Mercruiser GM V8 300 CID 5.0L / 350 CID 5.7L Service Workshop Manual

Workshop Service and Repair Manual for the Mercruiser GM V8 300 CID 5.0L / 350 CID 5.7L engines This full workshop manual set covers every component, service and repair procedure in full Mercury factory specification with clear concise step by step photographs and technical drawings for the GM V8 with torque setting values throughout where required for fasteners, below is an exhaustive list of the items covered within this workshop manual. This is the most comprehensive service manual available as used by marine engineers and boatyards the world over.

MAINTENANCE

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
Vapour 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
Flushing System Mie
(Inboard And Ski)
Transmission Fluid
Lubrication
Throttle Cable
Shift Cable And Transmission Linkage
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 Sterndrive
Recommissioning

Removal & Installation:
Mie Models
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
Alignment
Water Hose Connections
Electrical Connections
Fuel Supply Connections
Throttle Cable Installation And Adjustment
Power Steering Connections
Exhaust Hose Connections
Mim Models
Identification
Velvet Drive In-line And V-drive Transmissions
Velvet Drive
Down-angle Transmission
Hurth Transmissions
Torque Specifications
Lubricants / Sealants / Adhesives
Preparation
Removal
Installation And Alignment
Engine Final Alignment
Engine Connections
Attaching / Adjusting Reversed Attachment Morse Shift Cables

ENGINE

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
Intake Manifold
Rocker Arm / Push Rod
Valve Adjustment
Engine Stopped
Engine Operating
Hydraulic Valve Lifters
Locating Noisy Lifters
Valve Stem Oil Seal / Valve Spring
Removal – Head Installed
Valve Assembly (Exploded View)
Installation – Head Installed
Cylinder Head And Valve Conditioning
Disassembly
Valve Guide Bore Repair
Valve Springs – Checking Tension
Rocker Arm Stud Replacement
Valve Seat Repair
Valve Grinding
Crankcase Oil Dipstick Specifications
Oil Pan
Oil Pump
Torsional Damper
Crankcase Front Cover/Oil Seal
Oil Seal Replacement (Without Removing Front Cover)
Crankcase Front Cover
Flywheel
Rear Main Oil Seal
Rear Main Oil Seal Retainer
Main Bearings
Checking Clearances
Connecting Rod Bearings
Connecting Rod / Piston Assembly
Crankshaft
Timing Chain And Sprocket
Crankshaft Sprocket/Gear
Checking Timing Chain Deflection
Camshaft
Measuring Lobe Lift
Camshaft Bearings
Cylinder Block
Oil Filter By-pass Valve And
Adaptor Assembly

ELECTRICAL

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
Starter Motor Voltage
Voltage Drop In Starting System

Delco 14Mt Direct Drive Starter:
Starter Specifications
Torque Specifications
Lubricants / Sealants / Adhesives
Exploded View
Solenoid Switch
Motor
Checking Pinion Clearance
Checking Commutator
End Frame Gap
Installation

Delco Pg260F1 Starter:
Specifications
Starter Specifications
Torque Specifications
Lubricants / Sealants / Adhesives
Description
Exploded View
Motor
Checking Pinion Clearance
Installation

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
Spark Plug Wires
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
Mercury Marine Distributor
Distributor Cap
Rotor / Sensor Wheel
Distributor Repair
Distributor Installation
Replacing Distributor Gear
Gm Est Distributor
Testing Pickup Coil

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
Charging System
Alternator Repair
Pulley Removal
Battery Isolator Diagram
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
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

WIRING

Circuit Diagrams
Starting And Charging Harness
Fuel And Ignition System Harness

FUEL SYSTEMS

Fuel Delivery System For Carbureted Engines:
Identification
Replacement Parts Warning
Specifications
Torque Specifications
Tools
Lubricants / Sealants / Adhesives
Precautions
Fuel Supply Connections
Fuel Delivery System
Recommendations
Fuel System Components
Carburetor System
Water Separating Fuel Filter
Replacement
Vent Hose Routing

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
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

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
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

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)
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

Fuel Injection Disassembly And Reassembly:
Service Precautions
Specifications
Torque Specifications
Lubricants / Sealants / Adhesives
Sensor Voltage
Exploded Views – Mx 6.2L Mpi
Flame Arrestor And Throttle Body
Intake Manifold And Fuel Rail
Fuel Pressure Relief Procedure
Mx 6.2 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

Mx 6.2 Mpi Models:
Exploded Views – Mx 6.2 Black Scorpion 5E-20 Plenum, Throttle Body And Flame Arrestor
Intake Manifold And Fuel Rails
Fuel Pressure Relief Procedure
Mx 6.2 Black Scorpion Components
Flame Arrestor
Throttle Body
Plenum
Fuel Rails
Fuel Injectors
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

Mx 6.2 Black Scorpion Models:
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

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 5G-6
J-2 Circuits With Mefi 1 And Mefi 2 5G-8
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)
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
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

EXHAUST SYSTEM

Exhaust System Requirements
Exhaust Elbow Risers
Mcm (Sterndrive) Engines With Thru-transom Exhaust
Mie (Inboard) Engines
Exhaust Hose Connection
Exhaust Tube Requirements
Torque Specifications
Lubricants / Sealants / Adhesives
Disassembly
Cleaning And Inspection
Installation
Gaskets
Manifold
Sterndrive Exhaust Extension
Bullhorn Exhaust
Shutter Replacement
Component Replacement
Thru-transom Exhaust
Shutter Replacement
Component Replacement
Below Swim Platform Exhaust Pipe
Silent Choice Exhaust System
Exhaust Tube Installation
Air Tube Routing
Maintenance
Exhaust Muffler Kit
Cleaning And Inspection
Installation
Maintenance Instructions

DRIVES

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
Shift Cable Adjustment
Checking Transmission Fluid Level
Changing Transmission Fluid
Draining Transmission
Filling Transmission
Removal
Installation
Shift Lever Installation
Pressure Test
Transmission Repair

Velvet Drive 5000 Series Transmission:
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 8B-6
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

Hurth Transmissions:
Identification
Specifications
Torque Specifications
Operating Specifications
Fluid Specifications
Tools
Lubricants / Sealants / Adhesives
Rotation
Shift Cable Installation And Adjustment
Checking Transmission Fluid Level
Draining Transmission
Filling Transmission
Transmission Removal
Transmission Installation
Functional Tests

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
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

POWER STEERING SYSTEM:
Pump And Related Components
Torque Specifications
Tools
Lubricants / Sealants / Adhesives
Precautions
Power Steering Pump And Components
Serpentine Belt Routing
Serpentine Belt Adjustment
Removal
Installation
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