and it ran great on the muffs. I’ll be getting it wet this afternoon to see how it runs under load. I’m hoping the 250 HP Merc can push this 22’ barge almost as fast as the 190 TKS moved my 18’ Larson.

 

[Scott Danforth]

the only legal place to get manuals for your Mercruiser are from Mercruiser.
copyright laws prevail.

Mercury Marine Parts Accessories and Manuals

any non-mercruiser site claiming to have manuals is most likely a phishing and scam site.

 

[Stinnett21]

You might just have to get the paper and have the sections important to you scanned to pdf. Looks like a clean find. Let us know how it does.

 

[TomB985]

the only legal place to get manuals for your Mercruiser are from Mercruiser.
copyright laws prevail.

Mercury Marine Parts Accessories and Manuals

any non-mercruiser site claiming to have manuals is most likely a phishing and scam site.

Of course, I’ve always refused to buy illegal versions on eBay for that reason. I was looking for a licensed electronic copy, which doesn’t appear to exist.

You might just have to get the paper and have the sections important to you scanned to pdf. Looks like a clean find. Let us know how it does.

Yeah, that’s what I’ve resigned myself to doing. I just ordered a used copy on eBay for $60. I’ll take some time and scan the pages into a document to make it easier for me to use. Not the best solution, but it’ll work.

I took advantage of the warm-ish weather today to give the boat a quick run around the lake. It runs a lot better than I expected. 1100 hours is a lot more than my Larson has, but the engine doesn’t seem any the worse for wear. It was able to tach out at 5,200 at 49 MPH, which was a lot better than I expected for something this much larger. The electronic throttle control is also much more consistent.

So far, so good. No check engine light, but I’m sure something is bound to break sooner or later. Is there a good way to check for codes without getting something like the VesselView Mobile adapter?

 

[havoc_squad]

Of course, I’ve always refused to buy illegal versions on eBay for that reason. I was looking for a licensed electronic copy, which doesn’t appear to exist.



Yeah, that’s what I’ve resigned myself to doing. I just ordered a used copy on eBay for $60. I’ll take some time and scan the pages into a document to make it easier for me to use. Not the best solution, but it’ll work.

I took advantage of the warm-ish weather today to give the boat a quick run around the lake. It runs a lot better than I expected. 1100 hours is a lot more than my Larson has, but the engine doesn’t seem any the worse for wear. It was able to tach out at 5,200 at 49 MPH, which was a lot better than I expected for something this much larger. The electronic throttle control is also much more consistent.

So far, so good. No check engine light, but I’m sure something is bound to break sooner or later. Is there a good way to check for codes without getting something like the VesselView Mobile adapter?

Nope, got to open the wallet for the expensive Diacom or Rinda software I believe, pay someone qualified who does, or pray to find a friend who has it.

It's not just a code reader, they also provide real time sensor monitoring data essential for diagnosing.

If you gonna just throw a part at a code, you are better off spending the time finding a qualified technician for both your time and for your wallet.

 

[tpenfield]

When I got my 2016 boat w/ twin Mercruiser 6.2's I could not find any PDF versions available, so got the hard copy. Not sure if Mercury will offer PDF versions, since they tend to get pirated.

If you plan on doing your own work on the engines, you'd best get the Rinda Diacom software as well. These engines suffer from too much information coming from the controller, and it will drive you crazy with warning messages.

 

[TomB985]

Nope, got to open the wallet for the expensive Diacom or Rinda software I believe, pay someone qualified who does, or pray to find a friend who has it.

It's not just a code reader, they also provide real time sensor monitoring data essential for diagnosing.

If you gonna just throw a part at a code, you are better off spending the time finding a qualified technician for both your time and for your wallet.

I’ve been working on cars for decades and I’ve gotten pretty good at diagnosis. I’ve used various OBD readers over the years and rarely replace the wrong part anymore. Of course I want to be able to see data…I just had no idea how, which is why I was asking. I’m carb-stupid, and a carb issue on my TKS V6 confounded me for almost a month. I’m glad to have MPI this time around.

you plan on doing your own work on the engines, you'd best get the Rinda Diacom software as well. These engines suffer from too much information coming from the controller, and it will drive you crazy with warning messages.

Thanks! I’ll look into it.

 

[Bt Doctur]

Havent seen a scanned copy anywhere yet,but I keep looking

 

[TomB985]

I ended up buying a set of used manuals on eBay for the engine and PCM112. Much of it is about my own curiosity, but with 1,100 hours, I wouldn’t be surprised if some things started to wear out.

The engine doesn’t seem any the worse for wear, though. I was able to hit 49.5 MPH @ 5,200 RPMs, which is a lot more than I expected from a V6 in something this large.

 

[Scott Danforth]

but with 1,100 hours, I wouldn’t be surprised if some things started to wear out.

Seriously doubt the motor or drive will be wearing out. Most gasoline motors will go 5000 hours or more with proper maintenance, diesels will go 20000

Boat motors are normally killed by lack of maintenance

The boat on the other hand....

Plastic bits last 10-15 years max

Upholstery about the same

 

[Bondo]

Ayuh,...... Even the last motor Merc designed, 'n built,... the infamous 470s lasted alot longer than 1,100 hours,....

1,100 hours is just broken in for most I/O motors,....
Unless really beaten, 'n really abused,......
As Scott says, most boat motors are Killed by their owners,....

 

[TomB985]

Thanks, that give me more confidence. I found a few articles over the years suggesting rebuild may be needed at 1,500 hours, but that seemed absurdly low to me.

At first glance of spec sheets, it looks like the 4.5L is a stroked 4.3L. How much of a different animal is it than my 4.3L?

 

[Scott Danforth]

At first glance of spec sheets, it looks like the 4.5L is a stroked 4.3L. How much of a different animal is it than my 4.3L?

The 4.3 was a production truck/industrial motor made by GM and marinized by Mercruiser with parts available everywhere

The 4.5 is a Mercruiser designed and built motor with parts only available from Mercruiser

Some internal parts are similar

Other than that, they are both V6's

 

[tpenfield]

Mercruiser 4.5L with 1,100 hours ???

Those engines were introduced around 2014. . . . so, this boat must have gotten a lot of continued use. (either that or the ignition got left on )

As Scott mentioned - the engines are in-house design/built, not GM based
https://www.speedonthewater.com/mercruiser-4-5-liter-engine-earns-innovation-award/

 

[TomB985]

Mercruiser 4.5L with 1,100 hours ???

Those engines were introduced around 2014. . . . so, this boat must have gotten a lot of continued use. (either that or the ignition got left on )

As Scott mentioned - the engines are in-house design/built, not GM based
https://www.speedonthewater.com/mercruiser-4-5-liter-engine-earns-innovation-award/

Yup, it’s a 2019 with 1,100 hours. It was a fleet boat for a boat club here in Minnesota that I picked up at auction. They were selling 31 in this auction, and most of them were 2019s with 1,100-1,600 hours on them.

The condition of all of them reflected their use; there are far more scuffs, tears, and general wear and tear than what I’d expect from privately-owned boats. I spoke with two employees who insisted they changed oil and drive lube every 100 hours, and new spark plugs and impeller every 200. The drive on mine looked better than the other 2019s, so I asked after the auction closed if it had been replaced. The service manager confirmed it received a new drive in September, 2021.

All things considered, I think I made out pretty well on the deal. It needs a few odds and ends, but it seems to be in great mechanical shape for the $26K I paid for it.

 

[Lou C]

A relative has the 200 hp version of this in a 2020 Chap, they run well with more than enough power. The only things negative I have heard is warnings/check engine lights associated with the O2 sensors if you have cat converter exhaust.
If you look at parts diagrams, compare the old GM 4.3 to the Merc 4.5, you'd swear that Merc bought the old GM tooling. They are VERY similar, block, crank, main bearings, balance shaft, same 90* included angle of cyls, etc. The heads are slightly different and the ignition/EFI system appears much more advanced.
I do like them, good compromise between power and economy, for me though I just won't have a Cat Converter engine here in salt water. If you have to replace the exhaust as often as on the older engines, you're looking at a huge bill as no one else makes the parts, unlike the older engines. Fresh water not an issue, here is it is a BIG issue, like a $5000 parts cost issue. Every 7 or so years. That's a deal breaker for me.
That and the Merc OEM parts only for everything else, are 2-3x as much as GM marine was. A big price for more refinement.

 

[mrzooom]

The PDF manual does exist somewhere.
.frankly, when the subject surfaced, I went looking for my fully digitized complete index of ALL service repair manuals...but they had been hacked out of my storage (should have left them on an SD card im my drawer).
I lost the whole library!
Sorry.

 

[Scott Danforth]

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