Mercury MerCruiser Engines Service Manual Number 24 GM V-8 305 CID 350 CID, 1998,1999,2000,2001

User and Operator’s Vehicle Manual for 1998, 1999, 2000 and 2001 Mercury MerCrusier Marine Engines Number 24 GM V-8 305 CID 350 CID Engine Types:

• Mercury MerCrusier 305 CID (5.0L)
• Mercury MerCrusier 350 CID (5.7L)

Free MerCruiser service manual PDF Manual Download.

Contents

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

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

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