Installation; Distributor Repair; Removal; Disassembly - MerCruiser 305 CID (5.0L) Service Manual

IGNITION SYSTEM

Installation

1. Install sensor into housing and install two retaining screws.
2. Install sensor wheel, rotor and distributor cap.
3. Connect WHT/RED and WHT/GRN sensor wires (ring terminals on engine harness
wires, or bullet connectors from Ignition Module wires). Tighten hex nuts securely (if
equipped).

Distributor Repair

Removal

1. Unplug wiring harness from Ignition Module on distributor housing, or disconnect wires
from Ignition Module mounted on exhaust elbow.
2. Disconnect sensor wires.
3. Remove distributor cap. Do not remove high tension leads unless necessary.
4. Crank engine over until timing marks line up and rotor is pointing toward No. 1 cylinder
on distributor cap.
5. Mark distributor housing in reference to engine block.
6. Remove bolt and hold-down clamp and remove distributor.
IMPORTANT: To simplify distributor installation, do not turn crankshaft when distrib-
utor is removed from engine.

Disassembly

Refer to exploded view preceding for parts identification during disassembly and

reassembly.

1. Remove rotor, sensor wheel, sensor and Ignition Module (if mounted on distributor).
2. Remove roll pin, washer and driven gear from distributor shaft.
3. Check for side play between shaft and distributor housing bushings. Maximum side play
is .002 in. (0.05 mm).
4. Remove shaft from housing.
5. Check shaft for warp with a dial indicator and V-blocks. Maximum runout is .002 in. (0.5
mm).
Reassembly
1. Lubricate shaft with engine oil.
2. Install E-clip (if removed) on shaft in housing.
3. Install washer on shaft.
4. Install original gear; slide onto shaft and install roll pin.
IMPORTANT: Hole may be offset and gear will only fit in one direction.
5. If installing a new gear, the gear will come drilled on one side. Slide gear onto shaft; align
hole in gear with hole in shaft.
Index
Page 4B-22
NOTICE
90-861327--1 OCTOBER 1999
SERVICE MANUAL NUMBER 24