How do I pull the starter on a 1991 Mercruiser 3.0L?

Question

I'll be helping my brother try to pull the starter on his boat since he's been having problems. I figured I'd ask in advance if anyone here has pulled one and if you have any advice... my brother believes the engine may have to be pulled to get to the last bolt.

1991 Mercruiser 3.0L, 130 HP, inboard/outboard engine, serial number on the engine is 0D442474.

Thanks!

Answer 1

1.  Disconnect battery.

2.  Remove the two starter mount bolts from underneath.  On some models of boats, it is easier to reach under from the front of the motor with a long bar and socket, to break free the bolts.  I've never had to pull the motor on a 3L.

3. Remove the rear support bracket from the engine block(some models don't have this).

4. Pull the starter free of the motor, and disconnect the wiring.

Installation is the reverse, Use only NEW starter bolts, and if there where shims on the old starter, use them on the new one.

Answer 2

It seems highly unlikely that having the engine pulled will be needed to get the starter off of its mounts.  Getting the engine pulled is a time consuming process that will cost a lot of money, especially during the re-installation.  Inboard motors just cannot be dropped back on their mounts and just reinstalled, the engine must be aligned with the driveshaft.

Was all other issues ruled out like faulty battery wiring, starter relay, or ignition system?

Correction:

From the way my 1985 Mercrusier 4 cylinder I/O is arranged, the starter sits on three mounts (NOT two), with two in the back being the main mounts.  The first one is visible and mounts to the flywheel cover.  The second one is quite a pain, because it is farther back into the bilge and will need to be removed and installed blindly.  Get a mirror and a shop light and put it under the starter in the bilge to see what is under the starter.  

Don't quote me on my setup being the same for your mercrusier, but its worth relooking at it again.

Make sure you either have a service manual for that mercrusier model and year, or do a complete documentation of where all wires, connections, and fasteners went.  A couple of sheets of paper and a digital camera with the engine lighted well helps.

I would just go and spend the money for getting a service manual.  It helps with a LOT of troubleshooting issues, removal, and installing.