MerCruiser 305 CID (5.0L) Manuals

Manuals and User Guides for MerCruiser 305 CID (5.0L). We have 1 MerCruiser 305 CID (5.0L) manual available for free PDF download: Service Manual

MerCruiser 305 CID (5.0L) Service Manual

MerCruiser 305 CID (5.0L) Service Manual (895 pages)

Brand: MerCruiser | Category: Engine | Size: 12.9 MB

Table of Contents

Important Information

6
- Marine Engines
  1
- Table of Contents
  6
- Electrical Systems
  9
- Fuel System
  11
- Cooling System
  15
- Exhaust System
  16
Section 2

19
- Table of Contents
  19
- How to Use this Manual
  20
  - Page Numbering
    20
- Introduction
  20
- How to Read a Parts Manual
  21
- Directional References
  22
- Engine Rotation
  22
- Engine Serial Number Locations
  23
  - Propeller Information
    23
  - Water Testing New Engines
    24
  - Boat and Engine Performance
    24
  - Boat Bottom
    24
  - Marine Fouling
    26
  - Weight Distribution
    27
Section 3

29
- Table of Contents
  29
- Lubricants / Sealants / Adhesives
  30
- Tools
  30
- Maintenance Schedules
  31
  - Maintenance Intervals
    31
- Engine and Tune-Up Specifications
  35
  - Fluid Capacities
    39
- 20-Hour Break-In Period
  41
- After Break-In Period
  41
- End of First Season Checkup
  41
- Specifications
  42
  - Fuel Recommendations
    42
  - Vapor Locking
    42
  - Procedure
    44
  - Test for Alcohol Content in Gasoline 1B-16
    44
- Coolant for Closed Cooling System
  44
- Power Steering Fluid
  44
- Transmission Fluid
  44
- Crankcase Oil
  45
  - Overfilled Crankcase Oil
    45
  - Checking Engine Oil Level / Filling
    46
- Changing Oil and Filter
  46
  - Changing Water Separating Fuel Filter
    47
  - MCM (Sterndrive) Models
    47
  - MIE (Inboard and Ski) Models
    48
  - Checking Fluid Level
    49
  - Engine Cold
    49
  - Engine Warm
    49
  - Filling and Bleeding
    50
- Closed Cooling System
  51
  - Checking Coolant Level
    51
  - Boat out of Water
    52
  - Flushing System MCM (Sterndrive) . 1B-24
    52
  - Boat in Water
    53
- Transmission Fluid
  55
- Lubrication
  56
- Cleaning Flame Arrestor
  60
  - Top Mounted Flame Arrestor
    60
  - Black Scorpion Flame Arrestor
    61
- Serpentine Drive Belt
  62
  - Component Location
    62
  - Inspection
    64
  - Installation and Adjustment
    64
  - Removal
    64
  - Replacing And/Or Adjusting Tension
    64
- Ignition Timing
  65
  - Thunderbolt V Models
    65
  - EFI/MPI Models
    66
- Cold Weather or Extended Storage
  67
- Used Spark Plug Analysis
  84
  - Chipped Insulator
    84
  - Normal Condition
    84
  - Cold Fouling
    85
  - Overheating
    85
  - Wet Fouling (Oil Deposits)
    85
  - High Speed Glazing
    86
  - Pre-Ignition Damage
    86
  - Scavenger Deposits
    86
  - Mechanical Damage
    87
  - Reversed Coil Polarity
    87
  - Splashed Deposits
    87
- Poor Boat Performance And/Or Poor Maneuverability
  88
- Improper Full Throttle Engine RPM
  89
  - RPM too High
    89
  - RPM too Low
    89
- Engine Cranks over but will Not Start or Starts Hard
  90
  - Important Information
    90
  - Testing Thunderbolt V Ignition System
    91
  - Fuel System Lean
    92
  - Fuel System Rich
    92
  - Miscellaneous
    92
- Charging System Inoperative
  93
- Engine will Not Crank over
  93
- Instrumentation Malfunction
  94
- Noisy Alternator
  94
- Radio Noise
  94
- Poor Fuel Economy
  95
- Carburetor Malfunctions
  96
- Engine Runs Poorly at Idle
  97
  - Engine Runs Poorly at High Rpm
    98
  - Engine Acceleration Is Poor
    99
  - Troubleshooting with Vacuum Gauge
    99
  - Engine Noise
    100
  - Valve Cover Area
    100
  - Camshaft Area
    101
  - Cylinder Area
    101
  - Crankshaft Area
    102
  - High Oil Pressure
    105
  - Low Oil Pressure
    105
  - Excessive Oil Consumption
    106
  - Water in Engine
    107
- Power Steering
  112
  - Poor, Erratic, or no Assist
    112
  - Fluid Leaks
    113
  - Noisy Pump
    113
- Troubleshooting Silent Choice Exhaust Silencer System
  114
- Removal and Installation
  
  117
- Section 2A - MCM Models
  
  117
  - Lubricants / Sealants / Adhesives
    118
  - Tools
    118
  - Torque Specifications
    118
  - Preparation
    119
  - Removal
    119
  - Installation
    121
    
    Drive Shaft Extension Models
    123
    
    Engine Mount Adjustment was Not Disturbed During Service
    123
    
    Engine Mount Adjustment was Disturbed During Service
    126
  - Alignment
    131
    
    Water Hose Connections
    133
    
    Electrical Connections
    134
    
    Fuel Supply Connections
    136
    
    Throttle Cable Installation and Adjustment
    137
    
    Power Steering Connections
    139
    
    Exhaust Hose Connections
    140
  - Identification
    143
- SECTION 2B - MIE Models
  
  143
  - Preparation
    146
  - Removal
    146
  - Installation and Alignment
    148
    
    Engine Final Alignment
    149
    
    Engine Connections
    152
    
    General Specifications
    172
    
    Engine Specifications
    173
    
    Bearing Failures
    181
    
    Piston Failures
    182
    
    Engine Mounts
    184
    
    Rocker Arm Cover
    186
    
    Valve Adjustment
    190
    
    Cylinder Head and Valve Conditioning
    199
    
    Valve Guide Bore Repair
    202
    
    Valve Seat Repair
    204
    
    All Engines
    208
    
    Oil Pan
    210
    
    Oil Pump
    213
    
    Torsional Damper
    216
    
    Crankcase Front Cover
    219
    
    Rear Main Oil Seal
    223
    
    Checking Clearances
    226
    
    Main Bearings
    226
    
    Connecting Rod Bearings
    230
    
    Inspection and Replacement
    230
    
    Cylinder Block
    249
    
    Positive Current Flow
    259
    
    Charging Guide
    263
    
    Standard Starter Slave Solenoid
    264
    
    Installation
    269
    
    Delco PG260F1 Starter
    273
    
    Description
    273
    
    Lubricants / Sealants / Adhesives
    273
    
    Specifications
    273
    
    Starter Specifications
    273
    
    Torque Specifications
    273
    
    Exploded View
    274
    
    Disassembly
    275
    
    Motor
    275
    
    Removal
    275
    
    Cleaning and Inspection
    279
    
    Reassembly
    279
    
    Checking Pinion Clearance
    283
    
    Installation
    284
    
    General Precautions
    287
    
    Ignition Control System Components
    287
    
    Replacement Parts Warning
    287
    
    EFI System Maintenance Precautions
    288
    
    Lubricants / Sealants / Adhesives
    288
    
    Tools
    288
    
    Torque Specifications
    288
    
    Coil
    289
    
    Distributor
    289
    
    Firing Order
    289
    
    Ignition System Specifications
    289
    
    Spark Plugs
    289
    
    Thunderbolt V Models
    290
    
    Timing
    290
    
    EFI / MPI Models
    291
    
    Inspection
    291
    
    Removal
    291
    
    Inspection
    293
    
    Replacing
    293
    
    Spark Plug Wires
    293
    
    Ignition Coil
    294
    
    Carbureted Engines - Thunderbolt V Ignition
    296
    
    Spark Control Features
    296
    
    Circuit Description
    297
    
    Thunderbolt V Spark Control Graph
    298
    
    Installation
    303
    
    Cleaning and Inspection
    306
    
    Removal
    306
    
    Sensor
    306
    
    Testing
    306
    
    Disassembly
    307
    
    Distributor Repair
    307
    
    Installation
    307
    
    Reassembly
    307
    
    Removal
    307
    
    Distributor Installation
    308
    
    Installation
    310
    
    Removal
    310
    
    Replacing Distributor Gear
    310
    
    Disassembly
    311
    
    GM EST Distributor
    311
    
    Removal
    311
    
    Cleaning and Inspection
    312
    
    Reassembly
    313
    
    Testing Pickup Coil
    313
    
    Installation
    314
    
    Alternator Repair
    316
    
    Charging System
    316
    
    Charging System Resistance
    316
    
    Circuitry
    316
    
    Component
    316
    
    Exploded View
    316
    
    Section 4C - Charging System
    316
    
    Testing
    316
    
    Efi Electrical System Precautions
    317
    
    Multiple Efi Engine Battery Precautions
    318
    
    Disassembly
    332
    
    Removal
    332
    
    Cleaning and Inspection
    337
    
    Reassembly
    337
    
    Installation
    341
    
    Pulley Removal
    342
    
    Battery Isolator Diagram
    343
    
    Water Temperature
    355
    
    Audio Warning System
    359
    
    Oil Pressure Switch
    360
    
    Fuel System Components
    388
    
    Section 5B - Mercarb
    392
    
    Replacement Parts Warning
    394
    
    Fuel Delivery System
    395
    
    Recommendations
    395
    
    Specifications
    396
    
    Tools
    396
    
    Torque Specifications
    396
    
    High Altitude Re-Jetting
    397
    
    Flooding at Idle RPM
    398
    
    Important Service Information
    398
    
    Point Carburetor Check List
    398
    
    Adjustable Accelerator Pump Lever
    399
    
    Description
    399
    
    Flame Arrestor with Carburetor Cover 5B-9
    400
    
    Choke Inspection
    403
    
    Pump Rod
    403
    
    Choke Setting
    405
    
    Choke Unloader
    405
    
    Final Idle Speed and Mixture
    407
    
    Removal
    408
    
    Repair
    408
    
    Exploded View Parts List
    410
    
    Disassembly
    411
    
    Cleaning and Inspection
    419
    
    Reassembly
    421
    
    Installation
    431
    
    Water Separating Fuel Filter
    434
    
    Water Separating Fuel Filter Replacement
    434
    
    Cool Fuel System Repair
    443
    
    Removal
    443
    
    Disassembly
    444
    
    Reassembly
    445
    
    Installation
    447
    
    350 Mag MPI Models
    450
    
    Vacuum and Vent Hose Routing
    450
    
    Scorpion Models
    451
    
    Throttle Body EFI
    452
Fuel Systems

454
- Special Tools
  455
- Service Precautions
  456
- General Information
  458
  - Electrostatic Discharge Damage
    458
  - Diagnostic Information
    458
  - Wiring Harness Service
    458
  - Wiring Connector Service
    459
- Abbreviations
  460
  - Malfunction Indicator Lamp
    460
  - Intermittent Malfunction Indicator Lamp
    461
  - Reading Codes
    462
    
    Scan Tools
    463
  - EFI Diagnostic Circuit Check
    463
  - Scan Tool Use with Intermittents
    463
  - Non-Scan Diagnosis of Driveability Concerns (with no Codes Set)
    464
- Electronic Control Module (ECM) and Sensors
  465
  - General Description
    465
  - Computers and Voltage Signals
    465
  - Analog Signals
    465
  - Digital Signals
    466
  - Engine Control Module (ECM)
    467
  - Speed Density System
    468
  - ECM Input and Sensor Descriptions
    469
- Spark Management
  473
  - High Energy Ignition with Ignition Control
    473
  - Modes of Operation
    474
  - Base Ignition Timing
    475
  - Results of Incorrect Operation
    476
- Fuel Metering System
  477
  - General Description
    477
  - Cool Fuel Systems
    477
  - Modes of Operation
    477
  - 350 Mag MPI and Black Scorpion - Multi-Port Injection Components
    483
    
    Section 5E - Fuel Injection Disassembly and Reassembly
    490
  - Torque Specifications
    490
  - Service Precautions
    491
  - Torque Specifications
    492
  - Exploded Views - 350 Mag MPI
    493
    
    Flame Arrestor and Throttle Body
    493
    
    Flame Arrestor and Throttle Body
    494
    
    Intake Manifold and Fuel Rail
    495
    
    Intake Manifold and Fuel Rail
    496
  - Fuel Pressure Relief Procedure
    497
  - 350 Mag MPI Components
    497
    
    Flame Arrestor
    497
    
    Throttle Body
    500
    
    Throttle Position Sensor
    503
    
    Idle Air Control (IAC) Valve
    505
    
    Knock Sensor
    507
    
    Knock Sensor Module
    508
    
    Fuel Pump Relay
    509
    
    System Relay
    509
    
    Electronic Control Module (ECM)
    510
    
    Engine Coolant Temperature (ECT) Sensor
    512
  - Vacuum and Vent Hose Routing
    513
    
    350 Mag MPI Models
    513
  - Exploded Views - Black Scorpion
    514
    
    Plenum, Throttle Body and Flame Arrestor
    514
    
    Intake Manifold and Fuel Rails
    515
    
    Flame Arrestor
    516
    
    Throttle Body
    520
    
    Plenum
    524
    
    MAP Sensor
    529
    
    Throttle Position Sensor
    530
    
    Idle Air Control (IAC) Valve
    532
    
    Knock Sensor
    534
    
    Fuel Pump Relay
    535
    
    Knock Sensor Module
    535
    
    System Relay
    536
    
    Scorpion Models
    538
  - Exploded Views - Throttle Body EFI
    539
    
    Throttle Body Body and Adapter
    539
  - Fuel Pressure Relief Procedure
    541
  - Throttle Body EFI Components
    541
    
    Fuel Meter Cover Assembly
    541
    
    Fuel Injectors
    543
    
    Throttle Body
    545
    
    Throttle Body Adapter Plate
    547
    
    Engine Control Module (ECM)
    548
    
    Knock Sensor (KS) Module (MEFI 1 and MEFI 2 Only)
    550
    
    Engine Coolant Temperature (ECT) Sensor
    551
Fuel System

560
- Lubricants / Sealants / Adhesives
  562
- Sensor Voltage
  562
- Exploded Views - MX 6.2L MPI
  563
  - Flame Arrestor and Throttle Body
    563
  - Intake Manifold and Fuel Rail
    564
  - Flame Arrestor
    565
  - Throttle Body
    567
  - Idle Air Control (IAC) Valve
    572
  - Knock Sensor
    574
  - Fuel Pump Relay
    575
  - System Relay
    576
  - Engine Coolant Temperature
    577
  - (ECT) Sensor
    577
  - MX 6.2 MPI Models
    578
- Plenum, Throttle Body and Flame Arrestor
  579
- Intake Manifold and Fuel Rails
  580
- Flame Arrestor
  581
- Fuel Pressure Relief Procedure
  581
- MX 6.2 Black Scorpion Components
  581
- Throttle Body
  583
- Plenum
  587
- Fuel Rails
  589
- Fuel Injectors
  591
  - Manifold Absolute Pressure (MAP) Sensor
    592
- MAP Sensor
  592
  - Throttle Position (TP) Sensor
    593
  - Idle Air Control (IAC) Valve
    594
  - Knock Sensor
    596
  - Knock Sensor Module
    597
- Fuel Pump Relay
  598
- System Relay
  598
- Engine Coolant Temperature Sensor
  600
- MX 6.2 Black Scorpion Models
  601
  - Before Starting
    604
  - Diagnostic Trouble Codes
    632
  - Water Circulating Pump
    740
  - Coolant Specification
    751
  - Coolant Recommendations
    752
  - Pressure Cap Maintenance
    753
  - Heat Exchanger Repair
    754
  - Testing Coolant for Alkalinity
    755
  - Testing for Cylinder Head Gasket Leak
    756
  - Testing Heat Exchanger
    757
  - Testing Pressure Cap
    757
  - Changing Coolant
    762
  - Cleaning System
    763
  - Seawater Section
    763
  - Filling Closed Cooling Section
    765
  - MCM (Sterndrive) Engines with Thru-Transom Exhaust
    774
  - Exhaust Hose Connection
    776
  - MIE (Inboard) Engines
    776
- Exhaust Tube Requirements
  777
Exhaust System

780
- Disassembly
  781
- Lubricants / Sealants / Adhesives
  781
- Torque Specifications
  781
- Installation
  784
  - Gaskets
    784
  - Manifold
    785
  - Bullhorn Exhaust
    790
    
    Shutter Replacement
    790
    
    Component Replacement
    791
  - Thru-Transom Exhaust
    792
    
    Shutter Replacement
    792
    
    Component Replacement
    793
    
    Maintenance Instructions
    802
  - Specifications
    805
    
    Identification
    805
    
    Ratio
    805
    
    Fluid Specifications
    806
    
    Draining Transmission
    810
    
    Filling Transmission
    812
  - Removal
    813
  - Installation
    813
  - Shift Lever Installation
    815
  - Pressure Test
    816
  - Transmission Repair
    816
  - Pump Pulley Replacement
    884

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