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MAIN MENUSERVICE.MANUAL.Number 24.MARINE ENGINES.GM V-8.305 CID (5.0L) / 350 CID (5.7L)Printed in U.S.A. 1999, Mercury Marine90-861327--1 1099.90-861327--1MerCruiser #24 GM V-8.305 CID (5.0L) / 350 CID (5.7L)90-861327--190-iMerCruiser #24 GM V-8.305 CID (5.0L) / 350 CID (5.7L).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 hereinIt 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 suppliersWe 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 selectedAll 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 productsIt 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 batteryAny 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 1999Page i.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
