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Mercury Mercruiser Marine Engines #24 GM V-8 305 CID (5.0L) 350 CID (5.7L) Service Repair Manual

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Mercury Mercruiser Marine Engines #24 GM V-8 305 CID (5.0L) 350 CID (5.7L) Service Repair Manual

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  1. ??????? ?????? Number 24 MARINE ENGINES GM V-8 305 CID (5.0L) / 350 CID (5.7L) 1999, Mercury Marine Printed in U.S.A. 90-861327--1 1099

  2. MerCruiser #24 GM V-8 305 CID (5.0L) / 350 CID (5.7L) 90-861327--1 i MerCruiser #24 GM V-8 305 CID (5.0L) / 350 CID (5.7L) 90-861327--1 90-

  3. Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con- cerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these prod- ucts, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-861327--1 OCTOBER 1999 Page i

  4. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manu- al, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual. Page ii 90-861327--1 OCTOBER 1999

  5. Service Manual Outline 1 2 3 4 5 6 7 8 9 Important Information Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models B - MIE Models Section 3 - Engine A - 350 cid / 5.0L/ 305 cid / 5.7L Engines Section 4 - Electrical Systems A - Starting System B - Ignition System C - Charging System D - Instrumentation E - Wiring Diagrams Section 5 - Fuel Systems A - Fuel Delivery System For Carbureted Engines B - Mercarb 2 Barrel Carburetor C - Fuel Delivery System For Electronic Fuel Injection D - Fuel Injection Descriptions And System Operation E - Fuel Injection Disassembly And Reassembly F - Fuel Injection System Troubleshooting G - Diagnostics Section 6 - Cooling System A - Seawater Cooled Models B - Closed Cooled Models Section 7 - Exhaust System A - General B - Manifolds, Elbows and Risers C - Collectors Section 8 - Drives A - Velvet Drive In–Line and V-Drive Transmission B - Velvet Drive 5000 Series Transmission C - Hurth Models D - Drive Shaft / Propeller Shaft Models Section 9 - Power Steering System A - Pump and Related Components Removal and Installation Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives Power Steering System 90-861327--1 OCTOBER 1999 Page iii

  6. Table of Contents IMPORTANT INFORMATION Section 1A - General Information Table of Contents Introduction How to Use This Manual Page Numbering How to Read a Parts Manual Directional References Engine Rotation Engine Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 1A-2 1A-2 1A-2 1A-3 1A-4 1A-4 1A-5 Propeller Information Water Testing New Engines Boat and Engine Performance Boat Bottom Marine Fouling Weight Distribution Water in Boat Elevation and Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5 1A-6 1A-6 1A-6 1A-8 1A-9 1A-9 1A-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1B - Maintenance Table of Contents Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Maintenance Schedules Maintenance Intervals Engine and Tune-Up Specifications Fluid Capacities . . . . . . . . . . . . . . . . . . . . . Sterndrive Engines Inboard and Ski Engines Sterndrives . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . 20-Hour Break-In Period After Break-in Period End of First Season Checkup Specifications . . . . . . . . . . . . . . . . . . . . . . . Fuel Recommendations Vapor locking . . . . . . . . . . . . . . . . . . . . Test For Alcohol Content In Gasoline Procedure . . . . . . . . . . . . . . . . . . . . . . . Transmission Fluid . . . . . . . . . . . . . . . . . . Power Steering Fluid Coolant for Closed Cooling System Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase Oil Checking Engine Oil Level / Filling Changing Oil and Filter Changing Water Separating Fuel Filter MCM (Sterndrive) Models MIE (Inboard and Ski) Models Power Steering System Checking Fluid Level Engine Warm . . . . . . . . . . . . . . . . . . . . Engine Cold . . . . . . . . . . . . . . . . . . . . . Filling and Bleeding Closed Cooling System Checking Coolant Level Flushing System MCM (Sterndrive) Boat Out of Water Boat In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 1B-2 1B-2 1B-3 1B-3 1B-7 1B-11 1B-11 1B-11 1B-11 1B-12 1B-13 1B-13 1B-13 1B-14 1B-14 1B-14 1B-16 1B-16 1B-16 1B-16 1B-16 1B-17 1B-17 1B-18 1B-18 1B-19 1B-19 1B-20 1B-21 1B-21 1B-21 1B-21 1B-22 1B-23 1B-23 1B-24 1B-24 1B-25 Flushing System MIE (Inboard and Ski) Transmission Fluid Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable . . . . . . . . . . . . . . . . . . . . Shift Cable and Transmission Linkage 1B-28 MCM (Sterndrive) Models MIE (Inboard and Ski) Models Engine Coupler/U-Joint Shaft Splines Sterndrive Drive Shaft Extension Models . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . mie (Inboard and Ski) models Cleaning Flame Arrestor Top Mounted Flame Arrestor Black Scorpion Flame Arrestor Serpentine Drive Belt . . . . . . . . . . . . . . . . Component Location Inspection . . . . . . . . . . . . . . . . . . . . . . . Replacing and/or Adjusting Tension Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation and Adjustment Ignition Timing . . . . . . . . . . . . . . . . . . . . . . Thunderbolt V Models EFI/MPI Models . . . . . . . . . . . . . . . . . . Cold Weather or Extended Storage Precautions . . . . . . . . . . . . . . . . . . . . . . Power Package Layup Draining Instructions Draining Seawater (Raw-Water) Cooled Models . . . . . . . . . . . . . . . . . . Draining Seawater Section of Closed Cooled (Coolant) Models Draining Seawater Section of Closed Cooled (Coolant) Models Draining Sterndrive . . . . . . . . . . . . . . . Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-26 1B-27 1B-28 1B-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28 1B-29 1B-30 . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31 1B-31 1B-31 1B-32 1B-32 1B-33 1B-34 1B-34 1B-36 1B-36 1B-36 1B-36 1B-37 1B-37 1B-38 1B-39 1B-39 1B-40 1B-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 . . . . . . . . . . 1B-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50 1B-52 1B-53 . . . . . . . . . . . . . . . . . Page iv 90-861327--1 OCTOBER 1999

  7. Section 1C - Troubleshooting Used Spark Plug Analysis Normal Condition Chipped Insulator Wet Fouling (Oil Deposits) Cold Fouling Overheating High Speed Glazing Scavenger Deposits Pre-Ignition Damage Reversed Coil Polarity Splashed Deposits Mechanical Damage Poor Boat Performance and/or Poor Maneuverability Improper Full Throttle Engine RPM RPM Too High RPM Too Low Engine Cranks Over but Will Not Start or Starts Hard Important Information Testing Thunderbolt V Ignition System Fuel System Rich Fuel System Lean Miscellaneous Engine Will Not Crank Over Charging System Inoperative Noisy Alternator . . . . . . . . . . . . . . . . . . . . . Instrumentation Malfunction Radio Noise . . . . . . . . . . . . . . . . . . . . . . . . Poor Fuel Economy Carburetor Malfunctions Engine Runs Poorly at Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 1C-2 1C-2 1C-3 1C-3 1C-3 1C-4 1C-4 1C-4 1C-5 1C-5 1C-5 Engine Runs Poorly At High RPM Engine Acceleration Is Poor Troubleshooting with Vacuum Gauge Engine Noise . . . . . . . . . . . . . . . . . . . . . . . Important Information Valve Cover Area Cylinder Area . . . . . . . . . . . . . . . . . . . . Camshaft Area . . . . . . . . . . . . . . . . . . . Crankshaft Area . . . . . . . . . . . . . . . . . . Miscellaneous . . . . . . . . . . . . . . . . . . . . Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . Low Oil Pressure High Oil Pressure Excessive Oil Consumption Water In Engine . . . . . . . . . . . . . . . . . . . . . Important Information Water on Top of Pistons Water in Crankcase Oil Engine Overheats (Mechanical) Engine Overheats (Cooling System) Insufficient Water Flow from Belt Driven Seawater Pickup Pump Power Steering . . . . . . . . . . . . . . . . . . . . . Poor, Erratic, or No Assist Noisy Pump . . . . . . . . . . . . . . . . . . . . . . Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Silent Choice Exhaust Silencer System Compressor Will Not Run - Testing Mode Switch . . . . . . . . . . . . . . . . . . . . Compressor Will Not Run - Testing Air Pump . . . . . . . . . . . . . . . . . . . . . . . . Air Pump Runs - System Inoperative . . . . . 1C-16 1C-17 1C-17 1C-18 1C-18 1C-18 1C-19 1C-19 1C-20 1C-21 1C-22 1C-23 1C-23 1C-24 1C-25 1C-25 1C-26 1C-26 1C-27 1C-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-6 1C-7 1C-7 1C-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8 1C-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 1C-10 1C-10 1C-10 1C-11 1C-11 1C-12 1C-12 1C-12 1C-13 1C-14 1C-15 . . . . . 1C-29 1C-30 1C-30 1C-31 1C-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-32 . . . . . . . . . . 1C-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION Section 2A - MCM Models 1C-33 1C-33 Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Preparation . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Extension Models Engine Mount Adjustment Was Not Disturbed During Service Engine Mount Adjustment Was Disturbed During Service . . . . . . . . . . . . . . . . 2A-2 2A-2 2A-2 2A-3 2A-3 2A-5 2A-7 Alignment Water Hose Connections Electrical Connections Fuel Supply Connections Throttle Cable Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . Power Steering Connections Exhaust Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 2A-17 2A-18 2A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-21 2A-23 2A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 . . . . . . . . . . 2A-10 SECTION 2B - MIE Models Identification Velvet Drive In-Line and V-Drive Transmissions Velvet Drive Down-Angle Transmission Hurth Transmissions Torque Specifications Lubricants / Sealants / Adhesives . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Preparation Removal Installation and Alignment Engine Final Alignment Engine Connections Attaching / Adjusting Reversed Attachment Morse Shift Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 2B-4 2B-6 2B-7 2B-10 . . . . . . . . . . . . 2B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 2B-3 2B-3 2B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22 . . . . . 90-861327--1 OCTOBER 1999 Page v

  8. ENGINE Section 3A - 350 cid / 5.0L/ 305 cid / 5.7L Engines Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Specifications . . . . . . . . . . . . . . . . . . . . . . . General Specifications Engine Specifications General Information Repair Procedures Engine Identification Engine Rotation . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rods Camshaft and Drive Cylinder Head . . . . . . . . . . . . . . . . . . . . Valve Train . . . . . . . . . . . . . . . . . . . . . . Intake Manifold . . . . . . . . . . . . . . . . . . . Lubrication System Bearing Failures . . . . . . . . . . . . . . . . . . . . Piston Failures . . . . . . . . . . . . . . . . . . . . . . Pre-Ignition . . . . . . . . . . . . . . . . . . . . . . Detonation . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Cover . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm / Push Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Valve Adjustment . . . . . . . . . . . . . . . . . . . . Engine Stopped . . . . . . . . . . . . . . . . . . Engine Operating Hydraulic Valve Lifters Locating Noisy Lifters Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal / Valve Spring Removal - Head Installed Valve Assembly (Exploded View) Installation - Head Installed Cylinder Head . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Conditioning Disassembly . . . . . . . . . . . . . . . . . . . . . Valve Guide Bore Repair Valve Springs - Checking Tension Rocker Arm Stud Replacement . . . . . . . . . . . . . . . . 3A-3 3A-5 3A-6 3A-7 3A-7 3A-8 3A-12 3A-12 3A-12 3A-13 3A-13 3A-13 3A-13 3A-13 3A-14 3A-14 3A-14 3A-14 3A-15 3A-17 3A-17 3A-18 3A-19 3A-21 3A-21 3A-21 3A-22 3A-22 3A-22 3A-23 3A-24 3A-24 3A-24 3A-24 3A-25 3A-25 3A-26 3A-27 3A-27 3A-28 3A-29 3A-29 3A-30 3A-30 3A-31 3A-31 3A-32 3A-32 3A-32 3A-33 3A-34 3A-34 3A-37 3A-37 3A-38 Valve Seat Repair Valve Grinding Reassembly Crankcase Oil Dipstick Specifications All Engines . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Torsional Damper . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Crankcase Front Cover/Oil Seal Oil Seal Replacement (Without Removing Front Cover) Crankcase Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Rear Main Oil Seal . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Rear Main Oil Seal Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Main Bearings . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Checking Clearances Replacement . . . . . . . . . . . . . . . . . . . . . Connecting Rod Bearings Inspection and Replacement Connecting Rod / Piston Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-39 3A-40 3A-40 3A-43 3A-43 3A-45 3A-45 3A-45 3A-45 3A-48 3A-48 3A-49 3A-49 3A-49 3A-50 3A-50 3A-51 3A-51 3A-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-53 3A-54 3A-54 3A-54 3A-54 3A-56 3A-56 3A-57 3A-57 3A-58 3A-58 3A-59 3A-59 3A-60 3A-60 3A-60 3A-60 3A-61 3A-61 3A-61 3A-62 3A-65 3A-65 3A-67 3A-67 3A-68 3A-68 3A-70 3A-72 3A-74 3A-74 3A-76 3A-77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page vi 90-861327--1 OCTOBER 1999

  9. ELECTRICAL SYSTEMS Section 4A - Starting System Identification Replacement Parts Warning General Precautions Typical Starting System Components Positive Current Flow Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Cable Recommendations Maintenance . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide . . . . . . . . . . . . . . . . . . How Temperature Affects Battery Power . . . . . . . . . . . . . . . . . . . Standard Starter Slave Solenoid Identification . . . . . . . . . . . . . . . . . . . . . Testing / Replacement Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor Voltage Voltage Drop In Starting System Delco 14MT Direct Drive Starter Specifications . . . . . . . . . . . . . . . . . . . . . . . Starter Specifications Torque Specifications Lubricants / Sealants / Adhesives . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 4A-2 4A-2 4A-3 4A-4 4A-4 4A-4 4A-6 4A-7 4A-8 4A-8 Exploded View Solenoid Switch Removal Installation Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Checking Pinion Clearance Checking Commutator End Frame Gap . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Delco PG260F1 Starter Specifications . . . . . . . . . . . . . . . . . . . . . . . Starter Specifications Torque Specifications Lubricants / Sealants / Adhesives Description . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . . . . Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Reassembly . . . . . . . . . . . . . . . . . . . . . Checking Pinion Clearance Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 4A-14 4A-14 4A-14 4A-14 4A-14 4A-14 4A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-16 4A-17 4A-18 4A-18 4A-18 4A-18 4A-18 4A-18 4A-19 4A-20 4A-20 4A-20 4A-24 4A-24 4A-28 4A-29 . . . . . . . . . . . . . . 4A-9 4A-9 4A-9 4A-10 4A-10 4A-10 4A-11 4A-12 4A-12 4A-12 4A-12 4A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-861327--1 OCTOBER 1999 Page vii

  10. Section 4B - Ignition System Ignition Control System Components Replacement Parts Warning General Precautions EFI System Maintenance Precautions Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Ignition System Specifications Distributor . . . . . . . . . . . . . . . . . . . . . . . Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . Firing Order . . . . . . . . . . . . . . . . . . . . . . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thunderbolt V Models EFI / MPI Models Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Replacing . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Wires . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Replacing . . . . . . . . . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . Carbureted Engines - Thunderbolt V Ignition Spark Control Features Circuit Description Thunderbolt V Spark Control Graph Ignition System Wiring Diagram Thunderbolt V Ignition Module Knock Control Module . . 4B-2 4B-2 4B-2 4B-3 4B-3 4B-3 4B-3 4B-4 4B-4 4B-4 4B-4 4B-4 4B-5 4B-5 4B-6 4B-6 4B-6 4B-6 4B-7 4B-8 4B-8 4B-8 4B-9 Mercury Marine Distributor Description Exploded View Distributor Cap Removal Cleaning and Inspection Installation Rotor / Sensor Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Distributor Repair . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Distributor Installation Replacing Distributor Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . GM EST Distributor . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Testing Pickup Coil Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17 4B-17 4B-17 4B-18 4B-18 4B-18 4B-18 4B-19 4B-19 4B-19 4B-20 4B-21 4B-21 4B-21 4B-21 4B-22 4B-22 4B-22 4B-22 4B-22 4B-23 4B-25 4B-25 4B-25 4B-26 4B-26 4B-26 4B-27 4B-28 4B-28 4B-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-11 4B-11 4B-12 4B-13 4B-14 4B-15 4B-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4C - Charging System General Precautions EFI Electrical System Precautions Replacement Parts Warning Multiple EFI Engine Battery Precautions Situation . . . . . . . . . . . . . . . . . . . . . . . . . Recommendations Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Mando . . . . . . . . . . . . . . . . . . . . . . . . . . DelcoRemy . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Torque Specifications Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 4C-2 4C-2 4C-3 4C-3 4C-3 4C-4 4C-4 4C-4 4C-5 4C-5 4C-5 4C-5 4C-6 Testing Charging System Charging System Resistance Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . Component . . . . . . . . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . . . . Alternator Repair . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Pulley Removal . . . . . . . . . . . . . . . . . . Battery Isolator Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-7 4C-7 4C-8 4C-10 4C-11 4C-16 4C-17 4C-17 4C-17 4C-22 4C-22 4C-26 4C-27 4C-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page viii 90-861327--1 OCTOBER 1999

  11. Section 4D - Instrumentation Tools Lubricants / Sealants / Adhesives Identification . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Lighting Options . . . . . . . . . . . . . . . . . . Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . Oil, Fuel and Temperature Battery Gauge . . . . . . . . . . . . . . . . . . . Cruiselog Meter . . . . . . . . . . . . . . . . . . Vacuum Gauge . . . . . . . . . . . . . . . . . . . Speedometer . . . . . . . . . . . . . . . . . . . . Tachometer . . . . . . . . . . . . . . . . . . . . . . Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 4D-2 4D-2 4D-3 4D-3 4D-4 4D-4 4D-4 4D-6 4D-7 4D-7 4D-8 4D-8 4D-8 Senders Oil Pressure Water Temperature Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Key Switch Lanyard Stop Switches Start/Stop Switch Audio Warning System Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch Transmission Fluid Temperature Switch Sterndrive Gear Lube Monitor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9 4D-9 4D-10 4D-12 4D-12 4D-13 4D-14 4D-14 4D-14 4D-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-15 . . . . . . . . . . . . . . . . . 4D-18 Section 4E - Wiring Diagrams Starting and Charging Harness MCM 5.0L Engines MCM 5.7L Engines MEFI 1 and MEFI 2 MCM 5.0L EFI, 5.7L EFI and 350 Mag MPI Engines MEFI 3 MCM 5.0L EFI, 5.7L EFI and 350 Mag MPI Engines MIE 5.7L Inboard MIE 350 Mag MPI and Black Scorpion Engines - Starting and Charging System Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-2 4E-2 4E-4 Fuel and Ignition System Harness MEFI 1 MCM 5.0L EFI, 5.7L EFI Alpha Engines MEFI 3 5.0L EFI and 5.7L EFI Engines MEFI 1 and MEFI 2 MCM 350 Mag MPI Bravo Engines MEFI 3 350 Magnum MPI and All Black Scorpion Engines . . . . . 4E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-14 . . . . . . . . . . . . . . . . 4E-15 . . . . . . . . . . . . 4E-6 . . . . . . 4E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-8 4E-10 . . . . . . . . 4E-17 4E-12 FUEL SYSTEM Section 5A - Fuel Delivery System For Carbureted Engines Identification Replacement Parts Warning Specifications Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Precautions . . . . . . . . . . . . . . . . . . . . . . . . Fuel Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 5A-2 5A-3 5A-2 5A-3 5A-3 5A-4 5A-3 Fuel Delivery System Recommendations Fuel System Components Carburetor System Water Separating Fuel Filter Replacement Vent Hose Routing Carbureted Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 5A-4 5A-5 5A-5 5A-5 5A-6 5A-6 5A-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-861327--1 OCTOBER 1999 Page ix

  12. Section 5B - Mercarb 2 Barrel Carburetor Identification Replacement Parts Warning General Precautions Fuel Delivery System Recommendations Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . High Altitude Re-Jetting Important Service Information 8 Point Carburetor Check List Flooding At Idle RPM Needle / Seat Change Adjustable Accelerator Pump Lever Description . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Flame Arrestor with Carburetor Cover . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 5B-3 5B-3 5B-4 5B-4 5B-5 5B-5 5B-5 5B-6 5B-7 5B-7 5B-7 5B-7 5B-8 5B-8 5B-9 5B-9 Fuel Inlet Filter Choke Inspection Adjustments Pump Rod Choke Setting Choke Unloader Initial Idle Speed and Mixture Final Idle Speed and Mixture Replacing Carburetor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . . . . Exploded View Parts List Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 5B-12 5B-12 5B-12 5B-14 5B-14 5B-15 5B-16 5B-16 5B-17 5B-17 5B-18 5B-19 5B-20 5B-28 5B-30 5B-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5C - Fuel Delivery System For Electronic Fuel Injection Specifications Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Replacement Parts Warning Precautions . . . . . . . . . . . . . . . . . . . . . . . . Fuel Supply Connections Fuel Delivery System Recommendations Cool Fuel System Exploded View Fuel System Flow Diagrams Throttle Body Injection Multi-Port Injection with MEFI 1 and MEFI 2 Multi-Port Injection with MEFI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 5C-2 5C-2 5C-2 5C-2 5C-3 5C-3 5C-4 5C-4 5C-5 5C-6 5C-6 Water Separating Fuel Filter Water Separating Fuel Filter Replacement Cool Fuel System Repair Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Vacuum And Vent Hose Routing 350 Mag MPI Models Scorpion Models Throttle Body EFI . . . . . . . . . . 5C-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10 5C-10 5C-10 5C-11 5C-12 5C-14 5C-17 5C-17 5C-18 5C-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7 5C-8 . . . . . Page x 90-861327--1 OCTOBER 1999

  13. Section 5D - Fuel Injection Descriptions And System Operation Special Tools Service Precautions General Information Electrostatic Discharge Damage Diagnostic Information Wiring Harness Service Wiring Connector Service Abbreviations . . . . . . . . . . . . . . . . . . . . . . . ECM Self-Diagnostics Diagnostic Code Tool With Malfunction Indicator Lamp Intermittent Malfunction Indicator Lamp . . . . . . . . . . . . . . . . . . . Reading Codes . . . . . . . . . . . . . . . . . . . Scan Tools . . . . . . . . . . . . . . . . . . . . . . . EFI Diagnostic Circuit Check Scan Tool Use With Intermittents Non-Scan Diagnosis of Driveability Concerns (With No Codes Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-2 5D-3 5D-5 5D-5 5D-5 5D-5 5D-6 5D-7 5D-8 Electronic Control Module (ECM) and Sensors . . . . . . . . . . . . . . . . . . . . . . . General Description Computers and Voltage Signals Analog Signals . . . . . . . . . . . . . . . . . . . Digital Signals . . . . . . . . . . . . . . . . . . . . Engine Control Module (ECM) Speed Density System ECM Input and Sensor Descriptions Spark Management . . . . . . . . . . . . . . . . . . High Energy Ignition with Ignition Control (IC) Modes Of Operation Base Ignition Timing Results of Incorrect Operation Fuel Metering System General Description Cool Fuel Systems Modes of Operation Throttle Body Injection Components 350 Mag MPI And Black Scorpion - Multi-Port Injection Components 5D-12 5D-12 5D-12 5D-12 5D-13 5D-14 5D-15 5D-16 5D-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-20 5D-21 5D-22 5D-23 5D-24 5D-24 5D-24 5D-24 5D-26 5D-8 5D-9 5D-10 5D-10 5D-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-11 . . . . 5D-30 Section 5E - Fuel Injection Disassembly And Reassembly Service Precautions Torque Specifications Exploded Views - 350 Mag MPI Flame Arrestor And Throttle Body Flame Arrestor And Throttle Body Intake Manifold And Fuel Rail Intake Manifold And Fuel Rail Fuel Pressure Relief Procedure 350 Mag MPI Components Flame Arrestor Throttle Body . . . . . . . . . . . . . . . . . . . . Throttle Position Sensor Idle Air Control (IAC) Valve Knock Sensor . . . . . . . . . . . . . . . . . . . . Knock Sensor Module Fuel Pump Relay System Relay . . . . . . . . . . . . . . . . . . . . Electronic Control Module (ECM) Engine Coolant Temperature (ECT) Sensor . . . . . . . . . . . . . . . . . . . . Vacuum And Vent Hose Routing 350 Mag MPI Models Exploded Views - Black Scorpion Plenum, Throttle Body And Flame Arrestor . . . . . . . . . . . . . . . . . . . Intake Manifold And Fuel Rails Fuel Pressure Relief Procedure Black Scorpion Components Flame Arrestor . . . . . . . . . . . . . . . . . . . Throttle Body . . . . . . . . . . . . . . . . . . . . Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Rails . . . . . . . . . . . . . . . . . . . . . . . Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-2 5E-3 5E-4 5E-4 5E-5 5E-6 5E-7 5E-8 5E-8 5E-8 5E-11 5E-14 5E-16 5E-18 5E-19 5E-20 5E-20 5E-21 MAP Sensor Throttle Position Sensor Idle Air Control (IAC) Valve Knock Sensor Knock Sensor Module Fuel Pump Relay System Relay Engine Control Module Engine Coolant Temperature Sensor Vacuum And Vent Hose Routing Scorpion Models Exploded Views - Throttle Body EFI Throttle Body Body And Adapter Throttle Body Assembly Fuel Pressure Relief Procedure Throttle Body EFI Components Fuel Meter Cover Assembly Fuel Injectors . . . . . . . . . . . . . . . . . . . . Throttle Body . . . . . . . . . . . . . . . . . . . . Throttle Body Adapter Plate Engine Control Module (ECM) Knock Sensor (KS) Module (MEFI 1 and MEFI 2 Only) Engine Coolant Temperature (ECT) Sensor . . . . . . . . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Sensor . . . . . . . . . . . . . . . . . . . Throttle Position (TP) Sensor Idle Air Control (IAC) Valve Knock Sensor . . . . . . . . . . . . . . . . . . . . Vacuum And Vent Hose Routing Throttle Body EFI Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-40 5E-41 5E-43 5E-45 5E-46 5E-46 5E-47 5E-47 5E-48 5E-49 5E-49 5E-50 5E-50 5E-51 5E-52 5E-52 5E-52 5E-54 5E-56 5E-58 5E-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-23 5E-24 5E-24 5E-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-61 5E-25 5E-26 5E-27 5E-27 5E-27 5E-29 5E-35 5E-37 5E-39 5E-62 . . . . . . . . . . . . . . . . . . . . . . 5E-63 5E-64 5E-65 5E-67 5E-68 5E-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-861327--1 OCTOBER 1999 Page xi

  14. Section 5F - Fuel Injection System Troubleshooting Scan Tool Normal Specifications (Idle / Warm Engine / Closed Throttle / Neutral) Important Preliminary Checks Before Starting . . . . . . . . . . . . . . . . . . . Visual / Physical Check Intermittents . . . . . . . . . . . . . . . . . . . . . . . . Hard Start Symptom . . . . . . . . . . . . . . . . . Surges and/or Chuggles Symptom Lack of Power, Sluggish or Spongy Symptom . . . . . . . . . . . . . . . . . . . Detonation / Spark Knock Symptom Hesitation, Sag, Stumble Symptom Cuts Out, Misses Symptom Rough, Unstable, or Incorrect Idle, Stalling Symptom Poor Fuel Economy Symptom Dieseling, Run-On Symptom Backfire Symptom . . . . . . . 5F-11 5F-13 5F-15 . . . . 5F-2 5F-3 5F-3 5F-3 5F-4 5F-5 5F-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-17 5F-20 5F-22 5F-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-9 Section 5G - Diagnostics Special Tools Diagnostic Circuit Check Scan Tool Normal Specifications Diagnostic Trouble Codes ECM Connector and EFI Symptoms Chart J-1 Circuits with MEFI 1 and MEFI 2 J-2 Circuits with MEFI 1 and MEFI 2 J-1 Circuits with MEFI 3 J-2 Circuits with MEFI 3 Wiring System Diagrams MEFI 1 and MEFI 2 MEFI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . MEFI 3 With Mercury Distributor MEFI 3 With GM EST Distributor Injector Balance Test (Multi-Port Models) 5G-22 Test Procedure . . . . . . . . . . . . . . . . . . . Test Example . . . . . . . . . . . . . . . . . . . . General Diagnostic Tests On-Board Diagnostic (OBD) System Check . . . . . . . . . . . . . . . . . . . Chart A-1 No MIL or No DLC Data Chart A-2 MIL ON Steady - Will Not Flash DTC 12 Chart A-3 Engine Cranks But Will Not Run . . . . . . . . . . . . . . . . . . . . . Chart A-4 Fuel System Diagnosis Chart A-5 Fuel System Electrical Test Chart A-6 EFI System/Ignition Relay Check . . . . . . . . . . . . . . . . . . . . Chart A-7 Ignition System Check Chart A-8 Idle Air Control (IAC) Functional Test . . . . . . . . . . . . . . . . . . Discrete Input Circuit Check - Non-Scan Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-2 5G-4 5G-4 5G-5 Clearing Trouble Codes Using Code Mate Tester Using Scan Tool Diagnostic Testing Code 14 Engine Coolant Temperature (ECT) Sensor Circuit Code 15 Engine Coolant Temperature (ECT) Sensor Circuit Code 21 Throttle Position (TP) Sensor Circuit Code 22 Throttle Position (TP) Sensor Circuit Code 23 Intake Air Temperature (IAT) Sensor Circuit Code 25 Intake Air Temperature (IAT) Sensor Circuit Code 33 Manifold Absolute Pressure (MAP) Sensor Circuit Code 34 Manifold Absolute Pressure (MAP) Sensor Circuit Code 41 Ignition Control (IC) Circuit Code 42 Ignition Control (IC) Circuit Code 43 Knock Sensor (KS) Circuit Code 44 Knock Sensor (KS) Circuit Code 45 Ignition Coil Driver Fault Code 51 Calibration Memory Failure Code 52 EEPROM Failure Code 61 Fuel Pressure (FP) Circuit Code 62 Fuel Pressure (FP) Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-52 5G-52 5G-52 5G-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-6 5G-6 5G-8 5G-10 5G-12 5G-14 5G-14 5G-18 5G-20 5G-21 . . . . . . . . . . . . . 5G-53 . . . . . . . . . . . . . 5G-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-58 . . . . . . . . . . . . . . . 5G-61 . . . . . . . . . . . . . . . . . . . . . 5G-64 . . . . . . . . . . . . . . 5G-66 5G-22 5G-23 5G-24 . . . . . . . . . . . . . 5G-68 . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-71 5G-74 5G-76 5G-78 5G-81 5G-84 5G-86 5G-87 5G-88 5G-24 5G-26 . . . . . . . . . . . . . . . . . . 5G-28 . . . 5G-30 5G-32 5G-34 . . . . . . . . . . . . . 5G-36 5G-38 5G-91 . . . 5G-44 5G-46 Page xii 90-861327--1 OCTOBER 1999

  15. COOLING SYSTEM Section 6A - Seawater Cooled Models Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Specifications . . . . . . . . . . . . . . . . . . . . . . . Cooling System Capacity Thermostat . . . . . . . . . . . . . . . . . . . . . . Seawater Inlet Recommendations Transom Mounted or Thru-Hull Seawater Pickups and Hose Seacock (Seawater Inlet Valve) Sea Strainer . . . . . . . . . . . . . . . . . . . . . Seawater Pickups . . . . . . . . . . . . . . . . . . . Thru-Hull Mounted Transom Mounted Quicksilver Sea Strainer Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Seawater Pickup Pump Output Test . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 6A-2 6A-3 6A-3 6A-3 6A-3 6A-3 Seawater Pump Bearing Housing Disassembly Cleaning and Inspection Reassembly Water Circulating Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Drive Belt Tension Adjustment Flushing Seawater Cooling System Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Hot Water Heater Installation Water Tap Locations For Propshaft Coolers . . . . 6A-24 Water Flow Diagrams . . . . . . . . . . . . . . . . 305 cid and 350 cid Bravo, Inboard and Ski Engines . . . . . . . . . . . . . . . . . . . . . . . . . 305 cid and 350 cid Alpha Engines . . . . . 6A-14 6A-14 6A-15 6A-16 6A-19 6A-19 6A-19 6A-19 6A-20 6A-20 6A-20 6A-20 6A-21 6A-22 6A-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 6A-4 6A-4 6A-5 6A-5 6A-6 6A-7 6A-7 6A-8 6A-8 6A-10 6A-10 6A-12 6A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 . . . . . . . . . . . . . . 6A-25 6A-26 . . Section 6B - Closed Cooled Models Torque Specifications Lubricants / Sealants / Adhesives Specifications . . . . . . . . . . . . . . . . . . . . . . . Closed Cooling System Capacity Coolant Specification Thermostat . . . . . . . . . . . . . . . . . . . . . . Pressure Cap Rating Description . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Recommendations Maintaining Coolant Level Pressure Cap Maintenance Heat Exchanger Repair Testing Closed Cooling System Testing Coolant for Alkalinity Pressure Testing System Testing for Cylinder Head Gasket Leak . . . . . . . . . . . . . . . . . . . . . Testing Heat Exchanger Testing Pressure Cap . . . . . . . . . . . . . . . . 6B-2 6B-2 6B-2 6B-2 6B-2 6B-2 6B-2 6B-3 6B-3 6B-3 6B-4 6B-5 6B-6 6B-6 6B-6 Thermostat Removal Testing Installation Changing Coolant Closed Cooling Section Change Intervals Draining Instructions Cleaning System Closed Cooling Section Seawater Section Filling Closed Cooling Section Auxiliary Hot Water Heater Installation Heat Exchanger Bracket Hardware Heat Exchanger Hose Connections Closed Cooling System Water Flow Diagram MCM / MIE Models Draining Diagram (Coolant Section of System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 6B-10 6B-11 6B-12 6B-13 6B-13 6B-13 6B-13 6B-14 6B-14 6B-14 6B-16 6B-17 6B-19 6B-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7 6B-8 6B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 6B-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22 90-861327--1 OCTOBER 1999 Page xiii

  16. EXHAUST SYSTEM Section 7A - General Exhaust System Requirements Exhaust Elbow Risers MCM (Sterndrive) Engines With Thru-Transom Exhaust MIE (Inboard) Engines Exhaust Hose Connection Exhaust Tube Requirements . . . . . . . . . . . . . . . . . . . . 7A-2 7A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 7A-3 7A-3 7A-4 Section 7B - Manifolds, Elbows And Risers Torque Specifications Lubricants / Sealants / Adhesives Disassembly . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . 7B-2 7B-2 7B-2 7B-3 Installation Gaskets Manifold Sterndrive Exhaust Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-5 7B-5 7B-6 7B-7 . . . . . . . . . . . . . . . . . . . . . . . . . Section 7C - Collectors Torque Specifications Lubricants / Sealants / Adhesives Bullhorn Exhaust Shutter Replacement Component Replacement Thru-Transom Exhaust Shutter Replacement Component Replacement Below Swim Platform Exhaust Pipe . . . . . . . . . . . . . . . . 7C-2 7C-2 7C-3 7C-3 7C-4 7C-5 7C-5 7C-6 7C-7 DRIVES Silent Choice Exhaust System Exhaust Tube Installation Air Tube Routing Maintenance Exhaust Muffler Kit Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . Maintenance Instructions . . . . . . . . . . . . . . . . . . 7C-8 7C-8 7C-10 7C-11 7C-12 7C-13 7C-14 7C-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 8A - Velvet Drive In-Line And V-Drive Transmission Specifications Identification Ratio Torque Specifications Fluid Specifications Pressure Specifications Important Information Shift Control and Cables Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . Propeller . . . . . . . . . . . . . . . . . . . . . . . . Transmission Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 8A-2 8A-2 8A-2 8A-3 8A-3 8A-4 8A-4 8A-4 8A-4 8A-5 8A-5 Shift Cable Adjustment Checking Transmission Fluid Level Changing Transmission Fluid Draining Transmission Filling Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Installation Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . 8A-5 8A-6 8A-7 8A-7 8A-9 8A-10 8A-10 8A-12 8A-13 8A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page xiv 90-861327--1 OCTOBER 1999

  17. Section 8B - Velvet Drive 5000 Series Transmissions Velvet Drive 5000A Down Angle Specifications . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . Transmission Ratios and Part Numbers . . . . . . . . . . . . . . . . . . . Transmission Fluid Capacity Transmission Fluid Specification Transmission Pressure Specifications Torque Specifications Velvet Drive 5000V V-Drive Specifications . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . Transmission Ratios and Part Numbers . . . . . . . . . . . . . . . . . . . Transmission Fluid Capacities Transmission Fluid Specification Transmission Pressure Specifications Torque Specifications Shift Control and Cables Important Information Engine Transmission Propeller Transmission / Propeller Rotation Shift Control and Cables Transmission Shift Lever and Shift Cable Bracket Shift Cable Adjustment Checking Transmission Fluid Level Changing Transmission Fluid Draining Transmission Filling Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Installation Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . 8B-6 8B-6 8B-6 8B-6 8B-7 8B-9 8B-2 8B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 8B-2 8B-2 8B-3 8B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10 8B-11 8B-17 8B-18 8B-18 8B-19 8B-19 8B-20 8B-22 8B-23 8B-23 . . . . . . . . . . . . . . . . . 8B-4 8B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-4 8B-4 8B-4 8B-5 8B-5 8B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 8C - Hurth Transmissions . . . . . . . . . . . . . . . . . Identification Specifications Torque Specifications Operating Specifications Fluid Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2 8C-2 8C-2 8C-2 8C-3 8C-3 8C-3 8C-4 Shift Cable Installation and Adjustment Checking Transmission Fluid Level Draining Transmission Filling Transmission Transmission Removal Transmission Installation Functional Tests . . . . . . . . . . . . . . . . . . . . . . 8C-5 8C-10 8C-11 8C-12 8C-14 8C-15 8C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 8D - Drive Shaft / Propeller Shaft Models Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Flywheel Housing / Output Shaft Housing Repair (MCM Sterndrive Models) Exploded View . . . . . . . . . . . . . . . . . . . Removal and Installation Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Drive Shaft Repair (MCM Sterndrive Models) Removal . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Drive Shafts Drive Shafts Modified to Shorter Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2 8D-2 8D-2 Installation Bearing Support Repair (MCM Sterndrive Models) Removal Disassembly Reassembly Installation Propeller Shaft (MIE Inboard Models) Checks Made With Boat In Water Checks Made With Boat Out Of Water And Shaft Installed Checks Made With Propeller Shaft Removed From Boat Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-8 . . . . . . . . . . . . . . . . . 8D-10 8D-10 8D-10 8D-11 8D-12 8D-14 8D-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-3 8D-3 8D-4 8D-4 8D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5 8D-5 8D-7 8D-7 . . . . . . . . . . . . . . . 8D-15 . . . . . . . . . . . . . 8D-17 8D-17 . . . . . . . . . 8D-8 90-861327--1 OCTOBER 1999 Page xv

  18. POWER STEERING SYSTEM Section 9A - Pump And Related Components Torque Specifications Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives Precautions . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump and Components Serpentine Belt Routing Serpentine Belt Adjustment Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2 9A-2 9A-2 9A-3 9A-3 9A-4 9A-6 9A-6 9A-6 Important Service Information Pump Pulley Replacement Testing and Repair Checking Pump Fluid Level Filling and Air Bleeding System Pump Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses and Fluid Cooler . . . . . . . . . . . . . . . . . . 9A-7 9A-7 9A-8 9A-8 9A-8 9A-8 9A-8 9A-10 9A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page xvi 90-861327--1 OCTOBER 1999

  19. SERVICE MANUAL NUMBER 24 GENERAL INFORMATION IMPORTANT INFORMATION Section 1A - General Information 1 A Table of Contents Introduction How to Use This Manual Page Numbering How to Read a Parts Manual Directional References Engine Rotation Engine Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 1A-2 1A-2 1A-3 1A-4 1A-4 1A-5 Propeller Information Water Testing New Engines Boat and Engine Performance Boat Bottom Marine Fouling Weight Distribution Water in Boat Elevation and Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5 1A-6 1A-6 1A-6 1A-8 1A-9 1A-9 1A-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-861327--1 OCTOBER 1999 Page 1A-1

  20. GENERAL INFORMATION Introduction SERVICE MANUAL NUMBER 24 This comprehensive overhaul and repair manual is designed as a service guide for the mod- els previously listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines. Before attempting repairs or tune-up, it is suggested that the procedure first be read through to gain knowledge of the methods and tools used and the cautions and warnings required for safety. How to Use This Manual This manual is divided into sections which represent major components and systems. Some sections are further divided into parts which more fully describe the component. Sections and section parts are listed on the “Service Manual Outline” page following “V-8 Models Covered in This Manual” page. Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. g f c a d b e a - Section Number b - Section Part c - Page Number d - Manual Part Number e - Revision Number f - Month Printed g - Year Printed Page 1A-2 90-861327--1 OCTOBER 1999

  21. SERVICE MANUAL NUMBER 24 How to Read a Parts Manual GENERAL INFORMATION Power Steering Pump Assembly 8 2 10 6 1 4 3 7 9 5 REF. NO. 1 2 3 4 5 6 7 8 9 10 PART NO. SYM. QTY. DESCRIPTION 90507A12 36- 95805 73873A1 16- 41877 57- 65607T 32- 806684 25- 89879 25- 806232 13- 35048 61990 1 1 1 1 1 1 1 1 1 1 PUMP ASSEMBLY–Power Steering CAP PULLEY STUD V-BELT HOSE–Pressure (FITTINGS ON BOTH ENDS) O-RING O-RING LOCKWASHER (3/8 in.) CABLE TIE REF. NO. : Number shown next to part on exploded view PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM part number will be given in description column. QTY. : The quantity that must be ordered. DESCRIPTION : Description of part, what parts are included with a part (all indented items come with the main item above the indented parts), serial number information, and special information. 90-861327--1 OCTOBER 1999 Page 1A-3

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  23. GENERAL INFORMATION Directional References SERVICE MANUAL NUMBER 24 Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this maintenance manual, all directional references are given as they appear when viewing boat from stern looking toward bow. STARBOARD (RIGHT) FORE or BOW (FRONT) AFT or STERN (REAR) PORT (LEFT) 72000 Engine Rotation Engine rotation is determined by observing flywheel rotation from the rear (stern end) of the engine looking forward (toward water pump end). Propeller rotation is not necessarily the same as engine rotation. When ordering replacement engine, short blocks or parts for engine, be certain to check engine rotation. Do not rely on propeller rotation in determining engine rotation. 72001 Standard Left Hand Rotation Page 1A-4 90-861327--1 OCTOBER 1999

  24. SERVICE MANUAL NUMBER 24 Engine Serial Number Locations GENERAL INFORMATION a b 72923 Sterndrive (MCM) a- Serial Number Plate b- Starter Motor b a 72924 Inboard (MIE) a- Serial Number Plate b- Starter Motor Propeller Information Refer to the “Propeller” section in appropriate Mercury MerCruiser Sterndrive Service Manual, or order publication 90-86144-92, “Everything you need to know about propellers.” Changing diameter, pitch or coupling of a propeller will affect engine rpm and boat perfor- mance. The blade configuration also will affect performance. Two like propellers, same pitch and diameter, from two different manufacturers will perform differently. 1. It is the responsibility of the boat manufacturer and/or selling dealer to equip the boat with the correct propeller to allow the engine to operate within its specified rpm range at wide-open-throttle (WOT). Because of the many variables of boat design and operation, only testing will determine the best propeller for the particular application. 90-861327--1 OCTOBER 1999 Page 1A-5

  25. GENERAL INFORMATION SERVICE MANUAL NUMBER 24 To test for correct propeller, operate boat (with an average load onboard) at WOT and check rpm with an accurate tachometer. Engine rpm should be near top of the specified range so that, under heavy load, engine speed will not fall below specifications. If engine exceeds the specified rpm, an increase in pitch and/or diameter is required. If engine is below rated rpm, a decrease in pitch and/or diameter is required. Normally, a change of approximately 150 rpm will be achieved for each single inch of pitch change of a propeller. CAUTION If a propeller is installed that does not allow engine rpm to reach the specified full-throttle rpm range, the engine will “labor” and will not produce full power. Operation under this condition will cause excessive fuel consumption, engine overheating and possible piston damage (due to detonation). Conversely, installing a propeller, allowing engine to run above the specified rpm limit, will cause excessive wear on internal engine parts which will lead to premature engine failure. Water Testing New Engines Use care during the first 20 hours of operation on new Mercury MerCruiser engines or possible engine failure may occur. If a new engine has to be water-tested at full throttle before the break-in period is complete, follow this procedure. 1. Start engine and run at idle rpm until normal operating temperature is reached. 2. Run boat up on plane. 3. Advance engine rpm (in 200 rpm increments) until engine reaches its maximum rated rpm. IMPORTANT: Do not run at maximum rpm for more than 2 minutes. Boat and Engine Performance Boat Bottom For maximum speed, a boat bottom should be as flat as possible in a fore-aft direction (longi- tudinally) for approximately the last 5 ft (1.5 m). a 72002 a - Critical Bottom Area Page 1A-6 90-861327--1 OCTOBER 1999

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