Mercury MerCruiser GM V8 Marine Engines (5.0L/5.7L) OEM Service & Repair Manual

Number 17 Printed in U.S.A. 90-823225--1 1096 1996, Mercury Marine GM V-8 305 CID (5.0L) / 350 CID (5.7L) MARINE ENGINES SERVICE MANUAL Book 1 of 2 Sections 1 thru 4

90-823225--1 1096 i Notice Throughout this publication, “Dangers,” “Warnings” and “Cautions” are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incor- rectly 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 pre- vention 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 injury or death. ! CAUTION 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 here- in. It is assumed that these personnel are familiar with the servicing procedures of these products, of like or similar products manufactured and marketed by Mercury Marine, and that they have been trained in the recommended servicing procedures for these products which include the use of mechanic’s common hand tools and the special Mercury Marine or recommended 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 under- taken 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 product’s safety will be endangered by the service procedure selected. All information, illustrations and specifications con- tained in this manual are based on the latest product information available at time of publication. 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 inter- nal damage when the engine is started. It is important to note that, during any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. Numbers on the heads of the metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or mal- function, or possible personal injury. Therefore, fasteners removed should be saved for re-use in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that meets the same specifications as the original.

90-823225--1 1096 ii Engine Mechanical Components Many of the engine mechanical components are designed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and man- ufacturing specifications which are required to pro- vide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or cor- rode standard automotive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor engine performance and/or durability, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replacement parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replacement parts. Replacement Parts ! WARNING Electrical, ignition and fuel system components on MerCruiser Engines and Stern Drives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component open- ing would permit sparks to ignite fuel va- pors from fuel system leaks, if they existed.

90-823225--1 1096 iii Models Covered in This Manual MCM Alpha MODEL SERIAL NUMBER MODEL YEAR 5.0L OD832472 - OF601000 1993 199 5.0LX OD831003 - OF601000 1993 - 1995 5.7L (4 Barrel) OD830700 - OF601000 5.7L (2 Barrel) OF601000 and Above 1996 Th 199 5.7LX OF601957 and Above 1996 Th 199 5.7L EFI OF286830 and Above 1996 Thru 1997 5.7LX EFI OF752400 and Above 1996 Thru 1997 350 Magnum OD830982 and Above 350 Magnum EFI Gen+ OF800500 and Above MCM Bravo MODEL SERIAL NUMBER MODEL YEAR 5.0L OD833077 - OF601464 1993 - 1995 5.7L (4 Barrel) OD831826 - OF605335 1993 - 1995 5.7L (2 Barrel) OF605336 and Above 1996 Th 199 5.7LX OF601645 and Above 1996 Th 199 5.7L EFI OF225560 and Above 1996 Thru 1997 5.7LX EFI OF752408 and Above 1996 Thru 1997 350 Magnum OD800300 and Above 350 Magnum EFI Gen+ OF800500 and Above 350 Magnum EFI/MP OF289431 - OF601999 1995 350 Magnum MPI Gen+ OF602000 and Above 1996 Thru 1997

90-823225--1 1096 iv MIE Ski MODEL SERIAL NUMBER MODEL YEAR 5.7L Competition (4 Barrel) OD840220 - OF775199 1993 - 1995 5.7L Competition (2 Barrel) OF775200 and Above 1996 Thru 1997 350 Magnum Tournanment Ski OD840100 and Above 1993 Thru 1997 350 Magnum EFI Tournament Ski OF225157 - OK000000 1994 - 1996 350 Magnum EFI Gen+ Tournament Ski OK040006 and Above 1997 350 Magnum EFI/MP Tournament Ski OF350583 - OF745536 1995 350 Magnum MPI Tournament Ski OF745537 - OK000000 1996 350 Magnum MPI Gen+ Tournament Ski (Black Scorpion) OF800000 and Above 1996 MIE Inboard MODEL SERIAL NUMBER MODEL YEAR 5.7L OD84000 and Above 1993 Thru 1997 5.7L EFI Gen+ OK040300 and Above 1997

Important Information 8 1 2 3 4 5 6 7 9 Removal and Installation Engine Electrical Systems Fuel System Cooling System Exhaust System Drives Power Steering 90-823225--1 1096 v Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information Section 2 - Removal and Installation A - MCM Models - Alpha One Drives B - MCM Models - Alpha One Drives with Driveshaft Extension C - MCM Models - Bravo Drives D - MCM Models - Bravo Drives with Driveshaft Extension E - MIE Models - Velvet Drive Transmissions F - MIE Models - Hurth Transmissions Section 3 - Engine A - 5.0L / 305 CID / 5.7L /350 CID Section 4 - Electrical Systems A - Starting System B - Ignition System C - Charging System D - Instrumentation E - Electrical Kits F - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery Systems and Fuel Pumps B - MerCarb 2 Barrel Carburetor C - Rochester 4 Barrel Carburetor D - Weber 4 Barrel Carburetor E - Electronic Fuel Injection (Throttle Body and Multi-Port) F - BOS / SAV Emission Section 6 - Cooling System A - Seawater Cooled Models B - Closed Cooled Models Section 7 - Exhaust System A - General B - Manifold and Elbows C - Risers D - Collectors Section 8 - Drives A - Borg-Warner In-Line Transmission B - Borg-Warner V-Drive Transmission C - Hurth Down Angle Transmission D - Drive Shaft Models/Propeller Shaft Section 9 - Power Steering A - Pump

A 1 72000 IMPORTANT INFORMATION GENERAL INFORMATION

1A-0 –GENERAL INFORMATION 90-823225--1 1096 Table of Contents Page Introduction 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual 1A-1 . . . . . . . . . . . . . . . . . . Page Numbering 1A-1 . . . . . . . . . . . . . . . . . . . . . . How to Read Parts Manual 1A-2 . . . . . . . . . . . . . . . . Directional References 1A-3 . . . . . . . . . . . . . . . . . . . . Engine Rotation 1A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number Locations 1A-3 . . . . . . . . . . . Propeller Information 1A-4 . . . . . . . . . . . . . . . . . . . . . Water Testing New Engines 1A-4 . . . . . . . . . . . . . . . Boat and Engine Performance 1A-4 . . . . . . . . . . . . . Boat Bottom 1A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . Marine Fouling 1A-5 . . . . . . . . . . . . . . . . . . . . . . . . Weight Distribution 1A-6 . . . . . . . . . . . . . . . . . . . . . Water in Boat 1A-6 . . . . . . . . . . . . . . . . . . . . . . . . . Elevation and Climate 1A-7 . . . . . . . . . . . . . . . . . . NOTICE For information and procedures on troubleshooting, refer to Section 1C.

GENERAL INFORMATION - 1A-1 90-823225--1 1096 NOTICE Refer to appropriate Stern Drive Service Manual for transom assembly and stern drive unit repair. Introduction This comprehensive overhaul and repair manual is designed as a service guide for the models previous- ly 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 knowl- edge 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. Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. 72426

1A-2 –GENERAL INFORMATION 90-823225--1 1096 How to Read Parts Manual 841-81631 1 CYLINDER BLOCK ASSEMBLY 1 N.S.S. 2 PLUG, expansion (1-1/4”) (GM #3738306) 2 22-87238 3 DRAIN COCK, cylinder block 2 19-34270 4 PLUG, expansion - cylinder block (1-5/8” Diameter) 8 17-35465 5 PIN, dowel - block to head (5/16” Diameter) 4 22-72640 6 PLUG, expansion - camshaft bearing hole 1 23-85674 7 BEARING UNIT, camshaft (set) 1 72638 8 LIFTER, hydraulic valve 16 431-5943 9 CAMSHAFT 1 35378 10 CHAIN, camshaft timing 1 43-35338 11 SPROCKET, camshaft timing 1 43-48338 12 SPROCKET, crankshaft timing 1 10-34505 13 BOLT, camshaft timing sprockets (3/4”) 3 12-39167 14 WASHER, camshaft timing sprocket bolt 3 841-8163 Cylinder Block Assembly includes only standard pistons, piston rings, crankshaft bearings and camshaft bearings. PART NO. REF. NO. DESCRIPTION QUAN. a A. Part Number: For part ordering - Note N.S.S. for Reference Number 2, Plug, expansion - that means Not Sold Separately by Mercury Marine however, in this case, the G.M. Part Number (for the plug) is given in the Description Column. B. Reference Number: For part Shown on exploded parts view. C. Description: This is the most important column because it gives: 1) Description of Part: Ref. No. 1 is a Cylinder Block Assembly, No. 9 is a Camshaft, etc. 2) What parts are included with a certain part: Notice how the Description of Part, for Ref. Nos. 1 and 8 thru 14, are at the left side of the column. Description of Part for Ref. Nos. 2 thru 7 are indented under “Cylinder Block Assembly”. If Ref. No. 1 (Cylinder Block Assembly) was ordered, all indented parts (Ref. Nos 2thru 7) would come with the part. Ref. Nos. 8 thru 14 would not come with Ref. No. 1 and would have to be ordered separately. If 2 Cylinder Blocks were listed, both cylinder blocks would come with the indented parts. In some cases, an indented part will have another part indented under it. The second indented part will come with the first indented part. 3) Serial number break: If serial number information is listed, check product serial number to ensure that correct part is ordered. 4) Special information: Many times special information will be shown after description such as; L.H. Rotation, R. H. Rotation, Filter up, Filter Down, etc. This will help in selecting the correct part. D. Quantity: Quantity that has to be ordered. E. Special Information Block: Additional information, part numbers for gasket sets, etc. M0033-D8 b c d e CYLINDER BLOCK AND CAMSHAFT

Mercury MerCruiser GM V8 Marine Engines (5.0L/5.7L) OEM Service & Repair Manual

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