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main menu service manual number 24 marine engines gm v-8 305 cid 5.0l 350 cid 5.7l printed in u.s.a 1999 mercury marine 90-861327 1 1099

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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 i

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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 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 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 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 includes 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 90-861327 1 october 1999 page i

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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 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 described in this manual models covered page ii 90-861327 1 october 1999

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service manual outline 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 in­line 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 1 2 3 4 5 6 7 8 9 removal and installation engine electrical systems fuel systems cooling system exhaust system drives power steering system 90-861327 1 october 1999 page iii

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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 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-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

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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 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 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-29 1c-30 1c-30 1c-31 1c-31 1c-32 1c-33 1c-33 1c-33 removal and installation section 2a mcm 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 2a-2 2a-2 2a-2 2a-3 2a-3 2a-5 2a-7 2a-7 2a-10 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 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 90-861327 1 october 1999 2b-2 2b-2 2b-2 2b-3 2b-3 2b-4 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-22 page v

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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

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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 4a-9 4a-9 4a-9 4a-10 4a-10 4a-10 4a-11 4a-12 4a-12 4a-12 4a-12 4a-12 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 90-861327 1 october 1999 page vii

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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 4b-11 4b-11 4b-12 4b-13 4b-14 4b-15 4b-15 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 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

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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 4e-2 mcm 5.0l engines 4e-2 mcm 5.7l engines 4e-4 mefi 1 and mefi 2 mcm 5.0l efi 5.7l efi and 350 mag mpi engines 4e-6 mefi 3 mcm 5.0l efi 5.7l efi and 350 mag mpi engines 4e-8 mie 5.7l inboard 4e-10 mie 350 mag mpi and black scorpion engines starting and charging system harness 4e-12 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-16 4e-17 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

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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 5c-7 5c-8 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 page x 90-861327 1 october 1999

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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 5d-8 5d-8 5d-9 5d-10 5d-10 5d-10 5d-11 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-20 5d-21 5d-22 5d-23 5d-24 5d-24 5d-24 5d-24 5d-26 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 5e-23 5e-24 5e-24 5e-25 5e-25 5e-26 5e-27 5e-27 5e-27 5e-29 5e-35 5e-37 5e-39 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-61 5e-62 5e-63 5e-64 5e-65 5e-67 5e-68 5e-68 90-861327 1 october 1999 page xi

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section 5f fuel injection system troubleshooting scan tool normal specifications idle warm engine closed throttle neutral 5f-2 important preliminary checks 5f-3 before starting 5f-3 visual physical check 5f-3 intermittents 5f-4 hard start symptom 5f-5 surges and/or chuggles symptom 5f-7 lack of power sluggish or spongy symptom 5f-9 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-17 5f-20 5f-22 5f-23 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 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 5g-6 5g-6 5g-8 5g-10 5g-12 5g-14 5g-14 5g-18 5g-20 5g-21 5g-22 5g-22 5g-23 5g-24 5g-24 5g-26 5g-28 5g-30 5g-32 5g-34 5g-36 5g-38 5g-44 5g-46 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-53 5g-56 5g-58 5g-61 5g-64 5g-66 5g-68 5g-71 5g-74 5g-76 5g-78 5g-81 5g-84 5g-86 5g-87 5g-88 5g-91 page xii 90-861327 1 october 1999

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cooling system section 6a seawater cooled models torque specifications 6a-2 tools 6a-2 lubricants sealants adhesives 6a-3 specifications 6a-3 cooling system capacity 6a-3 thermostat 6a-3 seawater inlet recommendations 6a-3 transom mounted or thru-hull seawater pickups and hose 6a-3 seacock seawater inlet valve 6a-4 sea strainer 6a-4 seawater pickups 6a-5 thru-hull mounted 6a-5 transom mounted 6a-6 quicksilver sea strainer 6a-7 removal 6a-7 cleaning and inspection 6a-8 installation 6a-8 seawater pickup pump 6a-10 output test 6a-10 disassembly 6a-12 reassembly 6a-13 seawater pump bearing housing 6a-14 disassembly 6a-14 cleaning and inspection 6a-15 reassembly 6a-16 water circulating pump 6a-19 removal 6a-19 cleaning and inspection 6a-19 installation 6a-19 drive belt tension adjustment 6a-20 flushing seawater cooling system 6a-20 thermostat 6a-20 removal 6a-20 testing 6a-21 installation 6a-22 auxiliary hot water heater installation 6a-23 water tap locations for propshaft coolers 6a-24 water flow diagrams 6a-25 305 cid and 350 cid bravo inboard and ski engines 6a-25 305 cid and 350 cid alpha engines 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 6b-7 6b-8 6b-8 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-21 6b-21 6b-22 90-861327 1 october 1999 page xiii

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