2001-2006 Mercury Mercruiser V8 5.0L 5.7L 6.3L MPI Alpha Bravo Engine Repair Manual

Number 24 90-861327--1 1099 GM V-8 305 CID (5.0L) / 350 CID (5.7L) MARINE ENGINES SERVICE MANUAL

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

90-861327--1 OCTOBER 1999 Page i Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational 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 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 Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual It is assumed that these personnel are familiar with the servicing procedures of these products, 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 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 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.

Page ii 90-861327--1 OCTOBER 1999 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. 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 whenever 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 manual, 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.

1 2 3 4 5 6 7 8 9 Important Information Removal and Installation Engine Electrical Systems Fuel Systems Cooling System Exhaust System Drives Power Steering System 90-861327--1 OCTOBER 1999 Page iii Service Manual Outline 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

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

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

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

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

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

2001-2006 Mercury Mercruiser V8 5.0L 5.7L 6.3L MPI Alpha Bravo Engine Repair Manual

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