Mercury Mercruiser 5.7L MPI Engines Full Service Repair

90-864260001 JUNE 2003 Page i Notice Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning 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 Immediate hazards which will result in severe personal injury or death. WARNING Hazards or unsafe practices which could result in severe personal injury 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 marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury MerCruiser product, including the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or results of each method. 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. 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. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual.

Page ii 90-864260001 JUNE 2003 Precautions 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. 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 metric 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. Mismatched 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 whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original. 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 manufacturing specifications that are required to provide 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 corrode 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. Replacement Parts Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as a result. WARNING Electrical, ignition, and fuel system components on Mercury MerCruiser Engines and Sterndrives 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 opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed.

90-864260001 JUNE 2003 Page iii Models Covered in This Manual Carbureted Models Sterndrive (MCM) Serial Number 5.0L Alpha and Bravo 0M087348 and Above 5.7L Alpha and Bravo 0M087348 and Above Inboard (MIE) Serial Number 5.7L 0L677227 and Above Tow Sports (MIE) Serial Number 5.7L 0L677946 and Above MPI Models Sterndrive (MCM) Serial Number 5.0L MPI Alpha and Bravo 350 MAG MPI Alpha and Bravo 350 MAG MPI Bravo Horizon 0M300000 and Above MX 6.2 MPI MX 6.2 MPI Horizon Inboard (MIE) Serial Number 350 MAG MPI Inboard 350 MAG MPI Horizon Inboard 0M310000 and Above MX 6.2 MPI Inboard 0M310000 and Above MX 6.2 MPI Horizon Inboard Tow Sports (MIE) Serial Number 350 MAG MPI 0M310000 and Above Black Scorpion 0M391600 and Above MX 6.2 MPI 0M310000 and Above MX 6.2 Black Scorpion 0M391750 and Above

Page iv 90-864260001 JUNE 2003 NOTES:

1 2 3 4 5 6 7 8 Important Information Removal And Installation Engine Electrical System Fuel System Cooling System Exhaust System Drives 9 Power Steering 10 Water Flow Diagrams 90-864260001 JUNE 2003 Page v Service Manual Outline Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting D - California Emissions Information Section 2 - Removal and Installation A - MCM Models B - MIE Models Section 3 - Engine A - Engine Mechanical Section 4 - Electrical System A - Starting System B - Carbureted Ignition System C - MPI Ignition System D - Charging System E - Instrumentation Section 5 - Fuel System A - Carbureted Fuel System B - MPI Fuel System Excluding Scorpion Models C - Scorpion Fuel System Section 6 - Cooling System A - All Models B - Seawater Cooled Models C - Closed Cooled Models Section 7 - Exhaust System A - Manifolds, Elbows, And Risers For Wet Joint B - Dry Joint Identification C - Manifolds And Elbows With Dry Joint D - Cold Riser With Dry Joint E - Warm Riser With Dry Joint F - Collectors Section 8 - Drives A - Velvet Drive In-Line And V-Drive Transmission B - Velvet Drive 5000 Series Transmission C - ZF/Hurth 630 And 800 Series Transmission D - ZF Marine/Hurth 45C In-Line Transmission Section 9 - Power Steering A - Power Steering Pump Section 10 - Water Flow Diagrams A - General Information B - Seawater Cooled Carbureted Models C - Seawater Cooled MPI Models D - Closed Cooled Carbureted Models E - Closed Cooled MPI Models

Page vi 90-864260001 JUNE 2003 IMPORTANT INFORMATION Section 1A - General Information Introduction 1A-2 . . . . . . . . . . . . . . . . . . . . . . . . . How To Use This Manual 1A-2 . . . . . . . . . . . . . . Page Identification 1A-2 . . . . . . . . . . . . . . . . . . Engine Serial Number Locations 1A-3 . . . . . . Emission Control Information Label 1A-3 . . . Mercury/Quicksilver Lubricants, Sealants And Adhesives 1A-4 . . . . . . . . . . . . . IMPORTANT INFORMATION Section 1B - Maintenance Engine And Tune-Up Specifications 1B-3 . . . MPI MCM (Sterndrive) Models 1B-3 . . . . . . . MPI MIE (Inboard) Models 1B-4 . . . . . . . . . . . MIE (Tow Sports) Models 1B-5 . . . . . . . . . . . . Carbureted Models 1B-6 . . . . . . . . . . . . . . . . . Fluid Specifications 1B-7 . . . . . . . . . . . . . . . . . . Engines 1B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . MPI Models 1B-7 . . . . . . . . . . . . . . . . . . . . . Carbureted Models 1B-7 . . . . . . . . . . . . . . . Sterndrives 1B-7 . . . . . . . . . . . . . . . . . . . . . . . . Transmissions 1B-8 . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 1B-9 . . . . . Special Tools 1B-11 . . . . . . . . . . . . . . . . . . . . . . . Kent-Moore Tools 1B-12 . . . . . . . . . . . . . . . . . . . Torque Specifications 1B-13 . . . . . . . . . . . . . . . Maintenance Schedules 1B-14 . . . . . . . . . . . . . Maintenance Intervals 1B-14 . . . . . . . . . . . . . . Gas Sterndrive 1B-15 . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance * 1B-15 . . . . . . . . . . . . . Scheduled Maintenance * 1B-16 . . . . . . . . . . . Gas Inboard And Tow Sports 1B-18 . . . . . . . . . Routine Maintenance * 1B-18 . . . . . . . . . . . . . Scheduled Maintenance * 1B-19 . . . . . . . . . . . Crankcase Oil 1B-21 . . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase Oil 1B-22 . . . . . . . . . . . . Checking 1B-22 . . . . . . . . . . . . . . . . . . . . . . . . . Filling 1B-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Oil and Filter 1B-24 . . . . . . . . . . . . . Quick drain oil 1B-24 . . . . . . . . . . . . . . . . . . Crankcase Oil Pump 1B-24 . . . . . . . . . . . . All Models 1B-25 . . . . . . . . . . . . . . . . . . . . . . Flushing The Power Package - MCM 1B-26 . . Sterndrive Water Pickups 1B-26 . . . . . . . . . . . Flushing Attachments 1B-27 . . . . . . . . . . . . Alternative Water Pickups 1B-29 . . . . . . . . . . . Flushing The Power Package - MIE 1B-31 . . . Precautions 1B-31 . . . . . . . . . . . . . . . . . . . . . . . Models Equipped With Engine Mounted Flush Attachment 1B-31 . . . . . . . . . All Other Models 1B-33 . . . . . . . . . . . . . . . . . . . Transmission Fluid 1B-35 . . . . . . . . . . . . . . . . . . Checking 1B-35 . . . . . . . . . . . . . . . . . . . . . . . . . Warm 1B-35 . . . . . . . . . . . . . . . . . . . . . . . . . . Cold 1B-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing and Filling 1B-36 . . . . . . . . . . . . . . . Sterndrive Unit Oil 1B-37 . . . . . . . . . . . . . . . . . . Checking 1B-37 . . . . . . . . . . . . . . . . . . . . . . . . . Filling 1B-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing 1B-38 . . . . . . . . . . . . . . . . . . . . . . . . . Bravo Three 1B-41 . . . . . . . . . . . . . . . . . . . . . . Removal 1B-41 . . . . . . . . . . . . . . . . . . . . . . . Repair 1B-41 . . . . . . . . . . . . . . . . . . . . . . . . . Installation 1B-42 . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Fluid 1B-44 . . . . . . . . . . . . . . Checking 1B-44 . . . . . . . . . . . . . . . . . . . . . . . . . Filling 1B-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing 1B-44 . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Fluid 1B-45 . . . . . . . . . . Checking 1B-45 . . . . . . . . . . . . . . . . . . . . . . . . . Engine Warm 1B-45 . . . . . . . . . . . . . . . . . . . Engine Cold 1B-46 . . . . . . . . . . . . . . . . . . . . Filling and Bleeding 1B-46 . . . . . . . . . . . . . . . . Water Inlets 1B-48 . . . . . . . . . . . . . . . . . . . . . . . . . Seawater Strainer 1B-48 . . . . . . . . . . . . . . . . . Closed Cooling System 1B-49 . . . . . . . . . . . . . . Checking Coolant Level 1B-49 . . . . . . . . . . . . Cleaning and Inspection 1B-49 . . . . . . . . . . . . Changing Coolant 1B-49 . . . . . . . . . . . . . . . . . Anodes 1B-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft 1B-54 . . . . . . . . . . . . . . . . . . . . . . Power Package Surfaces (Saltwater Only) 1B-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Painting Your Power Package 1B-55 . . . . . . . Battery 1B-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruments 1B-56 . . . . . . . . . . . . . . . . . . . . . . . . . Gimbal Ring / Steering Connection 1B-56 . . . Changing Water Separating Fuel Filter 1B-57 Removal 1B-58 . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 1B-59 . . . . . . . . . . . . . . . . . . . . . . . .

90-864260001 JUNE 2003 Page vii Section 1B - Maintenance (continued) In-line Fuel Filter (MPI only excluding Alpha) 1B-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 1B-60 . . . . . . . . . . . . . . . . . . . . . . . . Special Information About Electric Fuel Pumps (Carbureted Only) 1B-62 . . . Steering System 1B-62 . . . . . . . . . . . . . . . . . . . . Remote Control 1B-62 . . . . . . . . . . . . . . . . . . . . . Sterndrive Components 1B-62 . . . . . . . . . . . . . Lubrication 1B-63 . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable MPI Models 1B-63 . . . . . . . . . . Throttle Cable Carbureted Models 1B-64 . . . Shift Cable Linkage 1B-64 . . . . . . . . . . . . . . . . Alpha Models 1B-64 . . . . . . . . . . . . . . . . . . . Bravo Models 1B-65 . . . . . . . . . . . . . . . . . . . inboard models 1B-65 . . . . . . . . . . . . . . . . . Tow Sports Models 1B-66 . . . . . . . . . . . . . . Gimbal Bearing 1B-66 . . . . . . . . . . . . . . . . . . . . Engine Coupler And Shaft Splines 1B-67 . . . U-joints 1B-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . U-joint and Pinion Gear Identification 1B-68 . . . . . . . . . . . . . . . . . . . Lubrication 1B-68 . . . . . . . . . . . . . . . . . . . . . Drive Shaft Extension Models 1B-69 . . . . . Continuity Circuit 1B-70 . . . . . . . . . . . . . . . . . . . MerCathode 1B-72 . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts 1B-72 . . . . . . . . . . . . . . . . . . . . . . Electrical System 1B-72 . . . . . . . . . . . . . . . . . . . Cleaning Flame Arrestor 1B-73 . . . . . . . . . . . . . Carbureted Models 1B-73 . . . . . . . . . . . . . . . . Removal 1B-73 . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 1B-73 . . . . . . . . . Installation 1B-73 . . . . . . . . . . . . . . . . . . . . . MPI Models 1B-74 . . . . . . . . . . . . . . . . . . . . . . . Installation 1B-75 . . . . . . . . . . . . . . . . . . . . . . . . Scorpion Models 1B-76 . . . . . . . . . . . . . . . . . . . Removal 1B-76 . . . . . . . . . . . . . . . . . . . . . . . Installation 1B-78 . . . . . . . . . . . . . . . . . . . . . Ignition Timing (Carbureted Models Only) 1B-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thunderbolt V Models 1B-79 . . . . . . . . . . . . . . Serpentine Drive Belt 1B-80 . . . . . . . . . . . . . . . . Inboard and Tow Sports Models 1B-80 . . . . . Sterndrive Models 1B-81 . . . . . . . . . . . . . . . . . Inspection 1B-81 . . . . . . . . . . . . . . . . . . . . . . . . Replacing Belt and/or Adjusting Tension 1B-82 . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 1B-82 . . . . . . . . . . . . . . . . . . . . . . . Installation and Adjustment 1B-82 . . . . . . . Exhaust System 1B-83 . . . . . . . . . . . . . . . . . . . . . Seawater Pump 1B-83 . . . . . . . . . . . . . . . . . . . . . Cold Weather And Extended Storage 1B-84 . Preparing Your Power Package For Storage 1B-84 . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tanks 1B-85 . . . . . . . . . . . . . . . . . . . . . Carbureted fuel system 1B-85 . . . . . . . . . . MPI Fuel System 1B-86 . . . . . . . . . . . . . . . . Draining Instructions 1B-87 . . . . . . . . . . . . . . . . Identification 1B-88 . . . . . . . . . . . . . . . . . . . . . . Carbureted Models 1B-88 . . . . . . . . . . . . . . MPI Models 1B-88 . . . . . . . . . . . . . . . . . . . . Manual Single Point Drain System 1B-89 Air Actuated Single Point Drain System 1B-90 . . . . . . . . . . . . . . . . . . . . . . . . 3 Point Manual Drain System 1B-90 . . . . . 7 Point Manual Drain System 1B-91 . . . . . Multi-Point Drain (MPD) System 1B-92 . . Boat In The Water 1B-93 . . . . . . . . . . . . . . . . . Manual Single Point Drain System 1B-93 Air Actuated Single Point Drain System 1B-94 . . . . . . . . . . . . . . . . . . . . . . . . 3 Point Manual Drain System 1B-96 . . . . . Boat Out Of The Water 1B-97 . . . . . . . . . . . . . Manual Single Point Drain System 1B-97 Air Actuated Single Point Drain System 1B-98 . . . . . . . . . . . . . . . . . . . . . . . . 3 Point Manual Drain System 1B-100 . . . . 7 Point Manual Drain System 1B-101 . . . . Multi-Point Drain (MPD) System 1B-103 . Power Package Recommissioning 1B-105 . . .

Page viii 90-864260001 JUNE 2003 IMPORTANT INFORMATION Section 1C - Troubleshooting Used Spark Plug Analysis 1C-2 . . . . . . . . . . . . Normal Condition 1C-2 . . . . . . . . . . . . . . . . . . . Chipped Insulator 1C-3 . . . . . . . . . . . . . . . . . . . Wet Fouling (Oil Deposits) 1C-3 . . . . . . . . . . . Cold Fouling 1C-4 . . . . . . . . . . . . . . . . . . . . . . . Overheating 1C-4 . . . . . . . . . . . . . . . . . . . . . . . . High Speed Glazing 1C-5 . . . . . . . . . . . . . . . . . Scavenger Deposits 1C-5 . . . . . . . . . . . . . . . . . Pre-Ignition Damage 1C-6 . . . . . . . . . . . . . . . . Reversed Coil Polarity 1C-6 . . . . . . . . . . . . . . . Splashed Deposits 1C-7 . . . . . . . . . . . . . . . . . . Mechanical Damage 1C-7 . . . . . . . . . . . . . . . . Poor Boat Performance And/Or Poor Maneuverability 1C-8 . . . . . . . . . . . . . . . . . . . . . . Improper Full Throttle Engine RPM 1C-10 . . . Engine Cranks Over But Will Not Start Or Starts Hard 1C-11 . . . . . . . . . . . . . . . . . Carbureted Important Information 1C-11 . . . . MPI Important Information 1C-11 . . . . . . . . . . Testing Thunderbolt V Ignition System (Carbureted) 1C-12 . . . . . . . . . . . . . . Engine Cranks Over But Will Not Start Or Starts Hard 1C-13 . . . . . . . . . . . . . . . Fuel System Rich (Carbureted) 1C-13 . . . . . . Fuel System Lean (Carbureted) 1C-14 . . . . . Engine Will Not Crank Over 1C-14 . . . . . . . . . . Charging System Inoperative 1C-15 . . . . . . . . Noisy Alternator 1C-15 . . . . . . . . . . . . . . . . . . . . Instrumentation Malfunction 1C-16 . . . . . . . . . Radio Noise 1C-16 . . . . . . . . . . . . . . . . . . . . . . . . Poor Fuel Economy 1C-17 . . . . . . . . . . . . . . . . . Carburetor Malfunctions 1C-18 . . . . . . . . . . . . . Engine Runs Poorly at Idle 1C-19 . . . . . . . . . . . Engine Runs Poorly At High RPM 1C-21 . . . . Engine Acceleration Is Poor 1C-23 . . . . . . . . . Troubleshooting with Vacuum Gauge 1C-24 . Engine Noise 1C-25 . . . . . . . . . . . . . . . . . . . . . . . Important Information 1C-25 . . . . . . . . . . . . . . Oil Pressure 1C-31 . . . . . . . . . . . . . . . . . . . . . . . . Excessive Oil Consumption 1C-33 . . . . . . . . . . Water In The Engine 1C-34 . . . . . . . . . . . . . . . . . Important Information 1C-34 . . . . . . . . . . . . . . Engine Overheats (Mechanical) 1C-36 . . . . . . Power Steering 1C-38 . . . . . . . . . . . . . . . . . . . . . Transmission 1C-40 . . . . . . . . . . . . . . . . . . . . . . . Drain System Will Not Drain Or Drains Slowly 1C-41 . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION Section 1D - California Emissions Information Emissions Information 1D-2 . . . . . . . . . . . . . . . Emission Control Information Label 1D-2 . . . Components Of The Emissions Control System 1D-3 . . . . . . . . . . . . . . . . . . . . Disclaimers And Limitations 1D-4 . . . . . . . . . . Star Label 1D-4 . . . . . . . . . . . . . . . . . . . . . . . . . Hang Tag 1D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . Emission Control Information Label Request Form 1D-4 . . . . . . . . . . . . . . . .

90-864260001 JUNE 2003 Page ix REMOVAL AND INSTALLATION Section 2A - MCM Models Lubricants / Sealants / Adhesives 2A-2 . . . . . Special Tools 2A-4 . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 2A-6 . . . . . . . . . . . . . . . . Removal 2A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation 2A-10 . . . . . . . . . . . . . . . . . . Electrical Connections 2A-15 . . . . . . . . . . . . . . MPI Electrical System Precautions 2A-15 . . . Installing Continuity Wire 2A-16 . . . . . . . . . . . Instrumentation Connections 2A-16 . . . . . . . . Trim Position Sender Connections 2A-17 . . . MerCathode Connections 2A-18 . . . . . . . . . . . Audio Warning Alarm Connections 2A-19 . . . Power Trim Pump Connections 2A-20 . . . . . . Fluid Connections 2A-22 . . . . . . . . . . . . . . . . . . . Fuel 2A-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Lube Monitor Hose 2A-23 . . . . . . . . . . . Gear Lube Monitor Hose with Quick Connect 2A-24 . . . . . . . . . . . . . . . . Power Steering Hoses 2A-25 . . . . . . . . . . . . . . Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups 2A-26 . . . . . Alpha or Bravo Models Using Alternative Water Pickups 2A-26 . . . . Coolant Recovery Bottle 2A-29 . . . . . . . . . . . . Shift Cable Installation 2A-30 . . . . . . . . . . . . . . Alpha Models 2A-31 . . . . . . . . . . . . . . . . . . . . . Shift Cable Travel 2A-31 . . . . . . . . . . . . . . . Separate Shift and Throttle Controls 2A-32 . . . . . . . . . . . . . . . Installation 2A-33 . . . . . . . . . . . . . . . . . . . . . Bravo Models 2A-36 . . . . . . . . . . . . . . . . . . . . . Throttle Cable Installation and Adjustment 2A-41 . . . . . . . . . . . . . . . . . . . . Battery Connection 2A-42 . . . . . . . . . . . . . . . . Engine Cover Installation 2A-42 . . . . . . . . . . . REMOVAL AND INSTALLATION Section 2B - MIE Models Lubricants / Sealants / Adhesives 2B-2 . . . . . Torque Specifications 2B-2 . . . . . . . . . . . . . . . . Removal 2B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mount Pre-Adjustment 2B-6 . . . . . . . . Engine Preparation 2B-7 . . . . . . . . . . . . . . . . . . . Engine Oil Dipstick Relocation (If Equipped) 2B-7 . . . . . . . . . . . . Engine Installation And Initial Engine Alignment 2B-8 . . . . . . . . . Models With 8 Degree Down Angle Transmissions - Velvet Drive Or ZF/Hurth 2B-8 . . . . . . . . . . . . . . . . . . . . . . . Models with V-Drive Transmissions 2B-9 . . . Exhaust System 2B-10 . . . . . . . . . . . . . . . . . . . . . Measuring Exhaust Elbow Height 2B-10 . . . . Straight Edge Method 2B-12 . . . . . . . . . . . Clear Hose Method 2B-13 . . . . . . . . . . . . . . Exhaust System Hose / Tube Connections 2B-14 . . . . . . . . . . . . . . . . . . Electrical Connections 2B-16 . . . . . . . . . . . . . . EFI Electrical System Precautions 2B-16 . . . Instrumentation Connections 2B-17 . . . . . . . . Fluid Connections 2B-18 . . . . . . . . . . . . . . . . . . . Coolant Recovery Bottle 2B-18 . . . . . . . . . . . . Transmission Cooler 2B-19 . . . . . . . . . . . . . . . Fuel 2B-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Engine Alignment 2B-21 . . . . . . . . . . . . . . Engine Cover Installation 2B-25 . . . . . . . . . . . Throttle Cable Installation And Adjustment 2B-26 . . . . . . . . . . . . . . . . . . . . Carbureted Models 2B-26 . . . . . . . . . . . . . . . . MPI Models 2B-27 . . . . . . . . . . . . . . . . . . . . . . . Scorpion Models 2B-28 . . . . . . . . . . . . . . . . . . . Shift Cable Installation And Adjustment For Inboard Models 2B-29 . Velvet Drive Transmissions 2B-29 . . . . . . . . . In-Line and Remote V-Drive 2B-29 . . . . . . 5000 Series (8 Degree Down Angle and V-Drive) 2B-33 . . . . . . . . . . . . . . . . . . . ZF Marine Transmissions 2B-37 . . . . . . . . . . . Shift Cable Installation And Adjustment For Tow Sports Models 2B-43 . . . . . . . . . . . . .

Page x 90-864260001 JUNE 2003 ENGINE Section 3A - Engine Mechanical Identification 3A-4 . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications 3A-5 . . . . . . . . . . . . . . . 5.0 Liter (305 CID) 3A-5 . . . . . . . . . . . . . . . . . . 5.7 Liter (350 CID) 3A-5 . . . . . . . . . . . . . . . . . . 6.2 Liter (377 CID) 3A-6 . . . . . . . . . . . . . . . . . . Engine Specifications - 5.0 Liter (305 CID) And 5.7 Liter (350 CID) 3A-7 . . . . . . . . . . Cylinder Head 3A-7 . . . . . . . . . . . . . . . . . . . . . . Cylinder Bore 3A-7 . . . . . . . . . . . . . . . . . . . . . . Oil Pump 3A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Bore Clearance 3A-7 . . . . . . . . . . . . . . Piston Rings 3A-8 . . . . . . . . . . . . . . . . . . . . . . . Top Compression 3A-8 . . . . . . . . . . . . . . . . Second Compression 3A-8 . . . . . . . . . . . . . Oil Control 3A-8 . . . . . . . . . . . . . . . . . . . . . . Piston Pin 3A-8 . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 3A-9 . . . . . . . . . . . . . . . . . . . . . . . . . Main Bearing Journal 3A-9 . . . . . . . . . . . . . Main Bearing Clearance 3A-9 . . . . . . . . . . Connecting Rod Journal 3A-9 . . . . . . . . . . Miscellaneous 3A-9 . . . . . . . . . . . . . . . . . . . Connecting Rod 3A-10 . . . . . . . . . . . . . . . . . . . Connecting Rod Bearing 3A-10 . . . . . . . . . Valve 3A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance (Lash) 3A-10 . . . . . . . . . . . . . . . Lifter 3A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . Head and Stem 3A-10 . . . . . . . . . . . . . . . . . Stem Clearance 3A-11 . . . . . . . . . . . . . . . . Valve 3A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat 3A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring 3A-11 . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 3A-12 . . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain 3A-12 . . . . . . . . . . . . . . . . . . . . . . Flywheel 3A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications - 6.2 Liter (377 CID) 3A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 3A-13 . . . . . . . . . . . . . . . . . . . . . Cylinder Bore 3A-13 . . . . . . . . . . . . . . . . . . . . . Oil Pump 3A-13 . . . . . . . . . . . . . . . . . . . . . . . . . Piston Clearance 3A-13 . . . . . . . . . . . . . . . . . . Piston Rings 3A-14 . . . . . . . . . . . . . . . . . . . . . . Top Compression 3A-14 . . . . . . . . . . . . . . . Second Compression 3A-14 . . . . . . . . . . . . Oil Control 3A-14 . . . . . . . . . . . . . . . . . . . . Piston Pin 3A-14 . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 3A-15 . . . . . . . . . . . . . . . . . . . . . . . . Main Bearing Journal 3A-15 . . . . . . . . . . . . Main Bearing Clearance 3A-15 . . . . . . . . . Connecting Rod Journal 3A-15 . . . . . . . . . Miscellaneous 3A-15 . . . . . . . . . . . . . . . . . . Connecting Rod 3A-16 . . . . . . . . . . . . . . . . . . . Connecting Rod Bore (Crankshaft End) 3A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Bearing 3A-16 . . . . . . . . . Valve 3A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance (Lash) 3A-16 . . . . . . . . . . . . . . . Lifter 3A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . Head and Stem 3A-17 . . . . . . . . . . . . . . . . . Stem Clearance 3A-17 . . . . . . . . . . . . . . . . Seat 3A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring 3A-18 . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 3A-18 . . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain 3A-18 . . . . . . . . . . . . . . . . . . . . . . Flywheel 3A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives 3A-19 . . . . Tools 3A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions 3A-22 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 3A-23 . . . . . . . . . . . . . . . General Information 3A-27 . . . . . . . . . . . . . . . . . Repair Procedures 3A-27 . . . . . . . . . . . . . . . . . Special Notice 3A-27 . . . . . . . . . . . . . . . . . . . . . Engine Rotation 3A-27 . . . . . . . . . . . . . . . . . . . Crankcase Oil Dipstick Measurements 3A-28 . . . . . . . . . . . . . . . . . . . . Gasoline Engine Compression Test 3A-29 . . Using Air to Test Combustion Chamber 3A-30 . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts 3A-31 . . . . . . . . . . . . . . . . . . . . . . Exploded Views 3A-31 . . . . . . . . . . . . . . . . . . . Valve Cover 3A-33 . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3A-33 . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 3A-33 . . . . . . . . . . . . Installation 3A-33 . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm / Valve Pushrod 3A-34 . . . . . . . . . Removal 3A-34 . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 3A-34 . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-34 . . . . . . . . . . . . . . . . . . . . . . . . Installation 3A-35 . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Mercruiser 5.7L MPI Engines Full Service Repair

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