Engine Mechanical

Engine
Section 3A - Engine Mechanical
Table of Contents

3
Engine Block Codes...........................................................3A-4 Intake Manifold for Scorpion Models................................3A-36
General Specifications....................................................... 3A-4 Intake Manifold Exploded View.................................3A-36
Engine Specifications.........................................................3A-4 Removal....................................................................3A-38
Cylinder Head............................................................. 3A-4
Cylinder Bore.............................................................. 3A-5
Cleaning and Inspection, Intake Manifold.................3A-39
Cleaning and Inspection, Plenum............................. 3A-39
A
Piston..........................................................................3A-5 Installation.................................................................3A-39
Piston Rings................................................................3A-5 Hydraulic Valve Lifters..................................................... 3A-42
Piston Pin....................................................................3A-6 Removal....................................................................3A-42
Crankshaft.................................................................. 3A-6 Cleaning....................................................................3A-43
Connecting Rod Bore (Crankshaft End)..................... 3A-7 Inspection................................................................. 3A-43
Valve Train..................................................................3A-7 Installation.................................................................3A-44
Camshaft.................................................................... 3A-8 Cylinder Head.................................................................. 3A-44
Oil Pump..................................................................... 3A-9 Removal....................................................................3A-44
Timing Chain...............................................................3A-9 Cylinder Head Cleaning............................................3A-45
Flywheel......................................................................3A-9 Cylinder Head Inspection..........................................3A-45
Tools.................................................................................. 3A-9 Cylinder Head Installation.........................................3A-46
SPX Corporation (Kent‑Moore)...................................3A-9 Cylinder Head Reconditioning......................................... 3A-47
Precautions...................................................................... 3A-10 Cylinder Head Disassembly......................................3A-47
Torque Specifications...................................................... 3A-11 Cleaning Valve Components.................................... 3A-48
External Engine Components................................... 3A-11 Valve Inspection....................................................... 3A-48
Engine Components................................................. 3A-11 Valve Stem to Bore Clearance................................. 3A-49
General Information......................................................... 3A-13 Valve Springs............................................................3A-50
Repair Guidelines..................................................... 3A-13 Valve Reconditioning................................................ 3A-50
Engine Rotation........................................................ 3A-13 Oversize Valve Installation....................................... 3A-51
Crankcase Oil Dipstick Measurements.....................3A-14 Valve Seat Reconditioning........................................3A-51
Gasoline Engine Compression Test................................ 3A-14 Rocker Arm Stud Replacement................................ 3A-52
Compression Gauge Testing.................................... 3A-14 Cylinder Head Reassembly...................................... 3A-54
Leak‑Down Testing...................................................3A-15 Flywheel Housing.............................................................3A-56
Engine Mounts................................................................. 3A-15 Removal....................................................................3A-56
Sterndrive Engine Mounts........................................ 3A-15 Cleaning....................................................................3A-57
Inboard and Tow Sports Engine Mounts.................. 3A-16 Inspection................................................................. 3A-57
Rocker Arm Cover........................................................... 3A-16 Installation.................................................................3A-57
Removal....................................................................3A-16 Flywheel...........................................................................3A-58
Cleaning and Inspection........................................... 3A-17 Removal....................................................................3A-58
Installation.................................................................3A-17 Cleaning and Inspection........................................... 3A-58
Rocker Arms and Valve Pushrods................................... 3A-17 Installation.................................................................3A-58
Removal....................................................................3A-17 Rear Oil Seal....................................................................3A-60
Cleaning....................................................................3A-18 Removal....................................................................3A-60
Inspection................................................................. 3A-18 Cleaning and Inspection........................................... 3A-60
Installation.................................................................3A-18 Installation.................................................................3A-60
Valve Springs...................................................................3A-19 Oil Pan............................................................................. 3A-61
Valve Spring Assembly Exploded View.................... 3A-19 Removal....................................................................3A-61
Valve Spring Assembly Removal..............................3A-19 Cleaning....................................................................3A-62
Valve Spring Assembly Installation...........................3A-20 Inspection................................................................. 3A-62
Finding Top Dead Center (TDC)......................................3A-23 Installation.................................................................3A-62
Method 1...................................................................3A-23 Oil Pump.......................................................................... 3A-66
Method 2...................................................................3A-24 Exploded View.......................................................... 3A-66
Valve Adjustment............................................................. 3A-24 Removal....................................................................3A-66
Intake Manifold Except Scorpion Models.........................3A-26 Disassembly............................................................. 3A-67
Intake Manifold Exploded View.................................3A-26 Cleaning....................................................................3A-67
Intake Manifold Removal.......................................... 3A-28 Inspection................................................................. 3A-67
Intake Manifold Disassembly.................................... 3A-29 Reassembly.............................................................. 3A-68
Cleaning and Inspection........................................... 3A-31 Installation.................................................................3A-69
Intake Manifold Assembly.........................................3A-31 Crankshaft Balancer........................................................ 3A-70
Intake Manifold Installation....................................... 3A-33 Removal....................................................................3A-70

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Engine Mechanical
Cleaning..................................................................... 3A-70 Connecting Rod Bearing Clearance, Plastic Gauge
Inspection...................................................................3A-71 Method....................................................................3A-88
Installation.................................................................. 3A-71 Connecting Rod Side Clearance................................ 3A-89
Front Cover Oil Seal (without Removing the Front Cover) Piston Inspection........................................................ 3A-90
.......................................................................................3A-72 Piston Pin Inspection..................................................3A-94
Removal..................................................................... 3A-72 Piston Ring Gap Inspection........................................3A-95
Installation.................................................................. 3A-72 Assembly....................................................................3A-96
Front Engine Cover........................................................... 3A-73 Installation.................................................................. 3A-97
Removal..................................................................... 3A-73 Crankshaft, Main Bearings, and Engine Block................ 3A-100
Cleaning and Inspection.............................................3A-74 Removal................................................................... 3A-100
Installation.................................................................. 3A-74 Cleaning................................................................... 3A-103
Timing Chain and Sprockets............................................. 3A-75 Crankshaft Inspection.............................................. 3A-104
Removal..................................................................... 3A-75 Main Bearing Inspection...........................................3A-105
Cleaning..................................................................... 3A-76 Main Bearing Tension.............................................. 3A-106
Inspection................................................................... 3A-76 Main Bearing Clearance, Plastic Gauge Method..... 3A-106
Assembly....................................................................3A-77 Crankshaft End Play................................................ 3A-108
Checking Timing Chain Deflection............................. 3A-77 Engine Block Inspection........................................... 3A-109
Installation.................................................................. 3A-77 Cylinder Reconditioning........................................... 3A-111
Camshaft........................................................................... 3A-78 Cylinder Boring.........................................................3A-111
Camshaft Bearing Service......................................... 3A-78 Cylinder Honing........................................................3A-111
Measuring Camshaft Lobe Lift................................... 3A-78 Piston Selection....................................................... 3A-111
Camshaft Removal.....................................................3A-78 Engine Block Plug Installation.................................. 3A-112
Camshaft Cleaning.....................................................3A-79 Main Bearing Replacement without Crankshaft
Camshaft Inspection.................................................. 3A-79 Removal................................................................3A-114
Camshaft Installation..................................................3A-80 Main Bearing and Crankshaft Replacement............ 3A-116
Camshaft Bearings............................................................ 3A-81 Rear Oil Seal Retainer.................................................... 3A-118
Camshaft Bearing Service......................................... 3A-81 Removal................................................................... 3A-118
Camshaft Bearing Removal....................................... 3A-81 Cleaning................................................................... 3A-119
Camshaft Bearing Inspection..................................... 3A-81 Inspection................................................................. 3A-119
Camshaft Bearing Installation.................................... 3A-82 Installation................................................................ 3A-119
Connecting Rod, Bearings, and Piston Assembly............. 3A-84 Oil Filter, Bypass Valve, and Block Adapter.................... 3A-120
Exploded View........................................................... 3A-84 Oil Filter Block Adapter.............................................3A-120
Removal..................................................................... 3A-84 Remote Oil Filter, Front Bracket Applications.......... 3A-121
Disassembly............................................................... 3A-85 Remote Oil Filter, Front Lifting Eye Applications......3A-122
Cleaning..................................................................... 3A-86 Remote Oil Filter Adapter Removal......................... 3A-122
Preliminary Inspection................................................ 3A-86 Cleaning................................................................... 3A-123
Connecting Rod Bearing Clearance, Micrometer Inspection.................................................................3A-123
Method....................................................................3A-86 Remote Oil Filter Adapter Installation...................... 3A-123

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Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
80W Gear Lube Rocker arm studs Obtain Locally
Needle Bearing Assembly
4 Valve stem locks 92-802868Q1
Lubricant
Cylinder head bolt threads
Pickup screen and pipe assembly
Loctite 567 PST Pipe
9 Camshaft rear bearing hole expansion plug 92-809822
Sealant
Oil gallery plug
Coolant drain plug
19 Perfect Seal Intake water passages 92-34227Q02
Upper intake manifold screws
Fuel rail screws
Throttle body studs
Intake manifold screws
66 Loctite 242 Threadlocker 92-809821
Camshaft thrust plate retaining bolts
Engine block expansion plug
Camshaft rear bearing hole expansion plug
Oil gallery plugs and oil pressure sender
82 Premium Gear Lubricant Rocker arm stud 92-858058K01

Engine block
End of the intake manifold gasket
Loctite 5900 Ultra Black
128 Oil pan gasket joints 92-809826
RTV Silicone Sealant
Crankshaft balancer keyway
Crankshaft front cover mating surface
Pushrod surfaces
Rocker arm and pivot
136 Lubriplate SPO 255 Camshaft lobes and valve lifters Obtain Locally
Valve lifters
Camshaft lobes
Valve stem bore and oil seal
Valve pushrods and rocker arm assemblies
Valve stem
Seal-to-retainer mating surfaces, seal lip, flywheel pilot flange,
flywheel locating pin
Crankcase
Oil pump components
Oil pump gears and shafts
Seal surface of the crankshaft balancer
Mercury MerCruiser Full- Rubber sealing surface
Synthetic Engine Oil Front cover crankshaft seal
154 92-858087K01
20W-40, NMMA FC-W Camshaft journals
rated Outer surface of the camshaft bearings
Cylinder walls
Connecting rod bearings, pistons, rings, and cylinder walls
Connecting rod and rod cap
Cylinder bores and other machined surfaces
Main bearing
Main and crankshaft bearing journals
Connecting rod bearings
Oil filter adapter seal
Quad ring seal

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Engine Mechanical

Special Tools
Piston Ring Expander 91‑24697

Expands piston rings for removal and installation.

6255

Engine Block Codes

The Mercury MerCruiser model can be determined by looking at the last letters of the engine code stamped into the engine
block at the time of assembly. If the engine serial number or model decals are missing, the engine code will help to determine
the engine model. The location of the engine code stamp is shown below.

50254

Engine code stamp (small block)

Refer to the latest engine block code service bulletin for current engine block code lists.

General Specifications
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Bore 94.89 mm (3.735 in.) 101.6 mm (4.00 in.) 101.6 mm (4.00 in.)
Stroke 88.39 mm (3.480 in.) 88.39 mm (3.480 in.) 95.25 mm (3.750in.)
Firing order 1‑8‑4‑3‑6‑5‑7‑2
Compression ratio 9.4:1 9.0:1
Heads Cast iron
Block Cast iron (two bolt main bearing caps)
Rods Powder metal
Crankshaft Cast iron Forged steel
Pistons Cast aluminum
Camshaft Steel Steel billet
Upper intake manifold Aluminum Cast aluminum Aluminum
Lower intake manifold Cast iron
Intake manifold, Scorpion n/a Cast aluminum

Engine Specifications
Cylinder Head
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Surface flatness, exhaust manifold deck 0.05 mm (0.0020 in.)

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 Engine Mechanical

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Surface flatness, cylinder head deck 0.10 mm (0.0039 in.)
Surface flatness, intake manifold deck 0.10 mm (0.0039 in.)

Cylinder Bore
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
94.894–94.947 mm
Diameter 101.618–101.643 mm (4.0007–4.0017 in.)
(3.7360–3.7381 in.)
Production 0.025 mm (0.0010 in.) maximum
Out‑of‑round
Service 0.05 mm (0.0020 in.) maximum
Production, thrust side 0.012 mm (0.0005 in.) maximum
Taper Production, relief side 0.025 mm (0.0010 in.) maximum
Service limit 0.025 mm (0.0010 in.) over production

Piston
Piston Diameter
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
94.894–94.947 mm
Piston diameter 101.618–101.643 mm (4.0007–4.0017 in.)
(3.7360–3.73881 in.)

Piston‑to‑Bore Clearance
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.018–0.061 mm 0.018–0.053 mm 0.018–0.053 mm
Production
(0.0007–0.0024 in.) (0.0007–0.0021 in.) (0.0007–0.0021 in.)
0.018–0.068 mm 0.018–0.061 mm 0.018–0.068 mm
Service
(0.0007–0.0027 in.) (0.0007–0.0024 in.) (0.0007–0.0027 in.)

Piston Rings
Top Compression Ring
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Production 0.030–0.070 mm (0.0012–0.0028 in.)
Groove clearance
Service 0.030–0.090 mm (0.0012–0.0035 in.)
0.25–0.51 mm 0.25–0.40 mm 0.25–0.51 mm
Production
(0.0098–0.0201 in.) (0.0098–0.0157 in.) (0.0098–0.0201 in.)
Gap
0.25–0.65 mm 0.25–0.50 mm 0.30–0.68 mm
Service
(0.0098–0.0259 in.) (0.0098–0.0197 in.) (0.0118–0.0268 in.)

Second Compression Ring

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.030–0.074 mm 0.038–0.080 mm 0.0408–0.080 mm
Production
(0.0012–0.0029 in.) (0.0015–0.0031 in.) (0.0015–0.0030 in.)
Groove clearance
0.030–0.090 mm 0.040–0.100 mm 0.040–0.100 mm
Service
(0.0012–0.0035 in.) (0.0016–0.0039 in.) (0.0015–0.0040 in.)
0.46–0.66 mm 0.038–0.058 mm 0.46–0.66 mm
Production
(0.0181–0.0298 in.) (0.0015–0.0023 in.) (0.0181–0.0260 in.)
Gap
0.46–0.90 mm 0.046–0.080 mm 0.51–0.94 mm
Service
(0.0181–0.0354 in.) (0.0181–0.0315 in.) (0.0201–0.0370 in.)

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Engine Mechanical

Oil Control Ring

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.051–0.203 mm 0.046–0.096 mm 0.051–0.170 mm
Production
(0.0020–0.0080 in.) (0.0018–0.0038 in.) (0.0020–0.0067 in.)
Groove clearance
0.051–0.220 mm 0.046–0.100 mm 0.051–0.195 mm
Service
(0.0020–0.0090 in.) (0.0018–0.0039 in.) (0.0020–0.0076 in.)
Production 0.25–0.76 mm (0.0098–0.0299 in.)
Gap 0.25–0.89 mm 0.25–0.90 mm 0.28–0.81 mm
Service
(0.0098–0.0350 in.) (0.0098–0.0354 in.) (0.0110–0.0319 in.)

Piston Pin
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
23.559–23.561 mm
Diameter 23.545–23.548 mm (0.9270–0.9271 in.)
(0.9275–0.9276 in.)
0.010–0.020 mm
Production 0.013–0.023 mm (0.0005–0.0009 in.)
Clearance (0.0004–0.0008 in.)
Service 0.013–0.025 mm (0.0005–0.0010 in.)
0.021–0.040 mm
Connecting rod fit (interference) 0.012–0.050 mm (0.0005–0.0019 in.)
(0.0008–0.0016 in.)

Crankshaft
Main Bearing Journal
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Number 1 62.189–62.212 mm (2.4484–2.4493 in.)
62.182–62.207 mm
Number 2, 3, and 4 62.189–62.212 mm (2.4484–2.4493 in.)
Diameter (2.4481–2.4491 in.)
62.182–62.212 mm
Number 5 62.185–62.207 mm (2.4479–2.4491 in.)
(2.4481–2.4493 in.)
Production 0.005 mm (0.0002 in.) maximum
Taper
Service 0.025 mm (0.0010 in.) maximum
Production 0.005 mm (0.0002 in.) maximum
Out‑of‑round
Service 0.025 mm (0.0010 in.) maximum

Main Bearing Clearance

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Number 1 0.018–0.053 mm (0.0007–0.0021 in.)
0.022–0.061 mm
Number 2, 3, and 4 0.030–0.068 mm (0.0012–0.0027 in.)
Production (0.0009–0.0024 in.)
0.025–0.069 mm
Number 5 0.020–0.060 mm (0.0008–0.0024 in.)
(0.0010–0.0027 in.)
Number 1 0.025–0.051 mm (0.0010–0.0020 in.)
Number 2, 3, and 4 0.025–0.064 mm (0.0010–0.0025 in.)
Service
0.038–0.076 mm
Number 5 0.038–0.064 mm (0.0015–0.0025 in.)
(0.0015–0.0030 in.)

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 Engine Mechanical

Connecting Rod Journal

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Diameter 53.284–53.335 mm (2.0978–2.0998 in.)
Production 0.007 mm (0.0003 in.) maximum
Taper
Service 0.025 mm (0.0010 in.) maximum
Production 0.007 mm (0.0003 in.) maximum
Out‑of‑round
Service 0.025 mm (0.0010 in.) maximum

Connecting Rod Bearing

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.033–0.088 mm
Production 0.033–0.078 mm (0.0013–0.0031 in.)
(0.0013–0.0035 in.)
Rod bearing clearance
0.025–0.076 mm
Service 0.025–0.063 mm (0.0010–0.0025 in.)
(0.0010–0.0030 in.)
0.15–0.68 mm
Rod side clearance 0.15–0.61 mm (0.006–0.024 in.)
(0.006–0.027 in.)

Crankshaft
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Runout 0.038 mm (0.0015 in.)
End play (thrust clearance) 0.05–0.20 mm (0.0020–0.0079 in.)

Connecting Rod Bore (Crankshaft End)

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Diameter 56.505–56.533 mm (2.2246–2.2257 in.)
Production 0.007 mm (0.0003 in.)
Taper
Service 0.025 mm (0.0010 in.)
Production 0.007 mm (0.0003 in.)
Out of round
Service 0.025 mm (0.0010 in.)

Valve Train
Valve
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Clearance (valve lash) Rotate the rocker arm nut clockwise 360° (1 turn) from zero clearance.

Lifter
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Type Hydraulic roller
Rocker arm ratio 1.50 : 1.00

Valve Head and Stem

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Intake 46.74 mm (1.84 in.) 49.28 mm (1.94 in.)
Valve diameter
Exhaust 38.10 mm (1.50 in.)

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Engine Mechanical

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Intake
Face angle 45°
Exhaust
Intake 0.79 mm (0.0311 in.)
Margin after surfacing
Exhaust 1.524–2.032 mm (0.0600–0.0800 in.)
Intake
Stem diameter 8.661–8.679 mm (0.3410–0.3417 in.) 8.66 mm (0.341 in.)
Exhaust
Oversize stem diameter Exhaust only + 0.774 mm (+ 0.0305 in.)
1.0–2.0 mm (0.0394–0.0787 in.)
Valve stem oil seal Installed height
(measured from the valve guide boss to the bottom of the valve stem oil seal)

Valve Stem Clearance

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Intake 0.025–0.069 mm (0.0010–0.0027 in.)
Production
Exhaust 0.025–0.069 mm (0.0010–0.0027 in.)
Intake 0.025–0.094 mm (0.0010–0.0037 in.)
Service
Exhaust 0.025–0.094 mm (0.0010–0.0037 in.)

Valve Seat
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Seat angle 46°
Intake and
Top correction cut angle 30°
exhaust
Bottom correction cut angle 60°
1.14–1.78 mm 1.02–1.65 mm 1.02–1.65 mm
Intake
(0.0449–0.0980 in.) (0.040–0.065 in.) (0.040–0.065 in.)
Width
1.65–2.49 mm 1.50–2.56 mm 1.50–2.56 mm
Exhaust
(0.0650–0.0980 in.) (0.059–0.101 in.) (0.059–0.101 in.)
Intake and 0.05 mm (0.002 in.)
Runout 0.05 mm (0.002 in.) maximum
exhaust maximum

Valve Spring
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Free length 51.3 mm (2.02 in.)
Valve closed 338–374 N at 43.2 mm (76–84 lb at 1.7008 in.)
Pressure
Valve open 832–903 N at 32.3 mm (187–203 lb at 1.2717 in.)
Intake
Installed height 42.92–43.43 mm (1.6898–1.7098 in.)
Exhaust
Approximate coil count 4

Camshaft
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Journal diameter 47.440–47.490 mm (1.8677–1.8697 in.)
Journal out‑of‑round 0.025 mm (0.0010 in.) maximum
Runout 0.065 mm (0.0026 in.) maximum

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 Engine Mechanical

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
6.97–7.07 mm 7.57–7.67 mm 7.52–7.72 mm
Intake
(0.2744–0.2783 in.) (0.298–0.302 in.) (0.296–0.304 in.)
Cam lift
7.20–7.30 mm 7.82–7.92 mm 7.77–7.98 mm
Exhaust
(0.2834–0.2874 in.) (0.308–0.312 in.) (0.306–0.314 in.)

Oil Pump
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Dowel height 6.44 mm (0.2520 in.)

Oil Pressure
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
At 2000 RPM 124 kPa (18 psi)
Minimum oil pressure
At idle 41 kPa (6 psi)

Timing Chain
Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Chain deflection 11 mm (0.4331 in.) maximum

Flywheel
Flywheel 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Runout 0.203 mm (0.0080 in.) maximum

Tools
SPX Corporation (Kent‑Moore)
The tools listed below are some of those available from SPX Corporation. Equivalent tools may be available from other tool
manufacturers. Regardless of supplier, always use the correct tool for the task at hand.
IMPORTANT: Part numbers are subject to change. Verify the correct tool part number with SPX Corporation.
SPX Corporation, Kent-Moore
28635 Mound Road
Warren, MI 48092-3499
1-800-345-2233
gmspecialservicetools.spx.com

Description Part Number

Valve spring compressor (cylinder head on the engine) J‑5892‑D
Valve spring compressor (cylinder head off the engine) J‑8062
Valve spring compressor (for testing) J‑9666
Valve guide cleaner J‑8101
Valve stem seal installer J‑42073
Rocker arm stud remover J‑5715
Rocker arm stud installer J‑6880
Stud reamer (0.382 in.) J‑6036
Carbon removing brush J‑8089
Piston pin service set J‑24086‑C
Piston ring groove cleaner J‑3936‑O3
Piston ring compressor J‑8037

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Engine Mechanical

Description Part Number

Bolt guide set J‑5239
Oil suction pipe installer J‑21882
Cam bearing remover and installer J‑6098‑O1
Cam bearing remover and installer adapter J‑6098‑10
Harmonic balancer remover and installer J‑23523‑F
Front cover seal installer J‑35468
Crankshaft gear puller J‑5825‑A
Spark plug port adapter J‑23590
Main bearing shell remover J‑8080
Rear main seal installer J‑35621‑B
Fuel line disconnect tool J‑44581
Cylinder hone (kit) J‑5902‑O1

Precautions
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.

! CAUTION
Using compressed air can cause serious injury. Always wear eye protection when working with compressed air to prevent
injury from ruptured hoses or flying debris.

NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.

NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.

IMPORTANT: Lubricate all moving engine components with clean engine oil or other specified lubricant during assembly.

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 Engine Mechanical

Torque Specifications
External Engine Components
Description Nm lb–in. lb–ft
Alternator brace to alternator bolt 28 21
Alternator brace to engine bolt 41 30
Alternator to mounting bracket bolt 48 35
Alternator mounting bracket bolt 41 30
Block adapter fitting or bushing 31 23
By‑pass valve block adapter bolt 27 20
Coupler to flywheel bolts (MCM) 48 35
Crankshaft position sensor bolt 9 80
Distributor cap screw 2.5 21
Distributor hold down clamp bolt 25 18
Drive plate to flywheel bolts (MIE) 48 35
Engine coolant temperature (ECT) sensor 20 15
Engine mount, front bracket 41 30
Engine mount, rear (MCM and MIE) 51 38
Fuel rail bracket bolt 6 53
Ignition coil bolt 12 106
Knock sensor 20 15
MAPT sensor bolt 12 106
Oil pressure switch fitting 15 132
Seawater pump bracket 41 30
New installation 30 22
Spark plug
All subsequent installations 15 132
Starter motor bolt 41 30
Nut 10 88
Throttle body fasteners
Stud 9 80
Transmission to flywheel housing 68 50
Water temperature sender 27 20

Engine Components
Description Nm lb–in. lb–ft
Camshaft thrust plate retainer bolt 12 106
Camshaft sprocket bolt 25 18
First pass 27 20
Connecting rod nut ‑ 5.0 L (305 cid) and 5.7 L (350 cid)
Final pass (angle torque) + 70°
First pass 27 20
Connecting rod nut ‑ 6.2 L (377 cid)
Final pass (angle torque) + 45°

90-879288300 AUGUST 2012 Page 3A-11

Engine Mechanical

Description Nm lb–in. lb–ft

First pass 20 15
2 bolt cap
Final pass (angle torque) + 73°
Crankshaft main bearing First pass, all 20 15
cap bolt and stud
Final pass, outboard bolt
(preferred method) + 43°
4 bolt cap (angle torque)
Final pass, inboard bolt
+ 73°
and stud (angle torque)
One pass—all bolts evenly
2 bolt cap 105 77
tightened
Crankshaft main bearing
Outboard, one pass—all
cap bolt and stud (optional 90 66
bolts evenly tightened
method) 4 bolt cap
Inboard, one pass—all
105 77
bolts evenly tightened
Crankshaft balancer bolt 95 70
Crankshaft oil deflector nut 41 30
Crankshaft pulley bolt 58 43
Long bolts 33 22
First pass in sequence Medium bolts 33 22

Cylinder head bolt Short bolts 33 22

(preferred method) Long bolts + 75°
Final pass (angle torque)
Medium bolts + 65°
in sequence
Short bolts + 55°
First pass 35 26
Cylinder head bolt All bolts in sequence:
Second pass 60 44
(optional method) long, medium, then short
Final pass 90 66
Engine flywheel bolt 100 74
Exhaust manifold cap screws 47 35
Flywheel housing studs and bolts 41 30
Flywheel housing cover 9 80
Front cover bolt 12 106
First pass 3 26.5
Intake manifold bolt Second pass 12 106
Final pass 25 18
Oil filter adapter (5/16 in.‑18) 27 20
Oil filter adapter bolt 25 18
Oil gallery plug 20 15
Oil lines 27 20
Oil pan bolt or nut 12 106
Oil pan stud (front) 6 53
Oil pan stud nut 25 18
Oil pan fitting hollow bolt 20 15
Oil pan drain plug 25 18
First pass 20 15
Oil pump bolt (to bearing cap)
Final pass (angle torque) + 65°

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 Engine Mechanical

Description Nm lb–in. lb–ft

Oil pump cover bolt 12 106
Rear main (crankshaft) oil seal retainer 12 106
Rear oil seal retainer nut and bolt 12 106
Rear oil seal retainer stud 6 53
Remote oil connector 34 25
Remote oil filter adapter fitting 27 20
Rocker arm cover bolt 12 106
Thermostat housing bolt 41 30
Valve lifter guide retainer bolt 25 18
Water circulating pump bolt 45 33
Water pump pulley bolt 25 18

General Information
Repair Guidelines
• Follow all warning, cautions, and notices contained in this manual.
• Disconnect the battery prior to performing any repair procedures.
• Boat design factors and the nature of particular repairs may require that the engine be removed from the boat. Place the
engine on a repair stand for major repairs.
• Lubricate all moving parts during assembly with clean engine oil or as specified. Apply appropriate lubricant, sealant, or
adhesive to all fasteners as specified.
IMPORTANT: To facilitate service or repair, some external components that are not mentioned in this section's procedural
steps must be removed. Refer to the appropriate sections of this manual for service information concerning any external
component that interferes with engine service or repair.

Engine Rotation
Engine rotation is observed from the rear of the engine (transmission or sterndrive end) looking forward (water pump end).
Engine rotation is not necessarily the same as propeller rotation .
IMPORTANT: All engines covered by this service manual are left‑hand (LH) rotation.

12710

Left-hand rotation (counter clockwise)

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Engine Mechanical

Crankcase Oil Dipstick Measurements

IMPORTANT: Crankcase dipsticks from different applications are not interchangeable.

c a - Length "A"
b - Length "B"
b c - Length "C"

49885

Part number Length "A" Length "B" Length "C" Model

861942‑2 19 mm (3/4 in.) 330 mm (13 in.) 396 mm (15‑½ in.) Inboard engines
861942‑3 13 mm (1/2 in.) 349 mm (14 in.) 396 mm (15‑½ in.) Inboard engines with remote drive transmissions
861942‑7 19 mm (3/4 in.) 787 mm (31 in.) 845 mm (33‑¼ in.) Sterndrive service and tow sports engines
861942‑9 13 mm (1/2 in.) 851 mm (33‑½ in.) 895 mm (35‑¼ in.) All OEM sterndrive engines

Gasoline Engine Compression Test

Compression Gauge Testing
IMPORTANT: Use a fully charged battery during this testing procedure.
IMPORTANT: Compression test failures generally indicate a serious engine malfunction has occurred. The engine should be
repaired prior to being returned to service.
IMPORTANT: Follow the instructions provided by the compression test gauge manufacturer. Use the correct threaded adapter.
1. With the engine cold, verify that the battery is fully charged.
IMPORTANT: Ground the ignition coil to distributor cap wire directly to engine ground to prevent spark from the
disconnected spark plug wires. A remote starting tool may energize the ignition coil through the "R" terminal of the starter
solenoid even though the key and lanyard stop switches are in the off position.
2. Ground the ignition coil to distributor cap wire directly to engine ground or otherwise disable the ignition system.
3. Remove all of the spark plugs.
IMPORTANT: Cranking the engine with fuel but no spark can result in damage to the catalyst.
4. Disconnect the fuel injector fuse or otherwise disable the fuel injection system.
5. Temporarily stop the throttle lever in the WOT position to hold the throttle plate completely open.
6. Install the compression gauge to the cylinder being tested.
7. Zero the compression gauge.
8. Crank the engine, cycling the test cylinder through four compression strokes.
9. Repeat the compression test for each cylinder, being certain to record the results.
Compression Test Diagnosis

Minimum compression 690 kPa (100 psi)

Compression difference
70%
(The lowest compression cylinder should be no less than 70% of the highest compression cylinder.)

NOTE: Example:If the highest compression cylinder has 1035 kPa (150 psi) of compression, the lowest allowable
pressure for any other cylinder would be 725 kPa (105 psi). [1035 × 70% = 725 kPa (150 × 70% = 105 psi)]
10. The interpretation of low cylinder compression test results can be aided by injecting three squirts of oil from a pump‑style
oil can into the test cylinder combustion chamber and rechecking compression.

Compression test result Oil injection retest result Diagnosis

Compression is low on the first stroke, increases on
Compression improves
the following strokes, but does not reach normal Piston rings are leaking.
significantly.
compression.

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 Engine Mechanical

Compression test result Oil injection retest result Diagnosis

Valves are leaking. Proceed to
Compression is low throughout the test cycle. No change.
Leak‑Down Testing.
Head gasket is leaking. Proceed to
Two adjacent cylinders have low compression. No change.
Leak‑Down Testing.

Leak‑Down Testing
Additional diagnosis of low compression cylinders can be performed using pressurized air to identify the source of combustion
chamber leaks.
1. Rotate the engine by hand until the number 1 cylinder is at top dead center (TDC) of the compression stroke.
2. Identify and note the engine firing order.
3. Rotate the crankshaft 90° to position the next cylinder in the firing order at TDC. Repeat until the first targeted test cylinder
is positioned at TDC.
NOTE: Example with a firing order of 1‑8‑4‑3‑6‑5‑7‑2: To test cylinder number 3, rotate the engine an additional 270° (3 ×
90°) to position the fourth cylinder of the firing order, cylinder number 3, at TDC of its compression stroke. To continue the
test and check cylinder number 6, rotate the engine an additional 90°.
4. Thread the air supply adapter into the spark plug hole.
IMPORTANT: The air supply must be regulated to provide 138–206 kPa (20–30 psi) of air pressure. Use the appropriate
compression‑gauge style threaded adapter to introduce the pressurized air into the test cylinder.
IMPORTANT: Do not rotate the engine by turning the crankshaft balancer bolt.
5. Hold the crankshaft balancer bolt with a large wrench to prevent the crankshaft from rotating when applying air pressure to
the cylinder.
IMPORTANT: The engine will try to rotate when air pressure is applied. Maintain a firm grip on the wrench to prevent
unexpected motion.
6. Apply 138–206 kPa (20–30 psi) of air pressure through the adapter hose into the cylinder to be tested. Keep the crankshaft
from rotating.
7. Test result interpretation:

Possible Cause Test Result

Leaking intake valve Air is heard leaking up through the intake manifold at the throttle body.
Leaking exhaust valve Air is heard leaking into the exhaust system.
A high volume of air leaks into the test cylinder's rocker arm cover and can be felt flowing
Leaking piston or piston rings
out of the oil fill or breather cap. (Low volume air bleed past the rings is normal.)

Engine Mounts
Sterndrive Engine Mounts
Front Mounts

29786

All sterndrive models

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Engine Mechanical

Rear Mounts
NOTE: White or yellow paint is used to identify the top of the mount assembly. The bottom has a knurled edge.

a Typical flywheel housing, all similar

a - Painted end (not visible)
b - Mount bottom
b
c - Knurled edge

16836
c

Inboard and Tow Sports Engine Mounts

48859

Front mount assembly, all inboard (MIE) and tow sports models

29790 29789

Rear mount assembly, most inboard and tow sports Typical rear mount assembly, inboard and tow sports
models models with Velvet Drive in-line transmission

Rocker Arm Cover

Removal
NOTE: For some applications it may be necessary to remove the exhaust manifold before removing a rocker arm cover.
For exhaust manifold removal, refer to Section 7B ‑ Manifolds and Elbows.
1. Disconnect the crankcase ventilation hoses.

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 Engine Mechanical
2. Remove any items that interfere with the removal of the rocker arm covers.
3. Remove the rocker arm covers.

Cleaning and Inspection

1. Remove any gasket material on the cylinder head and rocker arm cover sealing surfaces.
2. Clean all the sealing surfaces with degreaser.

Installation
1. Place a new rocker arm cover gasket in position.

a a - Gasket
b - Rocker arm cover

29791

2. Install the rocker arm cover. Tighten the bolts to specification.

Description Nm lb‑in. lb‑ft

Rocker arm cover bolt 12 106 –
3. Install any items that were removed.
4. Connect the crankcase ventilation hoses.
5. Supply cooling water to the power package.
6. Start the engine and check for oil leaks.

Rocker Arms and Valve Pushrods

Removal
NOTE: When servicing only one cylinder's rocker arms, bring that cylinder's piston up to TDC (top dead center) before
removing the rocker arms. When servicing all rocker arms, bring cylinder number 1 piston up to TDC before removing the
rocker arms.
1. Remove the rocker arm covers.
2. Remove the rocker arm assemblies and pushrods.

a- Pushrod
b- Rocker arm
d e c- Rocker arm pivot
d- Nut
c e- Stud

29792

NOTE: Organize and store the rocker arm assemblies and pushrods in sets for reassembly in their original locations.

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Engine Mechanical

Cleaning
1. Clean the rocker arm assemblies and pushrods with degreaser.
2. Clean the pushrod oil passages.
3. Dry the components with compressed air.

Inspection
1. Inspect all contact surfaces for excessive wear or scoring.
2. Inspect the pushrod oil passages for restrictions.
3. Roll the pushrods on a flat surface and inspect the shafts for bends.
4. Replace any damaged or excessively worn components.

Installation
1. Lubricate the outer surfaces and ends of the valve pushrods with Lubriplate SPO 255.

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Pushrod surfaces Obtain Locally
2. Install the valve pushrods in their original locations. Ensure that the valve pushrods seat in the lifter sockets.
3. Lubricate the contact surfaces of the rocker arm and the rocker arm pivot with Lubriplate SPO 255.

b a - Rocker arm
a b - Rocker arm pivot

51186

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Rocker arm and pivot Obtain Locally
4. Lubricate the threads of the rocker arm studs with 80W gear lube.

29796

Lube, rocker arm stud

Tube Ref No. Description Where Used Part No.

80W Gear Lube Rocker arm studs Obtain Locally

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 Engine Mechanical
5. Install the rocker arms, rocker arm pivots, and rocker arm nuts in their original locations.

a- Pushrod
b- Rocker Arm
d e c- Rocker arm pivot
d- Nut
c e- Stud

29792

6. Adjust the valve clearance, refer to Valve Adjustment.

7. Install the rocker arm covers and any other components removed during service.
8. Upon engine restart, check for oil leaks.

Valve Springs
Valve Spring Assembly Exploded View
e
a- Valve
b- Valve stem oil seal
d
c- Valve spring
c d- Valve spring cap
e- Valve spring lock
b
a
51187

Valve Spring Assembly Removal

1. Remove the rocker arm cover.
2. Remove the spark plug of the cylinder being serviced.
3. Remove the rocker arm assembly.
IMPORTANT: Keep air pressure in the cylinder while springs, caps, and valve locks are removed or the valves will fall into
the cylinder.
4. Install a spark plug port adapter in the spark plug hole and apply 138–206 kPa (20–30 psi) of compressed air to hold the
valves in place.

Description SPX Part Number

Spark Plug Port Adapter J‑23590

NOTE: If compressed air is not available, the piston may be brought up to TDC to keep the valves from falling out of the
cylinder head.

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Engine Mechanical
5. Insert a valve spring compressor under the rocker arm nut, compress the valve spring, and remove the valve locks.

29806

a - Rocker arm nut

b - Valve spring compressor
c - Valve locks

Description SPX Part Number

Valve Spring Compressor (cylinder head on engine) J‑5892‑D
6. Carefully release the valve spring compressor.
7. Remove the valve spring cap and valve spring.
IMPORTANT: If compressed air is not available, do not turn the crankshaft while valve springs, retainers, and locks are
removed or the valves will fall into the cylinder.
8. Remove and discard the valve stem oil seal.

29807

Typical valve stem oil seal

Valve Spring Assembly Installation

IMPORTANT: The intake valve stem oil seal is black. The exhaust valve stem oil seal material is either brown with a white paint
stripe on the outer diameter or it is red with no paint stripe. Also, the letters "EX" are molded into the top of the exhaust valve
stem oil seal.
1. Select the appropriate intake or exhaust valve stem oil seal.
2. Lightly lubricate the valve stem bore and the valve stem oil seal with clean engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Valve stem bore and oil seal 92-858087K01
20W-40, NMMA FC-W
rated
3. Install the valve stem oil seal onto the valve stem and push it down until it is seated against the cylinder head.

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 Engine Mechanical
4. Slide the valve stem seal installer over the valve stem and press the valve stem oil seal down until the tool contacts the
spring seat.

a - Valve stem oil seal

b b - Valve stem seal installer

29815

Description SPX Part Number

Valve stem seal installer J‑42073
5. Check for the correct valve stem oil seal installed height; it is the same for both the intake and exhaust valves. Measure the
space between the bottom edge of the valve stem oil seal and the top of the cylinder head valve guide boss.

c a - Top of valve guide boss

b
b - Bottom of valve stem oil seal
c - Installed height (gap)

29823

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve stem oil seal installed height 1.0–2.0 mm (0.0394–0.0787 in.)

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Engine Mechanical
6. Install the valve spring.

29806

a - Rocker arm nut

b - Valve spring compressor
c - Valve stem locks

7. Place the valve spring cap on valve spring.

a - Valve spring
b - Valve spring cap
c - Valve stem locks
b

c
a

29821

! CAUTION
Improperly compressed springs or improperly locked valve caps could allow the spring to be ejected with tremendous force,
which could cause personal injury. Use care when compressing the valve springs or releasing the valve spring compressor
tool.
8. Temporarily install the rocker arm nut onto the corresponding stud.
9. Coat the valve stem locks with needle bearing assembly lubricant to hold them in place.

Tube Ref No. Description Where Used Part No.

Needle Bearing Assembly
4 Valve stem locks 92-802868Q1
Lubricant

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 Engine Mechanical
10. Compress the valve spring with the valve spring compressor and install the valve stem locks.

29806

a - Rocker arm nut

b - Valve spring compressor
c - Valve stem locks

11. Ensure that the valve stem locks are seated properly in the groove of the valve stem.
12. Slowly release the valve spring compressor and remove the rocker arm nut.
13. Install the pushrods and rocker arm assemblies.
14. Remove the spark plug port adapter.
15. Adjust the valves. Refer to Valve Adjustment.
16. Install the rocker arm cover.
17. Install and tighten the spark plugs to specification.

Description Nm lb‑in. lb‑ft

Initial installation (new cylinder head) 30 22
Spark plug
All subsequent installations 15 11

Finding Top Dead Center (TDC)

IMPORTANT: Do not insert anything into a spark plug hole while turning the engine over.

49881

0° timing mark on crankshaft balancer

NOTE: Cylinder number 1 is the foremost cylinder on the left side of the engine, as observed from the rear of the engine.
Position cylinder number 1 at TDC by either of the following methods:

Method 1
1. Remove the cylinder number 1 spark plug.
2. Attach a suitable socket wrench to the crankshaft pulley nut.
3. Place a finger over the plug hole and turn the engine over in its normal rotation until compression is felt in the number 1
cylinder.
4. Continue turning the engine over by hand until the block‑mounted timing pointer aligns with the 0° timing mark on the
crankshaft pulley.

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Engine Mechanical

Method 2
1. Attach a suitable socket wrench to the crankshaft pulley nut.
2. Remove the left (as observed from the rear of the engine) rocker arm cover and turn the engine in its normal rotation until
the number 1 cylinder intake valve is fully closed.
3. Continue turning the engine over by hand until the block mounted timing pointer aligns with the 0° timing mark on the
crankshaft pulley.

Valve Adjustment
NOTE: Begin this procedure with cylinder number 1 in firing position at top dead center (TDC).
1. Remove both rocker arm covers.
2. With cylinder number 1 at TDC, adjust the following valves.

Description Cylinder Number

Adjust exhaust valves 1‑3‑4‑8
Number 1 cylinder at TDC
Adjust intake valves 1‑2‑5‑7
3. Adjust each valve indicated as follows:
a. Loosen the rocker arm nut until valve lash (vertical movement) is felt in the pushrod.
b. Tighten the rocker arm nut until all valve lash is removed. Zero valve lash can be felt by moving the valve pushrod up
and down between the thumb and forefinger until there is no more vertical movement of the pushrod.
c. Tighten the rocker arm nut one additional turn (360°). No other adjustment is required.

29830

Valve adjustment

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve lash adjustment Tighten the rocker arm nut clockwise 360° (1 turn) from zero clearance
4. Turn the engine over in its normal rotation 360° until the block mounted timing pointer aligns with the 0° timing mark on the
crankshaft pulley. This positions cylinder number 6 at TDC.
5. With cylinder number 6 at TDC, adjust the following valves.

Description Cylinder Number

Adjust exhaust valves 2‑5‑6‑7
Number 6 cylinder at TDC
Adjust intake valves 3‑4‑6‑8
6. Adjust each valve indicated as follows:
a. Loosen the rocker arm nut until valve lash (vertical movement) is felt in the pushrod.
b. Tighten the rocker arm nut until all valve lash is removed. Zero valve lash can be felt by moving the valve pushrod up
and down between the thumb and forefinger until there is no more vertical movement of the pushrod.

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 Engine Mechanical
c. Tighten the rocker arm nut one additional turn (360°). No other adjustment is required.

29830

Valve adjustment

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve lash adjustment Tighten the rocker arm nut clockwise 360° (1 turn) from zero clearance

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Engine Mechanical

Intake Manifold Except Scorpion Models

Intake Manifold Exploded View
25
20 19
18

13
11

10 12 14
16

21 21
11
15 22
21 8
17 26 9
7

23 2

1
3

24 22911

Page 3A-26 90-879288300 AUGUST 2012

 Engine Mechanical

Intake Manifold Exploded View

Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
1 1 Lower intake manifold
2 1 Brass plug
3 1 Lower intake manifold gasket set
First 3 26.5
4 8 Screw Second 12 106
Final 25 18
5 1 Upper intake manifold
6 1 Intake manifold gasket
First 5 44
7 13 Screw
Final 10 89
8 1 Manifold absolute pressure and air temperature (MAPT) sensor
9 2 Seal
10 1 Bracket
11 4 Screw 6 53
12 1 Fuel rail assembly
13 1 Fuel pressure regulator
14 1 Retaining clip
15 8 Fuel injector
16 1 Injector retainer
17 1 O‑ring kit
18 1 Fuel pressure service valve
19 1 Fuel pressure service valve cap
20 4 Screw
21 3 Hose
22 1 T‑fitting
23 1 Pipe plug (seawater cooling)
23 1 Connector barb (closed cooling)
24 1 EGR port plug
25 1 Fuel rail block‑off plug
26 1 90° vent fitting

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Engine Mechanical

Intake Manifold Removal

! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.

1. Disconnect both battery cables.

2. Remove the engine cover.
3. Drain the cooling system.
4. Remove the hoses from the thermostat housing.
5. For models with a mechanical throttle body, disconnect the throttle cable from the throttle cable bracket and throttle body.
6. Disconnect and move the engine harness out of the way as follows:
a. Disconnect the following components from the engine harness:
• Temperature sender
• Temperature sensor
• Oxygen sensors
• Exhaust coolant temperature sensors
• MerCathode controller (orange, black, and brown wires)

a b c MerCathode controller
a - Brown wire
b - Black wire
c - Orange wire

50304
• Gear lube monitor
• Idle air control valve
• Throttle position sensor
• Alternator sense lead (purple and pink‑yellow wires)
• Neutral safety start switch (on shift actuator)
• Crank position sensor
• Propulsion control module (PCM)
• Manifold absolute pressure and air temperature (MAPT) sensor
NOTE: Refer to Engine Control and Sensor Locations in Section 4E for assistance in locating the above listed
items.
b. Remove the fuse and relay blocks from their bracket.
c. Disconnect the electrical harness from the fuel injectors.
d. Remove the harness connectors and the circuit breaker from the PCM mounting bracket.
e. Move the two branches of the engine harness away from the top of the engine.
7. Remove the PCM and the PCM mounting bracket.

! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
8. Disconnect the fuel supply line from the fuel rail.

Description SPX Part Number

Fuel Line Disconnect Tool J‑44581

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 Engine Mechanical
9. Disconnect the fuel pressure regulator reference line from the T‑fitting above the intake manifold.

a b a - T‑fitting
b - Fuel pressure regulator reference line

50361
10. Remove the distributor.

b a - Distributor
b - Hold down screw
c - Hold down

29320

11. Remove the lower intake manifold screws.

IMPORTANT: The intake manifold may be removed as an assembly. Do not remove other components from the intake
manifold unless component service is required.
IMPORTANT: Properly seal the fuel system to avoid damage from dirt and debris.
12. Remove the intake manifold assembly.
NOTE: It may be necessary to loosen the rocker arm cover screws. With the screws loose, the rocker arm covers can be
shifted slightly as necessary, to gain access to the intake manifold.
13. Remove and discard the lower intake manifold gaskets.

Intake Manifold Disassembly

1. Remove any remaining crankcase ventilation hoses.
2. Remove the nut at the front mounting point of the throttle cable bracket. The nut at the rear mounting point should have
been removed during the PCM bracket removal.

Throttle cable bracket

a - Front mounting point
b - Rear mounting point

51071

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Engine Mechanical
3. Remove the throttle body attaching studs.

29880

Throttle body studs

4. Remove the throttle body.

5. Remove and discard the throttle body sealing ring.

b
a a - Sealing ring
b - Throttle body

29882

6. Remove the thermostat housing.

7. Remove the manifold absolute pressure and temperature (MAPT) sensor and discard the seal.

a - O‑ring
b - MAPT sensor

b a 29127

8. Remove the four screws that hold the fuel rail to the manifold.
9. Remove the fuel rail assembly, including all eight injectors.
NOTE: Be careful to not damage the injector O‑rings.
10. Perform the following steps if complete disassembly is required.
a. Remove the screws that secure the upper intake manifold to the lower manifold.

Page 3A-30 90-879288300 AUGUST 2012

 Engine Mechanical
b. Remove the upper intake manifold.

29890

Upper and lower intake manifold separation

c. Remove and discard the gasket from between the upper and the lower intake manifolds.
d. Remove the bracket from the lower intake manifold.

Cleaning and Inspection

IMPORTANT: When cleaning the cylinder head mating surface, do not allow gasket material to enter the engine crankcase or
intake ports.
1. Remove all gasket material from the intake manifold and cylinder head.
2. Clean the intake manifolds in cleaning solvent.

! CAUTION
Using compressed air can cause serious injury. Always wear eye protection when working with compressed air to prevent
injury from ruptured hoses or flying debris.
3. Dry the intake manifolds with compressed air.
4. Inspect the intake manifolds for cracks or damage to the exterior surfaces, the gasket grooves, or the gasket sealing
surfaces.
5. Inspect the cooling system passages for restriction.
6. Inspect the threads in the bolt holes for damage.

Intake Manifold Assembly

1. Perform the following steps if the intake manifold was completely disassembled.
a. Install the bracket onto the lower intake manifold.
b. Install a new gasket into groove on the bottom side of the upper intake manifold.
c. Place the upper intake manifold onto the lower intake manifold.
d. If reusing the fasteners, apply Loctite 242 to the threads of the screws that secure the upper intake manifold to the
lower.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Upper intake manifold screws 92-809821
e. Insert the screws and tighten to specification.

Description Nm lb‑in. lb‑ft

First 5 44
Upper intake manifold screws
Final 10 89

IMPORTANT: Verify that there is no damage to the injector O‑rings.

2. Install the fuel rail assembly and injectors onto the intake manifold.
3. If reusing the fasteners, apply Loctite 242 to the threads of the four screws that secure the fuel rail.

90-879288300 AUGUST 2012 Page 3A-31

Engine Mechanical

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Fuel rail screws 92-809821
4. Install the fuel rail screws. Tighten the fuel rail nuts to specification.

Description Nm lb‑in. lb‑ft

Fuel rail screws 3 27
5. Install a new seal on the MAPT sensor.

a - MAPT sensor seal

b - MAPT sensor

b a 29127

6. Apply one drop of clean engine oil to the MAPT sensor seal.
7. Install the MAPT sensor into the upper intake manifold. Tighten the MAPT sensor screw to specification.

Description Nm lb‑in. lb‑ft

MAPT sensor screw 6 53
8. Install the thermostat housing using a new gasket. Tighten the screws to specification.

Description Nm lb‑in. lb‑ft

Thermostat housing screw 41 30
9. Install a new throttle body sealing ring into the groove in the throttle body.

b
a a - Throttle body sealing ring
b - Throttle body

29882

10. Align the dowels and install the throttle body onto the upper intake manifold.
NOTE: New throttle body studs are supplied with adhesive.
11. If reusing the fasteners, apply Loctite 242 to the threads of the throttle body studs.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Throttle body studs 92-809821
12. Install and tighten the throttle body studs to specification.

Description Nm lb‑in. lb‑ft

Throttle body studs 9 81
13. Install the throttle cable bracket. Tighten the nuts to specification.

Description Nm lb‑in. lb‑ft

Throttle cable bracket nut 19 168

Page 3A-32 90-879288300 AUGUST 2012

 Engine Mechanical

Intake Manifold Installation

IMPORTANT: Excessive amounts of adhesive or sealer on gaskets or component surfaces may cause improper sealing
resulting in intake manifold air or fluid leaks.
1. Apply Perfect Seal around the port and starboard water passages of engine block.

29833

Sealant, intake water passages

Tube Ref No. Description Where Used Part No.

19 Perfect Seal Intake water passages 92-34227Q02

IMPORTANT: Do not get sealer into the oil sending unit hole at rear of engine.
2. Apply a 5 mm (3/16 in.) wide bead of Loctite 5900 to the engine block to intake manifold mating surface.

29834

Sealant, engine block

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 Engine block 92-809826
RTV Silicone Sealant

NOTE: For proper adhesion, the intake manifold gasket must be installed while the adhesive is wet.
3. Align the intake manifold gaskets with locator pins and install onto the cylinder heads.

90-879288300 AUGUST 2012 Page 3A-33

Engine Mechanical
4. Apply a 4 mm (5/32 in.) bead of Loctite 5900 at each end of the intake manifold gasket on the top side.

b
a

29845

a - Locator pin
b - Locator pin hole
c - Area for sealant

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 End of the intake manifold gasket 92-809826
RTV Silicone Sealant
5. Carefully install the intake manifold assembly onto the engine block.
6. Apply Loctite 242 to the threads of the intake manifold screws.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Intake manifold screws 92-809821

IMPORTANT: Always follow torque specifications and sequences when installing fasteners to ensure proper installation.
7. Install the intake manifold screws. Tighten to specification

5
3
6
2

4
1 8
7

29894

Intake manifold torque sequence

Page 3A-34 90-879288300 AUGUST 2012

 Engine Mechanical

Description Nm lb–in. lb–ft

First pass 3 26.5
Intake manifold screws (in sequence) Second pass 12 106
Final pass 25 18
8. Connect all ignition and electrical leads.
9. Connect the hoses to the thermostat housing and tighten the hose clamps.
10. Install the fuel supply line.
11. Connect the crankcase ventilation hoses and secure with clamps.
12. Install the distributor.
13. Install the ignition coil wire.
14. Connect any other components that were disconnected.
15. Refill the closed‑cooling system, if equipped.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
16. Provide cooling water to the engine and drive.
17. Start the engine.
18. Check all hose connections, gaskets, and seals for leaks.
19. Inspect all fuel line connections for fuel leaks.
20. Install the flame arrestor.

Description Nm lb‑in. lb‑ft

Flame arrestor retainer bracket nut 12 108
21. Install the engine cover.

90-879288300 AUGUST 2012 Page 3A-35

Engine Mechanical

Intake Manifold for Scorpion Models

Intake Manifold Exploded View
5 6
7
8
9
10 11

12
4
13
3 14
15
16
17
18

19

2 20 21

22
29 28
27
23

26 24
1 25
23
50019

Page 3A-36 90-879288300 AUGUST 2012

 Engine Mechanical

Intake Manifold Exploded View

Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
1 2 Intake manifold gasket
2 1 Intake manifold assembly
3 2 Brass fitting
4 2 Quad ring seal
5 4 Fuel rail spacer
6 4 Screw 12 108
7 1 Schrader valve cap
8 1 Schrader valve
9 2 Fuel rail assembly
10 1 Fuel crossover tube
11 1 90° fitting
12 8 Fuel injector assembly
13 2 ‑ Injector seals (1 upper and 1 lower per injector)
14 1 ‑ Fuel injector clip (1 per injector)
15 1 Damper
16 2 Pipe plug
17 1 90° brass fitting
18 1 Hose
First 3 26.5
19 8 Screw Second 12 106
Final 25 18
20 1 Barb fitting
21 1 Hose
22 1 Bracket
23 2 Screw and lockwasher 12 108
24 1 Hose
25 1 Bracket
26 1 Manifold absolute pressure sensor
27 1 Clip
28 1 Screw
29 1 Barb fitting

90-879288300 AUGUST 2012 Page 3A-37

Engine Mechanical

Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

1. Disconnect both battery cables from the battery.

2. Remove the PCV hose from the flame arrestor.
3. Disconnect the harness connector from the MAP sensor. The sensor is located on the underside of the plenum near the
throttle body.
4. Remove the screws retaining the intake plenum to the manifold. Remove the two nuts from the underside of the plenum in
the front. Remove the plenum and gasket.
5. Drain the cooling system.
6. Remove the water hoses from the thermostat housing.

a- Coolant hoses
b- Closed‑cooling hose
c c- Starboard exhaust elbow hose
d- Port exhaust elbow hose

b d

a
29898

! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.

IMPORTANT: To prevent contamination, cap or cover all open fuel lines.

7. Disconnect the fuel supply line from the fuel rail.
8. Remove the distributor cap. Mark the positions of the rotor on the distributor housing and of the distributor housing on the
intake manifold.
9. Remove the distributor.
IMPORTANT: Do not turn the engine over after the distributor has been removed.
10. Disconnect the electrical harness from the fuel injectors.
11. Remove the intake manifold screws.
IMPORTANT: Properly cap or cover the fuel system components to prevent system contamination.
IMPORTANT: It may be necessary to pry the intake manifold away from the cylinder heads and block. Use extreme care to
prevent damage to the sealing surfaces.

Page 3A-38 90-879288300 AUGUST 2012

 Engine Mechanical
12. Remove the intake manifold assembly.

29900

Intake manifold and gaskets

13. Remove and discard the intake manifold gaskets.

NOTE: If the intake manifold requires replacement, transfer all remaining parts to the new manifold.

Cleaning and Inspection, Intake Manifold

IMPORTANT: When cleaning the cylinder head mating surface, do not allow gasket material to enter the engine crankcase or
intake ports.
1. Remove all gasket material from the intake manifold and cylinder head.
2. Inspect the intake manifold for cracks or scratches. Machined surfaces must be clean and free of all marks and deep
scratches or leaks may result.
IMPORTANT: Do not contaminate the IAC filter and gasket components. Complete disassembly of the intake manifold is
recommended before using cleaning solvent.
3. Inspect the intake passages for varnish buildup and debris. Clean as necessary.
4. Inspect the threads in the bolt holes for damage.

Cleaning and Inspection, Plenum

IMPORTANT: Use care when removing gasket material from the intake manifold and plenum. Failure to do so could result in
damage to the intake manifold and plenum.
1. Carefully remove all gasket material from the intake manifold and plenum.
2. Inspect the mating surfaces for damage that could affect gasket sealing.
3. Inspect the plenum for cracks.
IMPORTANT: Do not contaminate the throttle body gasket components. Complete disassembly of the plenum is
recommended before using cleaning solvent.
4. If needed, clean the plenum in solvent and dry with compressed air.

Installation
IMPORTANT: Excessive amounts of adhesive or sealer on gaskets or component surfaces may cause improper sealing
resulting in intake manifold air or fluid leaks. Do not apply excessive amounts of adhesive or sealer.
IMPORTANT: Do not get sealer into the oil sending unit hole at rear of engine.

90-879288300 AUGUST 2012 Page 3A-39

Engine Mechanical
1. Apply Perfect Seal around the port and starboard water passages of engine block.

29833

Sealant, intake water passages

Tube Ref No. Description Where Used Part No.

19 Perfect Seal Intake water passages 92-34227Q02

NOTE: For proper adhesion, install the lower intake manifold gasket while the adhesive is still wet.
2. Apply a 5 mm (3/16 in.) wide bead of Loctite 5900 to the engine‑block‑to‑intake‑manifold mating surface.

29834

Sealant, engine block

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 Engine block 92-809826
RTV Silicone Sealant
3. Align the intake manifold gaskets with the locator pins. Install the intake manifold gaskets onto the cylinder heads.

Page 3A-40 90-879288300 AUGUST 2012

 Engine Mechanical
4. Apply a 4 mm (5/32 in.) bead of Loctite 5900 at each end of the intake manifold gasket on the top side.

b
a

29845

a - Locator pin
b - Locator pin hole
c - Area for sealant

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 End of the intake manifold gasket 92-809826
RTV Silicone Sealant
5. Carefully install the intake manifold onto the engine block.
6. Apply Loctite 242 to the threads of the intake manifold screws.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Intake manifold screws 92-809821

IMPORTANT: Always follow torque specifications and sequences when installing fasteners to ensure proper installation.
7. Install and tighten the intake manifold screws to specification and in the sequence shown below.

5 4
3 8
6
2
1
7

51080

Intake manifold torque sequence

90-879288300 AUGUST 2012 Page 3A-41

Engine Mechanical

Description Nm lb‑in. lb‑ft

First 3 26.5
Intake manifold screw (each pass in sequence) Second 12 106
Final 25 18
8. Connect all ignition and electrical leads.
9. Connect the coolant hoses to the thermostat housing.
10. Install the fuel supply line to the fuel rail.
11. Connect the crankcase ventilation hose.
12. Install and confirm alignment of the distributor.
13. Install the plenum as follows.
a. Verify all old gasket material has been removed from the plenum gasket surface.
b. Position the new plenum gasket on the intake manifold. The word "FRONT" faces up on the gasket at the front edge
of the intake manifold.
c. Place the plenum over the gasket.
d. Install the screws that retain the intake plenum to the manifold. Install the two nuts on the underside of the plenum in
front.
e. Tighten the fasteners to specification, evenly, and in a diagonal pattern.

Description Nm lb‑in. lb‑ft

Scorpion plenum screw 11 96
Scorpion plenum nut 11 96
f. Connect the MAP sensor (under the plenum, near the throttle body) to the appropriate harness connector.
g. Connect the PCV hose to the flame arrestor.
14. Refill the closed‑cooling system, if equipped.
15. When repairs are complete, test the installation as follows.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.

a. Provide cooling water to the engine and drive.

b. Start the engine.
c. Check all hose connections, gaskets, and seals for leaks.
d. Inspect fuel line connections for fuel leaks.

Hydraulic Valve Lifters

Removal
1. Drain the seawater and closed‑cooling systems.
2. Remove the rocker arm covers.
IMPORTANT: Organize and store the rocker arm assemblies, pushrods, and valve lifters in matched sets for reassembly
and installation in their original locations.
3. Remove the rocker arm assemblies and valve pushrods. Keep the parts in matched sets.
4. Remove the intake manifold.

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 Engine Mechanical
5. Remove the lifter guide retainer.

Head removed for clarity (removal is not necessary)

b a - Lifter guide retainer
b - Bolts

29906

IMPORTANT: Store the valve lifters in the upright position to prevent oil loss.
6. Remove the lifter guides and valve lifters. Store lifters in the upright position in the order of removal.

b a - Valve lifter
b - Lifter guide

29907

Cleaning
1. Except for the valve lifters, clean the parts with cleaning solvent.
2. Dry the parts with compressed air.
3. Keep the valve lifter upright, wipe with a clean, oil saturated, lint free cloth. Store valve lifters in the upright position.

Inspection
1. Ensure that the lifter seat retainer clip is not broken or damaged.
2. Inspect the pushrod seat. If the seat is scuffed or worn, inspect the pushrod for warping or damage.
3. Inspect outer lifter body. If the lifter is scuffed or worn, inspect the engine block lifter bore.
4. Inspect the roller of valve lifter. If roller is scuffed or worn, inspect the camshaft lobe.
5. Ensure the oil hole is unobstructed.
6. Inspect all parts carefully. Replace any valve lifter assembly that is damaged or excessively worn.

b c Lifter inspection points

a - Seat retainer clip
b - Pushrod seat
c - Valve lifter body
a d d - Roller
e - Oil hole

e 30150

90-879288300 AUGUST 2012 Page 3A-43

Engine Mechanical

Installation
IMPORTANT: Do not install used valve lifters if a new camshaft has been installed.
IMPORTANT: Before installing valve lifters, coat the camshaft lobes and valve lifters with engine assembly lube.

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Camshaft lobes and valve lifters Obtain Locally

1. Lubricate the valve lifters with Lubriplate SPO 255. Install the valve lifters in original locations if being reused.

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Valve lifters Obtain Locally
2. Install the lifter guides.
3. Install the lifter guide retainer. Tighten the screws to specification.

Shown with head removed for clarity only

b a - Lifter guide retainer
b - Bolts

29906

Description Nm lb‑in. lb‑ft

Valve lifter guide retainer bolt 25 19
4. Lubricate and install the valve pushrods and rocker arm assemblies.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Valve pushrods and rocker arm assemblies 92-858087K01
20W-40, NMMA FC-W
rated
5. Adjust the valve clearance. Refer to Valve Adjustment.
6. Install the intake manifold. Refer to Intake Manifold.
7. Install the rocker arm covers. Refer to Rocker Arm Cover.
8. Change the engine oil and filter. Refer to Section 1C ‑ Maintenance.
9. Refill the closed‑cooling system, if equipped.
10. Check for leaks when the engine is started.

Cylinder Head
Removal
1. Drain the seawater and closed cooling systems.
2. Remove the exhaust elbows and manifolds.
3. Remove any other external components that might interfere with access to the cylinder heads
4. Remove the rocker arm covers.
5. Remove the intake manifold assembly.
IMPORTANT: Keep the rocker arm assemblies, valve pushrods, and hydraulic valve lifters from each valve together as a
matched set. Mark and organize the components so they can be installed in the same location later.

Page 3A-44 90-879288300 AUGUST 2012

 Engine Mechanical
6. Remove the rocker arm assemblies and valve pushrods. Keep in matched sets.
7. Remove the spark plugs.
8. Remove the cylinder head bolts.

a
a - Long bolts
b - Medium bolts
b
c - Short bolts
c

30169

9. Remove the cylinder head.

10. Place the cylinder head on wooden blocks, a rubber mat, or other material that will prevent damage to gasket surfaces.
11. Repeat this process for the second cylinder head.

Cylinder Head Cleaning

1. Clean all gasket material and sealant from the engine block, cylinder, intake manifold, and exhaust manifold head sealing
surfaces.
2. Clean all the carbon from the combustion chambers and the intake and exhaust ports using a carbon removing brush.

30174

Carbon removing brush

Description SPX Part Number

Carbon removing brush J‑8089
3. Clean all cylinder head and engine block bolt hole threads.
4. Clean the surface of the cylinder head with solvent.
5. Dry the cylinder head, including the cylinder head and engine block bolt hole threads, with compressed air.

Cylinder Head Inspection

1. Inspect sealing surfaces for burrs, scratches, deep nicks, erosion, or other damage.
2. Inspect for cracks in exhaust ports, water jackets, and combustion chambers (especially around spark plug holes and valve
seats).
3. Replace the cylinder heads if necessary.
4. Inspect for rusted, damaged, or leaking core plugs. Replace the core plugs if necessary.
5. Inspect for corrosion around the cooling passages.

90-879288300 AUGUST 2012 Page 3A-45

Engine Mechanical
6. Check the flatness of the cylinder head gasket surfaces (head, exhaust, and intake gaskets) using a machinist's straight
edge and feeler gauges. Take measurements diagonally across the cylinder head from all four corners and straight down
the center of the cylinder head lengthwise.

Head deck shown, exhaust and intake decks are similar

b a - Cylinder head deck
b - Machinist's straight edge
c - Feeler gauge

a c

30171

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Head deck
0.10 mm (0.004 in.)
(deviation within a 152 mm [6.0 in.] area)
Surface flatness
Exhaust manifold deck 0.05 mm (0.002 in.)
Intake manifold deck 0.10 mm (0.004 in.)
7. If a measured value is greater than specified, the cylinder head must be repaired to specifications or replaced.

Cylinder Head Installation

1. Ensure that the engine block and cylinder head sealing surfaces are clean.
2. Place a new head gasket in position over the dowel pins.
3. Carefully set the cylinder head in place over the dowel pins.
4. Apply Loctite 567 to the cylinder head bolt threads. Install the bolts to finger‑tight.

Tube Ref No. Description Where Used Part No.

Loctite 567 PST Pipe
9 Cylinder head bolt threads 92-809822
Sealant
5. Tighten the cylinder head bolts to specification in passes using the numbered sequence shown.

Cylinder head tightening

a 13 5 2 10 sequence
a - Long bolts (sequence
numbers 1, 2, 5, 6, 9, 10,
b 17 9 1 6 14 b and 13)
b - Medium bolts (14 and 17)
c - Short bolts (3, 4, 7, 8, 11,
12, 15, and 16)
c 16 12 8 4 3 7 11 15
30179

Cylinder Head Bolt Torque Specifications—Preferred Method

Description Nm lb–in. lb–ft
All bolts in sequence First 30 22
Long bolts + 75°
Torque angle (in sequence) Final Medium bolts + 65°
Short bolts + 55°

Page 3A-46 90-879288300 AUGUST 2012

 Engine Mechanical

Cylinder Head Bolt Torque Specifications—Alternate Method

Description Nm lb‑in. lb‑ft
First 35 26
All bolts in sequence Second 60 44
Final 90 66

IMPORTANT: Keep the pushrods and rocker arm assemblies together as matched sets and install them in their original
locations.
6. Install the pushrods and rocker arm assemblies in their original positions.
7. Install the intake manifold assembly.
8. Install the rocker arm covers.
9. Install the exhaust manifolds and elbows.
10. Install all other removed components.
11. Refill the closed‑cooling system.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
12. Provide a sufficient water supply to all cooling water inlets.
13. Start the engine.
14. Check for leaks.

Cylinder Head Reconditioning

Cylinder Head Disassembly
1. Using a valve spring compressor, compress the valve spring and remove the valve locks. Slowly release the tool.

30170

Valve spring compressor

Description SPX Part Number

Valve spring compressor (cylinder head off the engine) J‑8062

IMPORTANT: Keep individual valve related components together. Mark and organize parts for reassembly in their original
locations.
2. Remove the valve spring cap and spring.
3. Remove the valves from the cylinder head and store, in order, for reassembly in their original locations.
4. Label and organize all components for reassembly in their original locations.
5. Remove and discard the valve oil seals.
6. Place the cylinder head on wooden blocks, a rubber mat, or other material that will prevent damage to gasket surfaces.

90-879288300 AUGUST 2012 Page 3A-47

Engine Mechanical

Cleaning Valve Components

1. Thoroughly clean the valve guides with a valve guide cleaner.

30175

Valve guide cleaner

Description SPX Part Number

Valve Guide Cleaner J‑8101
2. Clean the valve locks, valve spring caps, and valve springs in cleaning solvent.
3. Clean all carbon from the valves using a wire wheel.
4. Clean the valves in cleaning solvent.
5. Dry parts with compressed air.

Valve Inspection
1. Inspect each valve for a burned head, cracked or pitted face or seat, or damaged stem.

b a - Face: check for cracks or pits

a b - Seat: check for damage
c c - Stem: check for damage

30188
IMPORTANT: Excessive valve stem to bore clearance will cause excessive oil consumption and possibly broken valves.
Insufficient clearance will result in noisy, binding valves.
2. Measure valve stem diameter in three places.

a - Measuring points
b - Dial indicator
b

30190

3. Replace valves that do not meet specification.

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Intake
Production valve stem diameter 8.661–8.679 mm (0.3410–0.3417 in.)
Exhaust
Service stem oversize diameter Exhaust only + 0.774 mm (+ 0.0305 in.)

Page 3A-48 90-879288300 AUGUST 2012

 Engine Mechanical
4. Measure the valve head margin.

30192

a - Valve head
b - Valve head margin

5. Replace valves that do not meet specification.

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Intake 0.79 mm (0.031 in.)
Minimum margin after surfacing
Exhaust 1.524–2.032 mm (0.060–0.080 in.)

Valve Stem to Bore Clearance

Use a new valve, or a valve with production specified stem diameter, as a reference to measure the valve stem to bore
clearance.
1. Attach a dial indicator to the cylinder head near the valve guide bore being checked.

Measuring valve stem clearance

a - Dial indicator and attaching hardware
b - Valve stem
c - Valve guide
a

19458

2. Measure the valve stem clearance.

a. Insert the reference valve in the cylinder head with the valve head off the seat approximately 2 mm (1/16 in.).
b. Position the dial indicator against the valve stem near the valve guide.
c. Shift the valve stem from side to side in the guide and note the dial indicator readings at each end of the valve stem's
range of motion. The difference between the two readings will be the valve stem clearance.
d. Compare the valve stem clearance to the specifications.

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve stem clearance— production 0.025–0.069 mm (0.0010–0.0027 in.)
Valve stem clearance—service 0.025–0.0944 mm (0.0010–0.0037 in.)
3. If an exhaust valve stem clearance exceeds specifications ream the valve guide and install a valve with an oversized stem.
Refer to Oversize Valve Installation.

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Engine Mechanical
4. If an intake valve stem clearance exceeds specifications replace the cylinder head. Intake valves are not available with
oversize stems.
5. Repeat this procedure for each valve stem bore being checked.

Valve Springs
1. Use a vernier caliper to measure the valve spring free length. Replace the spring if it is more or less than the specified limit.

20973

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve spring free length 51.3 mm (2.02 in.)
2. Check if the valve spring is square with a machinists square. Replace any non‑square or bent valve springs.
3. Use a valve spring tester to measure the valve spring tension. Replace the spring if the measured value is less than the
specified limit.

a - Valve spring tester

b - Torque wrench

b
a

19464

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve closed 338–374 N at 43.2 mm (76–84 lb at 1.7008 in.)
Valve spring tension
Valve open 832–903 N at 32.3 mm (187–203 lb at 1.2717 in.)

Description Part Number

Valve spring tester Obtain locally

Valve Reconditioning
NOTE: Several different types of equipment are available for reconditioning valves. The manufacturer's recommendation
should be carefully followed to attain proper results.
1. Recondition the valve face to the proper angle if the valve face is pitted or worn.
2. Measure the valve margin. If the valve margin is less than specified after reconditioning, replace the valve.

a Valve reconditioning
measurements
a - Valve margin
b - Valve face angle
b

50572

Page 3A-50 90-879288300 AUGUST 2012

 Engine Mechanical

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Intake 0.79 mm (0.031 in.) minimum
Valve margin (after surfacing)
Exhaust 1.524–2.032 mm (0.060–0.080 in.)
Intake
Valve face angle 45°
Exhaust

Oversize Valve Installation

IMPORTANT: Measure the valve stem diameter of both the intake and exhaust valve; the valve stem diameter may or may not
be the same for both valves.
1. If exhaust valves with oversize valve stems are required, ream the valve guide bores.

28949

Valve guide reamer

Description SPX Part Number

Valve Guide Reamer (0.015 in. oversize) J‑37378
2. Remove any sharp edges created by the reamer at the top of the valve guide.
3. Install a valve with an oversized stem.
4. Measure the valve stem to bore clearance. Refer to Valve Stem to Bore Clearance.

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Intake
Production valve stem diameter 8.661–8.679 mm (0.3410–0.3417 in.)
Exhaust
Service oversize stem diameter Exhaust only + 0.774 mm (0.0305 in.)

Valve Seat Reconditioning

IMPORTANT: It is essential that the valve guide bores be free from any debris to allow accurate setup of the machine tool
fixture's center pilot.
IMPORTANT: Follow all of the reconditioning equipment manufacturer's instructions carefully.

90-879288300 AUGUST 2012 Page 3A-51

Engine Mechanical
1. Recondition the valve seats if pitted or worn.

a b
d

30201

Typical 3-angle valve seat

a - Top correction cut angle
b - Seat angle
c - Bottom correction cut angle
d - Seat width

Description 5.0 L (305 cid) 5.7 L (350 cid) and 6.2 L (377 cid)
Valve seat angle 46°
Top correction cut Intake and exhaust 30°
Bottom correction cut 60°
Intake 1.14–1.78 mm (0.045–0.070 in.) 1.02–1.65 mm (0.040–0.065 in.)
Seat width
Exhaust 1.65–2.49 mm (0.065–0.098 in.) 1.50–2.56 mm (0.059–0.101 in.)
2. Measure valve seat concentricity (runout) and recondition if specification is exceeded.

30207

Valve seat concentricity tool (machine shop)

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Intake
Valve seat concentricity (runout) 0.05 mm (0.0020 in.)
Exhaust

Rocker Arm Stud Replacement

IMPORTANT: This procedure does not apply to the 377 HO models, which use screw‑in studs.
IMPORTANT: Replace worn or loose valve rocker arm studs with oversize studs. The studs are pressed into the cylinder head.
Two replacement valve rocker arm ball studs sizes are available.

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 Engine Mechanical

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)

Rocker arm ball First oversize 0.076 mm (0.003 in.)

studs Second oversize 0.330 mm (0.013 in.)

1. Place the stud remover and flat washer over the stud.

b a - Stud remover
b - Nut and flat washer

30208

Description SPX Part Number

Stud Remover J‑5802‑01
2. Install a 3/8‑24 threaded nut.
3. Turn the nut clockwise to remove the stud.
IMPORTANT: The rocker arm stud hole must be reamed with an appropriate tool to accept an oversize replacement stud.
4. Ream the rocker arm stud hole using the appropriately sized reaming tool.

30212

Reaming rocker arm stud hole

Description SPX Part Number

Rocker Arm Stud Bore Reamer Tool (0.003 in.) J5715
Rocker Arm Stud Bore Reamer Tool (0.013 in.) J‑6036
5. Coat the end of the oversize rocker arm stud with premium gear lubricant.

Tube Ref No. Description Where Used Part No.

82 Premium Gear Lubricant Rocker arm stud 92-858058K01

6. Install the oversize stud using the rocker arm stud installer.

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Engine Mechanical
NOTE: When using the rocker arm stud installer, the installation depth is correct when the tool contacts the cylinder head.

a - Oversize rocker arm stud

b - Rocker arm stud installer
a
b

30213

Description SPX Part Number

Rocker Arm Stud Installer J‑6880

Cylinder Head Reassembly

IMPORTANT: Install each valve into the port from which it was removed or for which it has been fitted.
IMPORTANT: Intake valve stem oil seals are black. Exhaust valve stem oil seals are red or they are brown with a white paint
stripe on the outer diameter. The letters "EX" are molded into the top of exhaust valve stem oil seals.
1. Assemble a valve into its proper port and valve guide. Apply clean engine oil to the valve stem.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Valve stem 92-858087K01
20W-40, NMMA FC-W
rated
2. Select the appropriate intake or exhaust valve stem oil seal.
3. Coat the outside surface of the valve stem bore and all surfaces of the valve stem oil seal with clean engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Valve stem 92-858087K01
20W-40, NMMA FC-W
rated
4. Assemble the valve stem oil seal onto the valve stem and slide it down until it contacts the valve spring seat.
5. Press the valve stem oil seal with the valve stem seal installer until the tool contacts the spring seat.

Typical
b
a a - Valve stem seal
b - Valve stem seal installer

30218

Description SPX Part Number

Valve stem seal installer J‑42073

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 Engine Mechanical
6. For all intake and exhaust valves, ensure that the installed height (the gap between the bottom edge of the valve stem oil
seal and the cylinder head valve guide boss) is as specified.

a - Valve guide boss

b - Bottom of valve stem oil seal
c - Installed height (gap)

b
c
a

30220

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Valve stem seal installed height 1.0 – 2.0 mm (0.0394 – 0.0787 in.)
7. Install the valve spring.
8. Place a valve spring cap on the valve spring.

! CAUTION
Improperly compressed springs or improperly locked valve caps could allow the spring to be ejected with tremendous force,
which could cause personal injury. Use care when compressing the valve springs or releasing the valve spring compressor
tool.
9. Compress the valve spring using a valve spring compressor.

a
a- Valve spring locks (2)
b b- Valve spring cap
e c- Valve spring
c d- Valve stem
e- Valve spring compressor
d

30216

Description SPX Part Number

Valve spring compressor J‑8062
10. Coat the valve stem locks with needle bearing assembly lubricant to them hold in place.

Tube Ref No. Description Where Used Part No.

Needle Bearing Assembly
4 Valve stem locks 92-802868Q1
Lubricant
11. Install the valve stem locks.
12. Confirm that the valve stem locks are properly seated in the grooves of the valve stem.
13. Slowly release the valve spring compressor.
14. Set the assembly by tapping the valve stem with a soft plastic hammer.
15. Check the installed height of the valve springs using a narrow, thin scale. Measure from the spring seat to the top of the
valve spring.

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Engine Mechanical
IMPORTANT: If the measurement exceeds the specified height, install a valve spring shim and recheck. Do not shim the
valve springs to give an installed height less than the minimum specified.

19503

Typical
a - Cut away scale
b - Valve spring installed height

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Intake
Valve spring installed height 42.92–43.43 mm (1.6898–1.7098 in.)
Exhaust

Flywheel Housing
Removal
1. For sterndrive models, remove the sterndrive.
2. For inboard models, remove the transmission.
3. Remove the engine from boat.
4. Remove the water hoses from the power steering cooler (if equipped).
5. For inboard models, remove rear mounted starter (if equipped).
6. Remove the power steering cooler (if equipped).
7. Remove the flywheel housing cover.

49810

30643 MIE flywheel housing

a - Flywheel housing cover
MCM flywheel housing
a - Flywheel housing cover
b - Screws (2)
c - Flywheel housing

8. Remove the ground wires from the flywheel housing.

IMPORTANT: The flywheel housing bolts must be installed in same location as removed.
9. Remove the bolts and studs from the flywheel housing.

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 Engine Mechanical
10. Remove the flywheel housing.

30644

MCM shown, MIE similar

Cleaning
1. Clean all parts in solvent.
2. Dry the parts with compressed air.

Inspection
1. Inspect the flywheel housing for cracks, damaged bolt or stud holes, and excessive wear. Replace if necessary.
2. Inspect the guide dowels for the correct amount of protrusion from the engine block. Repair if necessary.

a - Guide dowels (2)

b - Measured protrusion 13 mm
b (0.5 in.)

a
a a

30645

Installation
1. Align the flywheel housing on the guide dowels of the engine.
IMPORTANT: The flywheel housing fasteners must be installed in same location as removed.
2. Install the studs and bolts into their original locations.
3. Tighten the flywheel housing fasteners to specification.

Description Nm lb‑in. lb‑ft

Flywheel housing fasteners 41 – 30
4. Install the flywheel housing cover.

Description Nm lb‑in. lb‑ft

Flywheel housing cover bolts 9 80 –
5. Install the ground wires.
6. Install the power steering cooler (if equipped).
7. Install the water hoses.
8. For inboard models, install the transmission and the rear mounted starter (if equipped).
9. Install the power package in the boat.

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Engine Mechanical

Flywheel
Removal
1. For sterndrive models, remove the sterndrive.
2. Remove the engine from the boat.
3. For inboard models, remove the transmission.
4. Remove the flywheel housing.
5. Remove the coupler or drive plate.

a b c
a- Alpha coupler
b- Bravo coupler
c- HD Bravo coupler
d- Inboard drive plate
e- Driveshaft extension coupler

d e

30655

6. Remove the flywheel.

a - Flywheel
b - Screws (6)

a b

30684

Cleaning and Inspection

1. Clean the mating surfaces of the flywheel and crankshaft. Remove any burrs. The mating surfaces must be clean, bare
metal.
2. Inspect the flywheel ring gear for worn and missing teeth.
3. Inspect the splines in the drive plate or coupler for damage or excessive wear.
4. Replace components as necessary.

Installation
NOTE: If the crankshaft is to be replaced, but the old pilot bushing is to be reused, then the bushing can be removed without
damage by filling the pilot bushing cavity with grease, then inserting an old transmission input shaft into the bore of the bushing
and hitting it with a hammer. This will create hydraulic pressure in the pilot bushing cavity, forcing the bushing out.
1. Clean the mating surfaces of the flywheel and the crankshaft until the metal is bare.

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 Engine Mechanical
2. Align the dowel hole in the flywheel with the dowel in the crankshaft and install the flywheel. Tighten the mounting screws
to specification in sequence.

a - Flywheel
b - Mounting screw (6)
c - Tightening sequence

c
1 4
6 2
a
3 5

b 30676

Description Nm lb‑in. lb‑ft

Flywheel mounting screw 100 74
3. Check flywheel runout:
a. Attach a dial indicator to the engine block.
b. Push in on the flywheel to remove any crankshaft end play.
c. Turn the flywheel in the direction of normal engine rotation and measure flywheel runout at the smooth outer edge of
the flywheel, just inside the ring gear.

a - Dial indicator
b - Runout measurement

b a

6442

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid )
Runout 0.20 mm (0.008 in.)
4. Install the drive coupler or drive plate. Tighten to specification.

Description Nm lb‑in. lb‑ft

Drive coupler or drive plate mounting screw 48 35
5. Install the flywheel housing and related parts. Tighten the screws to specification.

Description Nm lb‑in. lb‑ft

Flywheel housing mounting screw 48 35
6. Install the flywheel housing cover. Tighten the screws to specification.

Description Nm lb‑in. lb‑ft

Flywheel housing cover mounting screw 9 80
7. Install the transmission or sterndrive as is applicable.

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Engine Mechanical

Rear Oil Seal

Removal
The rear main crankshaft oil seal can be replaced without removing the oil pan or the rear main bearing cap from the engine.
1. Remove the flywheel.
2. Remove the seal by using a screwdriver to pry it out of the engine block as shown.

a - Rear main seal

b - Slots (3)
c - Oil seal retainer

c
a b

30695
IMPORTANT: Do not nick or gouge the engine block or the rear main bearing cap sealing surface. Protect the crankshaft to
seal running surface from damage.

Cleaning and Inspection

1. Clean the crankshaft‑to‑seal running surface and the seal retainer.
2. Inspect the seal retainer for damage.
3. Inspect the seal lip for tears and deformity.

Installation
1. Apply engine oil to the seal‑to‑retainer mating surfaces, the seal lip, the flywheel pilot flange, and the flywheel locating pin.

b a - Flywheel pilot flange

b - Flywheel locating pin
c - Seal‑to‑retainer mating surface
c

30696

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil Seal-to-retainer mating surfaces, seal lip, flywheel pilot
154 92-858087K01
20W-40, NMMA FC-W flange, flywheel locating pin
rated
2. Orient the seal so that the seal lip is facing toward the inside of the engine and place it squarely into the rear main seal
installer.

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 Engine Mechanical
IMPORTANT: The oil seal must be oriented correctly to prevent oil leaks.

a - Toward the interior of the engine

b - Rotation of the crankshaft
c - Rear seal with helical grooves and seal lip toward inside of the engine

b
c

51082

Description SPX Part Number

Rear main seal installer J‑35621‑B
3. Install the seal using the rear main seal installer.
a. Attach the rear main seal installer to the crankshaft and evenly tighten the attaching bolts until the installer is squarely
flush against the engine.

30697

Rear main seal installer

b. Turn the installer wing‑nut clockwise until the seal is evenly seated in the seal retainer.
c. Turn the installer wing‑nut counterclockwise to release the installer from the oil seal.
4. Remove the installer.
5. Wipe off any excess oil.

Oil Pan
Removal
1. Drain the engine oil.
IMPORTANT: Do not alter the orientation of the oil pan oil drain connection fitting.
2. Tow Sports and Inboard Models: Remove the dipstick and dipstick tube.

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Engine Mechanical
NOTE: Tow Sports and inboard models may be equipped with two dipstick tubes.

d
c
c
d
b
e
b d a
a c a
f 30222

Oil drain and dipstick tube connection for MIE models

a - Hollow bolt
b - Plug
c - Hollow bolt fitting
d - Sleeve nut
e - Sealing washer (2)
f - Model with two dipstick tubes (plug not used)

3. Mark the orientation of the oil drain connection fitting.

4. If equipped, remove the quick oil drain connection assembly and sealing washer from the engine oil pan.

Quick oil drain connection styles

b a - Quick oil drain assembly installed in oil pan
b - One piece assembly for MCM and Tow Sport

30223

5. Remove the oil pan.

6. Remove and discard the oil pan gasket.

Cleaning
1. Clean the sealing surfaces of the engine block and oil pan.
2. Clean the oil pan in cleaning solvent.
3. Dry parts with compressed air.

Inspection
1. Inspect the oil pan for cracks, holes, warped sealing surfaces, or other damage.
2. Replace the oil pan if necessary.

Installation
IMPORTANT: The adhesive sets up in approximately 15 minutes. Complete assembly while the adhesive is still wet.

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 Engine Mechanical
1. Apply a 5 mm (13/64 in.) wide and 25 mm (1 in.) long bead of Loctite 5900 to both the right and left side joints of the rear
seal retainer and the joints of front cover.

a b

51073

a - Front cover joints

b - Rear seal retainer joints

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 Oil pan gasket joints 92-809826
RTV Silicone Sealant

IMPORTANT: Always install a new oil pan gasket.

2. Install a new oil pan gasket.

30225

Oil pan gasket

3. Install the oil pan.

4. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing.
5. Starting from the center and working outward in each direction, tighten the oil pan stud nuts and oil pan bolt or stud to
specification.

Description Nm lb–in. lb–ft

Oil pan stud nut 25 18
Oil pan bolt or nut 12 106
6. Sterndrive Models: Install the quick oil drain:
a. Assemble the sealing washer to the oil drain fitting.

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Engine Mechanical
b. Hand start the oil drain fitting into the oil pan drain hole. Tighten the oil drain fitting to specification.

b Quick oil drain connection

styles for MCM models
a - Oil drain fitting for the one
c piece assembly
b - Sealing washer (2)
d c - Oil drain fitting for the quick
connect assembly
d - Release button
e - Quick connect fitting
a e f - Hose
f
30226

Description Nm lb‑in. lb‑ft

Oil drain fitting 20 180
c. If equipped with a quick‑connect assembly, install the drain hose to the quick‑connect fitting and secure with a hose
clamp.
d. Press the release button on the oil drain fitting (previously installed to the oil pan) and insert the quick‑connect fitting
until seated.
7. Tow Sports Models: Install the quick oil drain:
a. Assemble the drain hose to the hollow bolt fitting. Secure with a hose clamp.
b. Assemble the sealing washer to the hollow bolt.
c. Install the hollow bolt fitting to the hollow bolt.
d. Assemble the sealing washer to the hollow bolt.
e. Hand start the hollow bolt into the oil pan drain hole.
f. Tighten the oil drain fitting hollow bolt to specification.

Quick oil drain connection for Tow Sports models

a - Hollow bolt
b - Hollow bolt fitting
c
d c - Drain hose
d - Sealing washer (2)
b

a
30227

Description Nm lb‑in. lb‑ft

Hollow bolt 20 180
8. Inboard Models: Install the dipstick tube and dipstick:
a. Assemble the sealing washer to the hollow bolt.
b. Install the hollow bolt fitting to the hollow bolt.
c. Assemble the sealing washer to the hollow bolt.
d. Hand start the hollow bolt into the oil pan drain hole. Tighten to finger‑tight.
NOTE: Dipstick tube can be positioned on either side of the engine.
e. Install the dipstick tube and secure with hardware as shown. Finger‑tighten the sleeve nut to the hollow bolt fitting.
f. Secure the dipstick tube with a J‑clip and screw.
g. Tighten the sleeve nut in the hollow bolt fitting.
h. If equipped with two dipstick tubes, repeat steps "e" through "g."
i. If equipped with one dipstick tube, install the plug in the hollow bolt fitting. Securely tighten the plug at the fitting.

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 Engine Mechanical
j. Tighten the oil drain fitting hollow bolt to specification.

Typical oil drain and dipstick tube connection for inboard models
d a - Hollow bolt
c b - Plug
c - Hollow bolt fitting
e d - Sleeve nut
e - Sealing washers (2)
b

a
30228

Description Nm lb‑in. lb‑ft

Hollow bolt 20 180
k. Install the appropriate engine oil dipstick.

b
c

33139

30229 Typical inboard engine oil dipstick location

Typical sterndrive engine oil

dipstick location
a - Dipstick
b - Dipstick tube
c - Clamp

9. Fill the crankcase with the specified engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Crankcase 92-858087K01
20W-40, NMMA FC-W
rated

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Engine Mechanical

Oil Pump
Exploded View

5 6
3

7
8

10 11
4

12
1
30248

Oil pump assembly

1 - Driveshaft retainer
2 - Driveshaft
3 - Pump body
4 - Drive gear and shaft
5 - Idler gear
6 - Pressure regulator spring
7 - Pressure regulator valve
8 - Pump cover
9 - Screw (4)
10 - Retaining pin
11 - Pick up screen and suction pipe
12 - Plug

Removal
1. Drain the engine oil from the oil pan.
2. Remove the oil pan.
3. Remove and discard the oil pan gasket.

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 Engine Mechanical
4. Remove the crankshaft oil deflector.

a - Crankshaft oil deflector

b - Oil pump
c - Nuts (5)
c
c

a
b

30249
5. Remove the oil pump, driveshaft retainer, and driveshaft.

d a- Driveshaft
b- Oil Pump
c
e e
c- Nuts (4)
d- Bolt
b e- Oil deflector
f- Driveshaft retainer
a f

30253

Disassembly
1. Remove the pump cover.
IMPORTANT: Gear teeth must be marked for exact positioning when reassembled.
2. Make alignment marks on the idler gear and drive gear teeth.
3. Remove the idler gear and drive gear from pump body.

! CAUTION
The pressure regulator valve is spring‑loaded, retained by a snap ring. The force of the spring can cause injury during
removal. Use caution when disassembling components and wear protective eye equipment.
4. Remove the retaining pin, spring, and pressure regulator valve from the pump cover.
IMPORTANT: Removing the suction pipe and pickup screen can cause air leaks into the oil system, damaging the engine.
Remove the suction pipe and pickup screen assembly for replacement only.
5. If the pickup screen and suction pipe assembly require replacement, mount the pump in a soft‑jawed vise and extract the
suction pipe from the pump.

Cleaning
1. Clean all parts in cleaning solvent.
2. Dry parts with compressed air.

Inspection
IMPORTANT: Pump gears and body are not serviced separately. If the pump gears or body are damaged or worn, replace the
oil pump assembly.
1. Inspect the pump body and cover for cracks or excessive wear.

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Engine Mechanical
2. Inspect the pump gears for damage and excessive wear, such as chipped teeth and galling.
3. Check the gear shafts in the pump body for galling, scoring, or excessive shaft‑to‑bore clearance.
4. Inspect the inside of the pump cover for wear that would permit oil to leak past the gears.
5. Inspect the pickup screen and suction pipe assembly for damage or blockage.
6. Check the pressure regulator valve for smooth, non‑binding fit in its bore in the oil pump cover.
7. Inspect the oil pump locator dowel pins for damage and proper height.

a - Dowel pins
b - Oil pump dowel pin height

b
a

30250

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Oil pump dowel pin height 6.4 mm (0.25 in.)

Reassembly
1. Liberally coat the surfaces of the pressure regulator valve, pressure relief spring, and the pressure regulator bore in the oil
pump body with engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Oil pump components 92-858087K01
20W-40, NMMA FC-W
rated

! CAUTION
The pressure regulator valve is spring‑loaded, retained by a snap ring. The force of the spring can cause injury during
removal. Use caution when disassembling components and wear protective eye equipment.
2. Install the pressure regulator valve and a new pressure relief spring if reusing the existing pump and retaining pin.
3. Liberally coat the surfaces of the oil pump gears and shafts with engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Oil pump gears and shafts 92-858087K01
20W-40, NMMA FC-W
rated
4. Install the drive gear in the pump body.
5. Install the idler gear in the pump body with the smooth side of gear toward the pump cover.
6. Align the gear teeth marks made during disassembly.
7. Fill the gear cavity with engine oil.

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 Engine Mechanical
8. Install the oil pump cover and cover screws. Tighten the screws to specification, using a diagonal pattern.

a - Cover
b b - Screws (4)

30251

Description Nm lb‑in. lb‑ft

Oil pump cover screw 12 106
9. Turn the oil pump driveshaft by hand to ensure smooth pump operation.
IMPORTANT: Improperly installing the intake pipe can cause improper lubrication, damaging the engine. Install the intake
pipe so that the pickup screen is parallel to the bottom of the oil pan. Do not twist, shear, or collapse the oil pump intake
pipe during installation.
10. If the pickup screen and pipe assembly were removed:
a. Mount the pump in a soft‑jawed vise.
b. Apply Loctite 567 to the end of a new suction pipe.

Tube Ref No. Description Where Used Part No.

Loctite 567 PST Pipe
9 Pickup screen and pipe assembly 92-809822
Sealant
c. Using the oil suction pipe installer, tap the suction pipe in place with a hammer.

b a- Oil pump
c b- Pickup screen
c- Oil suction pipe installer
d- Plastic mallet
d
a

30252

Description SPX Part Number

Oil suction pipe installer J‑21882
d. Confirm that the pickup screen is parallel to the bottom of the oil pan when installed.

Installation
1. Align the oil pump driveshaft with the distributor driveshaft.
IMPORTANT: Do not reuse the oil pump driveshaft retainer.
2. Install the oil pump driveshaft, a new driveshaft retainer, and oil pump to the rear main bearing cap.
3. Install the crankshaft oil deflector, nuts, and last oil pump bolt.

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Engine Mechanical
4. Tighten the oil pump bolt and oil deflector nuts to specification.

d a- Driveshaft
b- Oil Pump
c
e e
c- Nuts (4)
d- Bolt
b e- Oil deflector
f- Driveshaft retainer
a f

30253

Description Nm lb‑in. lb‑ft

Oil deflector nut 40 30
First pass 20 15
Oil pump bolt (to rear crankshaft bearing cap)
Final pass (angle torque) + 65°

IMPORTANT: Always install a new oil pan gasket.

5. Install a new oil pan gasket.
6. Install the oil pan. Refer to Oil Pan for installation details.

Crankshaft Balancer
Removal
1. Remove the serpentine belt.
2. Remove the crankshaft drive pulley.
3. Remove the crankshaft balancer retaining bolt.
IMPORTANT: Do not use a universal claw type puller to remove the crankshaft balancer. The outside ring of the balancer
is bonded to the hub with rubber. Use of a claw type puller may damage the balancer.
4. Remove the crankshaft balancer with a harmonic balancer remover and installer.

a - Harmonic balancer remover and installer

b b - Crankshaft balancer

30254

Description SPX Part Number

Harmonic balancer remover and installer J‑23523‑F

Cleaning
1. Clean the crankshaft balancer in cleaning solvent.
2. Dry the parts with compressed air.

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 Engine Mechanical

Inspection
1. Inspect the crankshaft balancer for worn or damaged bolt hole threads.
2. Inspect the crankshaft balancer for damaged or deteriorated rubber between the inner and outer hubs.
3. Inspect the crankshaft balancer for improperly installed or loose balance weights.
4. Inspect the crankshaft balancer keyway for damage.

Installation
IMPORTANT: The inertia weight section of the crankshaft balancer is bonded to the hub with a rubber type material. The
installation procedure (with the proper tool) must be followed or movement of the inertia weight on the hub will destroy the
tuning of the crankshaft balancer.
1. Coat the seal surface of the crankshaft balancer with engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Seal surface of the crankshaft balancer 92-858087K01
20W-40, NMMA FC-W
rated
2. Replace the crankshaft key if it is damaged.
3. To prevent oil leaks, apply Loctite 5900 to the crankshaft balancer keyway.

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 Crankshaft balancer keyway 92-809826
RTV Silicone Sealant
4. Align the keyway of the crankshaft balancer with the crankshaft balancer woodruff key.
5. Use the harmonic balancer remover and installer tool to press the crankshaft balancer onto the crankshaft.

a - Harmonic balancer remover and installer tool

b b - Crankshaft balancer

30256

Description SPX Part Number

Harmonic balancer remover and installer J‑23523‑F

a. Install the plate and screws onto the front of the crankshaft balancer and tighten the screws to specification.

Description Nm lb‑in. lb‑ft

Harmonic balancer remover and installer plate screws 25 18
b. Install the screw into the end of the crankshaft.
c. Install the harmonic balancer remover and installer's bearing, washer, and nut onto the tool screw.
d. Rotate the harmonic balancer remover and installer's nut clockwise until the crankshaft balancer hub is completely
seated against the crankshaft position sensor reluctor ring.
6. Remove the harmonic balancer remover and installer.

90-879288300 AUGUST 2012 Page 3A-71

Engine Mechanical
7. Install the crankshaft pulley and tighten the screws to specification.

a b a - Crankshaft pulley
b - Crankshaft balancer

30255

Description Nm lb‑in. lb‑ft

Crankshaft pulley screw 58 43

a. Install the crankshaft balancer washer with the washer crown facing out from the engine.

a - Crankshaft balancer bolt

b - Crowned washer (crown facing out)
c - Crankshaft pulley

a 30257

b. Install the crankshaft balancer bolt. Tighten to specification.

Description Nm lb‑in. lb‑ft

Crankshaft balancer bolt 95 70
8. Install and adjust the serpentine belt.

Front Cover Oil Seal (without Removing the Front Cover)

Removal
1. Remove the belt and crankshaft pulley.
2. Remove the crankshaft balancer.
3. Pry the seal out of the front of the cover with a seal removal tool. Be careful not to distort the front cover or damage the
crankshaft.

Installation
1. Apply Loctite 5900 to the seal‑to‑crankshaft‑front‑cover mating surface.

Tube Ref No. Description Where Used Part No.

Loctite 5900 Ultra Black
128 Crankshaft front cover mating surface 92-809826
RTV Silicone Sealant
2. Lubricate the rubber sealing surface with clean engine oil.

Page 3A-72 90-879288300 AUGUST 2012

 Engine Mechanical

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Rubber sealing surface 92-858087K01
20W-40, NMMA FC-W
rated
3. Install the new seal with the open end of the seal facing inward. Using the front cover seal installer, drive the seal in until it
seats.
IMPORTANT: Do not use excessive force to drive in the seal.

30311

Front cover seal installer

Description SPX Part Number

Front cover seal installer J‑35468
4. Install the crankshaft balancer.
5. Install the crankshaft pulley and belt.

Front Engine Cover

Removal
1. Drain the seawater and closed cooling systems.
2. Remove the serpentine belt.
3. Remove the crankshaft pulley
4. Remove the hoses from the water circulating pump.
5. Remove the crankshaft balancer.
6. Remove the water circulating pump.
7. Remove the oil pan.
8. Remove the crankshaft position sensor.

c a - Bolt
b - Crankshaft position sensor
c - Engine front cover

a 30312

9. Remove and discard the crankcase front cover.

IMPORTANT: Crankcase front cover is not reusable per manufacturer's specification. It must be replaced if removed.

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Engine Mechanical

Cleaning and Inspection

IMPORTANT: Clean all components thoroughly.
1. Clean old gasket material and sealant from sealing surfaces on engine block.
2. Remove and discard the crankshaft position sensor O‑ring seal.

b a - Crankshaft position sensor

b - O‑ring

30313

Installation
NOTE: New front covers are supplied complete with gasket and crankshaft seal.
1. Lubricate the new crankshaft seal with clean engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Front cover crankshaft seal 92-858087K01
20W-40, NMMA FC-W
rated
2. Install the new front cover, ensuring that the holes in the cover align with the dowel pins in the block. Tighten the screws to
specification.

Description Nm lb‑in. lb‑ft

Front cover screw 12 106

a - Front crankshaft seal

c b - Front engine cover
c - Timing chain and sprockets

a
30314

3. Install a new crankshaft position sensor O‑ring seal.

IMPORTANT: The crankshaft position sensor must be fully seated in the front cover. Erratic engine operation can occur if
the sensor is not properly installed.

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 Engine Mechanical
4. Install the crankshaft position sensor. Ensure that the sensor is fully seated in the cover.

c a - Bolt
b - Crankshaft position sensor
c - Engine front cover

a 30312

5. Install the crankshaft position sensor screw. Tighten to specification

Description Nm lb‑in. lb‑ft

Crankshaft position sensor screw 9 80
6. Install the oil pan.
7. Install the crankshaft balancer.
8. Install the water circulating pump.
9. Connect the hoses to the water circulating pump.
10. Fill the crankcase with engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Crankcase 92-858087K01
20W-40, NMMA FC-W
rated
11. Fill the closed‑cooling system, if equipped.
12. Install the crankshaft pulley.
13. Install the serpentine belt.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
14. Provide a sufficient supply of water to the engine seawater system.
15. Start the engine and check for water and oil leaks.

Timing Chain and Sprockets

Removal
1. Remove the serpentine belt.
2. Remove the water circulating pump.
3. Remove the crankshaft balancer.
4. Remove the oil pan.
5. Remove the front cover.
6. Remove the crankshaft position sensor reluctor ring.

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Engine Mechanical
7. Turn the crankshaft to align the timing marks on the crankshaft and camshaft timing sprockets, or turn the crankshaft to
cylinder number 1 TDC and mark both gears for alignment during reassembly.

a - Crankshaft sprocket
b - Camshaft sprocket
c c - Timing marks
b

30411
8. Check timing chain deflection. Refer to Checking Timing Chain Deflection.
9. Remove the camshaft sprocket.
NOTE: If the sprocket does not come off easily, a light tap on the lower edge of the sprocket with a plastic mallet should
dislodge it.
10. Remove the timing chain.

a- Bolt
b- Timing chain
c- Camshaft sprocket
c d- Crankshaft sprocket keys
e- Crankshaft sprocket

e d 30412

11. Remove the crankshaft sprocket using a crankshaft gear puller.

Description SPX Part Number

Crankshaft Gear Puller J‑5825‑A

Cleaning
1. Clean all parts in solvent.
2. Dry the parts with compressed air.

Inspection
1. Inspect timing chain for wear and damage.
2. Inspect sprockets for wear and damage.
3. Replace as necessary.

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 Engine Mechanical

Assembly
1. Install the sprocket on the crankshaft by using the crank gear installer.

a - Crank gear installer

b - Crankshaft sprocket
a b

30640

Description SPX Part Number

Crank Gear Installer/Seal Driver J‑5590
2. Align the marks on the crankshaft and the camshaft sprockets.
3. Install camshaft sprocket and timing chain. Tighten the sprocket bolts to specification.

Description Nm lb‑in. lb‑ft

Camshaft sprocket bolts 25 18

Checking Timing Chain Deflection

1. Rotate the camshaft (in either direction) to place tension on one side of the chain.
2. Establish and mark a reference point on the block (on taut side of chain) and measure from this point to the chain.

30641

Measuring timing chain deflection

3. Rotate the camshaft in the opposite direction until the non‑reference side of the chain is taut and the reference side of the
chain is slack.
4. Push the chain in toward the sprockets and measure the distance between the reference point and the timing chain.
5. The deflection is the difference between these two measurements. If the deflection exceeds specification, the timing chain
should be replaced.

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Timing chain deflection 11 mm (0.43 in.) maximum

Installation
1. Install the crankshaft position sensor reluctor ring.
IMPORTANT: The front cover is not reusable per manufacturer's specification. It must be replaced if removed.
2. Install a new front cover and gasket.
3. Install the oil pan.
4. Install the crankshaft balancer.

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Engine Mechanical
5. Install the water circulating pump.
6. Install the serpentine belt.

Camshaft
Camshaft Bearing Service
IMPORTANT: Camshaft bearings can be replaced while the engine is disassembled for overhaul or without complete
disassembly. To replace the bearings without complete disassembly, remove the camshaft and crankshaft. Leave the cylinder
heads attached and the pistons in place. Disconnect and position the connecting rods against the outside of the cylinder walls
so that they will not interfere with camshaft bearing replacement.

Measuring Camshaft Lobe Lift

NOTE: This procedure is similar to checking valve timing. If improper valve operation is indicated, measure the lift of each valve
pushrod in consecutive order, record the readings, and compare to specification.
1. Remove the rocker arm covers.
IMPORTANT: Keep the rocker arm assembly from each valve together as a matched set. Mark and organize parts so that
they can be installed in the same location later.
2. Remove the rocker arm assemblies. Keep them in matched sets.
3. Position the dial indicator with the ball socket adapter tool on the valve pushrod. Ensure that the valve pushrod is in the
lifter socket.

c a- Pushrod
b- Ball socket adapter tool
d c- Dial indicator
b d- Dial indicator holding fixture
e- Rocker arm stud
a
e

30151
4. Slowly rotate the crankshaft balancer in the direction of engine rotation until the lifter is on the heel of the cam shaft lobe. At
this point, the valve pushrod will be in its lowest position.
5. Set the dial indicator to 0°.
6. Slowly rotate the crankshaft balancer in the direction of engine rotation until the valve pushrod is in the fully raised position.
7. Compare the total lift recorded from dial indicator to specification.

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
6.97–7.07 mm 7.57–7.67 mm 7.52–7.72 mm
Intake
(0.2744–0.2783 in.) (0.298–0.302 in.) (0.296–0.304 in.)
Cam lift
7.20–7.30 mm 7.82–7.92 mm 7.77–7.98 mm
Exhaust
(0.2834–0.2874 in.) (0.308–0.312 in.) (0.306–0.314 in.)
8. Continue to rotate the engine until the dial indicator reads 0°. This will confirm the accuracy of the original reading.
9. Replace the camshaft if valve lift is not within specifications.
10. If the camshaft readings for all lobes are within specifications, remove the dial indicator assembly.
11. Install the rocker arm assemblies.
12. Adjust the valve clearance.
13. Install the rocker arm covers.
14. Upon starting the engine, check for leaks.

Camshaft Removal
1. Remove all of the components from the front of the engine.
2. Remove the rocker arm covers.
3. Remove the rocker arm assemblies.
4. Remove the valve pushrods.

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 Engine Mechanical
5. Remove the valve lifters.
6. Remove the crankcase front cover.
7. Remove the camshaft sprocket and timing chain.
8. Remove the camshaft thrust plate.

a - Bolts (2)
b - Thrust plate
c c - Engine block

30154

9. Install three 5/16‑18 x 5 in. bolts into the camshaft bolt holes.
10. Carefully rotate and remove the camshaft as shown.

30155

Removing the camshaft

Camshaft Cleaning
1. Clean the camshaft thrust plate with cleaning solvent.
2. Clean the camshaft with cleaning solvent
3. Dry parts with compressed air.

Camshaft Inspection
1. Inspect the camshaft thrust plate for damage. Replace if damaged or worn.
2. Inspect the camshaft for worn, scored, or damaged bearing journals or lobes.
3. Inspect the camshaft bolt hole threads.
4. Inspect the camshaft sprocket locator pin.
5. Measure the camshaft bearing journals with a micrometer. If the journals are not within specification, the camshaft should
be replaced.

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Journal diameter 47.440–47.490 mm (1.8677–1.8697 in.)

90-879288300 AUGUST 2012 Page 3A-79

Engine Mechanical

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Journal out of round 0.025 mm (0.0010 in.)
6. Measure camshaft runout with V‑blocks and a dial indicator. If runout exceeds specification, the camshaft must be
replaced.

b a Checking camshaft runout

a - Camshaft
b - Dial indicator

19672

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Camshaft runout 0.065 mm (0.0026 in.)

Camshaft Installation
If installing new camshaft bearings, refer to Camshaft Bearings.
1. If they have been removed (or when installing a new camshaft), install three 5/16‑18 x 5 in. bolts into the camshaft bolt
holes.
2. Lubricate the camshaft journals with engine oil and install the camshaft. Do not damage the bearings.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Camshaft journals 92-858087K01
20W-40, NMMA FC-W
rated
3. Lubricate the camshaft lobes with Lubriplate SPO 255.

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Camshaft lobes Obtain Locally
4. Remove the three bolts from the camshaft bolt holes.
5. Apply Loctite 242 to the threads of the camshaft thrust plate retaining bolts.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Camshaft thrust plate retaining bolts 92-809821
6. Install the camshaft thrust plate retainer and screws. Tighten the screws to specification.

Description Nm lb–in. lb–ft

Camshaft thrust plate retainer screw 12 106
7. Install the camshaft sprocket and timing chain.
IMPORTANT: The crankcase front cover is not reusable per the manufacturer's specification. If removed, it must be
replaced.
8. Install a new crankcase front cover and gasket.
9. Install the valve lifters.
10. Install the rocker arm assemblies.
11. Adjust the valve clearance.
12. Install the rocker arm covers.

Page 3A-80 90-879288300 AUGUST 2012

 Engine Mechanical

Camshaft Bearings
Camshaft Bearing Service
IMPORTANT: Camshaft bearings can be replaced while the engine is disassembled for overhaul or without complete
disassembly. To replace the bearings without complete disassembly, remove the camshaft and crankshaft. Leave the cylinder
heads attached and the pistons in place. Disconnect and position the connecting rods against the outside of the cylinder walls
so that they will not interfere with camshaft bearing replacement.

Camshaft Bearing Removal

1. With the camshaft and crankshaft removed, drive the camshaft rear plug from the engine block.
NOTE: This procedure involves the removal of the center camshaft bearings first. This process makes the removal of the
outer camshaft bearings easier.
2. Install a nut and thrust washer to the end of the threads on the camshaft bearing remover and installer.

Description SPX Part Number

Camshaft bearing remover and installer J‑6098‑10
3. Position the index pilot in the front camshaft bearing.

c
a- Bearing driver
b- Bearing
c- Wrench
d- Tool screw
e- Index pilot
b

e d
a
30157

4. Install the puller screw through the index pilot.

5. Install the driver with its shoulder toward the center bearing. Ensure that a sufficient number of tool screw threads are
engaged.
6. Using one wrench to hold the puller screw, turn the nut with a second wrench.
7. Pull the bearing from the bore.
8. Remove the driver and bearing from the puller screw.
9. Remove the front intermediate bearing in a similar manner.
10. Position the index pilot in the rear camshaft bearing to remove the rear intermediate bearing.
11. Assemble the driver and driver handle of the camshaft bearing remover and installer. Drive the front and rear camshaft
bearings toward the center of the engine block, and remove the bearings.

a - Driver
b - Driver handle
c - Bearing
c

b a 19677

Camshaft Bearing Inspection

1. Inspect the camshaft bearings for excessive wear or scoring. If any one camshaft bearing is excessively worn or scored,
replace all of the camshaft bearings.

90-879288300 AUGUST 2012 Page 3A-81

Engine Mechanical
2. Inspect the camshaft bearings for correct fit into the engine block camshaft bearing bores. The camshaft bearings have an
interference fit to the engine block and must not be loose in their bores.

Camshaft Bearing Installation

IMPORTANT: Front and rear bearings must be installed last, as the index pilot will not fit into the bearing bores if the front and
rear bearings are installed.
1. Lubricate the outer surface of the new camshaft bearings with engine oil to ease installation.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Outer surface of the camshaft bearings 92-858087K01
20W-40, NMMA FC-W
rated

IMPORTANT: The camshaft bearings are designed for specific installed positions. Install the bearings in their proper
locations and position them correctly as indicated by the bearing manufacturer.
2. Plan the camshaft bearing installation such that the camshaft bearing oil holes are indexed as indicated below.

30161

Camshaft bearing oil hole

Camshaft Bearing Oil Hole Indexing (from front of engine)

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Front camshaft bearing 6 o'clock
5 o'clock
Intermediate and center camshaft bearings
(Position even with the bottom of the cylinder bore)
Rear camshaft bearing 12 o'clock
3. Install the intermediate and center camshaft bearings using the cam bearing remover and installer tool.
a. Install a nut and thrust washer onto the puller screw.
b. Position the tool pilot in the front camshaft bearing bore and insert the tool screw through the pilot.
c. Index the center camshaft bearing.
d. Position an appropriately sized removal and installation tool in the bearing and thread the puller screw into the tool.
Engage at least 13 mm (1/2 in.) of puller screw threads.
e. Using two wrenches, hold the puller screw and turn the nut until the bearing is pulled into position.
f. Remove the removal and installation tool and confirm bearing oil hole indexing.
g. Install the front intermediate bearing in a similar manner. Confirm bearing oil hole indexing.

Page 3A-82 90-879288300 AUGUST 2012

 Engine Mechanical
h. Position the removal and installation tool pilot in the rear camshaft bearing bore to install the rear intermediate
bearing. Confirm bearing oil hole indexing.

c
a- Bearing driver
b- Bearing
c- Wrench
d- Tool screw
e- Index pilot
b

e d
a
30157

Description SPX Part Number

Cam bearing remover and installer J‑6098‑O1
Cam bearing remover and installer adapter J‑6098‑10
4. Install the front and rear camshaft bearings using the cam bearing remover and installer.
a. Install the appropriately sized removal and installation tool onto the drive handle.
b. Index the front bearing and drive it into position with the tool.
c. Index the rear bearing and drive it into position with the tool.
d. Confirm bearing oil hole indexing.
IMPORTANT: The camshaft rear bearing hole plug must be installed 8.8 mm (0.3465 in) deep and must be parallel
with the rear surface of the engine block.

a - Driver
b - Driver handle
c - Bearing
c

b a 19677

5. Apply Loctite 567 to the outside of a new camshaft rear bearing hole expansion plug.

Tube Ref No. Description Where Used Part No.

Loctite 567 PST Pipe
9 Camshaft rear bearing hole expansion plug 92-809822
Sealant
6. Install the new camshaft rear bearing hole expansion plug so that it is parallel to the outer engine block surface and inset
8.80 mm (0.3465 in).

90-879288300 AUGUST 2012 Page 3A-83

Engine Mechanical

Connecting Rod, Bearings, and Piston Assembly

Exploded View
1 1- Upper compression ring
2- Lower compression ring
3- Upper oil control ring
2
4- Oil control ring spacer
5- Lower oil control ring
3 6- Piston pin
7- Piston
8- Connecting rod
4 9- Rod bolt (2)
10 - Upper bearing half
5 11 - Lower bearing half
12 - Bearing cap
6 13 - Nuts (2)
7

8
9

10
11

12

13
30318

Removal
1. Remove the engine cover.
2. Drain the seawater and closed‑cooling systems.
3. Drain the engine oil.
4. Remove all components from the front of the engine.
5. Remove the exhaust elbow and manifold assemblies.
6. Remove the rocker arm covers.
7. Remove the distributor and intake manifold assembly.
8. Remove the cylinder heads.
9. Remove the dipstick tube and oil pan.
10. Remove the crankshaft oil deflector and oil pump.
11. Using a ridge reamer, remove any ridge or combustion deposits from the top of the cylinder bore.
a. Turn the crankshaft until the piston is at the bottom of its stroke.
b. Place a cloth on top of the piston to collect cuttings.
c. Use a cylinder bore ridge reamer to remove any ridge or deposits.

Description Part Number

Cylinder bore ridge reamer obtain locally
d. Turn the crankshaft until the piston is at the top of its stroke.
e. Remove the cloth and cuttings.
12. Turn the crankshaft to gain access to the connecting rods and bolts.

Page 3A-84 90-879288300 AUGUST 2012

 Engine Mechanical
IMPORTANT: Mark or identify each connecting rod and bearing cap assembly to ensure placement in its original location
during reassembly.
13. Mark the connecting rods and bearing caps with their corresponding cylinder number (port bank 1, 3, 5 and 7; starboard
bank 2, 4, 6 and 8 from front to rear of engine).
IMPORTANT: Before removing the connecting rod cap, mark and organize the connecting rods and caps so that they can
be installed in the same location later.
14. Remove the connecting rod bearing cap.
IMPORTANT: Connecting rod bolt threads can damage the crankshaft journal and cylinder bore.
15. Cover the connecting rod bolt threads with protective caps.
NOTE: Appropriately sized clean rubber tubing may be used as protective caps in place of the connecting rod bolt guides.

b a - Connecting rod bolts

b - Protective caps

30338

Description SPX Part Number

Connecting rod bolt guide J‑ 5239 (bolt guide set)
16. Push the piston and connecting rod out of the top of the cylinder bore.
IMPORTANT: The mating surfaces of the connecting rods and the connecting rod bearing caps form an individual fit and
as a result must not be interchanged or damaged under any circumstances. To avoid damage, do not lay connecting rods
or connecting rod bearing caps on their mating surfaces.
17. Remove the connecting rod bearings. Keep each bearing pair and their original connecting rod and connecting rod cap
together as a matched set.

Disassembly
1. Remove the piston rings from the pistons.

Piston Ring Expander 91‑24697

2. Press the piston pin from the connecting rod using a piston pin press. Follow the tool manufacturer's instructions.

a a - Piston pin press

b - Remover
c - Piston and rod assembly
b

30339

Description SPX Part Number

Piston pin press J‑24086‑C (piston pin service set)
3. Mark, separate, and organize parts so that they can be installed in the same locations.

90-879288300 AUGUST 2012 Page 3A-85

Engine Mechanical

Cleaning
1. Connecting rods
a. Clean the connecting rods in cleaning solvent.
b. Dry parts with compressed air.
2. Connecting rod bearings
a. Clean the connecting rod bearings in cleaning solvent. Do not scratch the bearing contact surfaces.
b. Wipe the bearings clean with a soft cloth.
c. Dry parts with compressed air.
3. Pistons
a. Clean the pistons in non‑corrosive cleaning solvent.
b. Clean varnish from the piston skirt and pin with a suitable cleaning solvent.
c. Clean the piston ring grooves.
d. Clean the piston oil lubrication holes and slots.
e. Dry parts with compressed air.
4. Piston pin
a. Clean parts in cleaning solvent.
b. Dry parts with compressed air.

Preliminary Inspection
IMPORTANT: All measurements should be taken when components are at room temperature.
1. Connecting rod
a. Check for twisted or bent connecting rods.
b. Inspect for nicks and cracks.
c. Inspect for damage to the bearing cap or bolt threads.
d. Replace damaged connecting rods.
2. Connecting rod bearings
NOTE: Refer to Crankshaft Main Bearings for examples of common bearing failures.
a. Inspect the connecting rod bearings for craters, pockets or flattened sections.
b. Inspect the connecting rod bearings for excessive scoring, discoloration, or damage.
c. Inspect the connecting rod bearings for dirt or debris imbedded in the bearing material.
d. Replace damaged or faulty bearings.

Connecting Rod Bearing Clearance, Micrometer Method

IMPORTANT: The micrometer method is the preferred method of determining connecting rod bearing clearance.
IMPORTANT: All measurements should be taken when components are at room temperature.
Connecting rod bearings are of the precision insert type and do not use shims for adjustment. Replace the bearing if clearance
is found to be excessive. Service bearings are available in standard size and 0.001 in. and 0.002 in. undersized for use with
new and used standard size crankshafts. They are also available in 0.010 in. and 0.020 in. undersized for use with
reconditioned crankshafts.
NOTE: When removing a connecting rod cap, you may find a 0.010 in. undersized bearing. These are used during
manufacturing for selective fitting.
1. Wipe both the upper and lower connecting rod bearings clean with a soft cloth.
2. Install the upper and lower connecting rod bearings.
3. Install the bearing cap.
4. In a two‑pass sequence, tighten the bearing cap nuts to specification.

Description Nm lb–in. lb–ft

Connecting rod nut, First pass 27 20

5.0 L (305 cid) and 5.7 L (350 cid) Final pass (angle torque) + 70°

Connecting rod nut, First pass 27 20

6.2 L (377 cid) Final pass (angle torque) + 45°
5. Use an inside dial indicator to measure the connecting rod bearing inside diameter, out‑of‑round, and taper. Measure in
several places approximately 90° apart and average the measurements.

Page 3A-86 90-879288300 AUGUST 2012

 Engine Mechanical
IMPORTANT: Do not measure inside diameter close to the connecting rod and bearing split line.

a - Inside dial indicator

b - Assembled rod and bearings
c - Split line

a b
c
30340

6. Record the measurements.

7. Wipe the crankshaft connecting rod journal with a clean cloth. Remove any oil film.
8. Measure the crankshaft connecting rod journal diameter with a micrometer. Take a second measurement at a position on
the connecting rod journal at a point 90° from the first measurement.

a - Measurement point "a"

b b - Measurement point "b"

a a

30347

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Rod bearing journal diameter 53.284–53.335 mm (2.0978–2.0998 in.)
Production 0.007 mm (0.0003 in.)
Rod bearing journal taper
Service limit 0.025 mm (0.0010 in.)

Rod bearing journal Production 0.007 mm (0.0003 in.)

out‑of‑round Service limit 0.025 mm (0.0010 in.)

NOTICE
Inadequate clearance or interference between the bearing and its mating surface will result in rapid bearing wear and
catastrophic component failure. Check all bearing clearances.
9. If the crankshaft rod bearing journal diameters are not within specifications, replace or recondition the crankshaft.
10. If the crankshaft rod bearing journal diameters are within specifications, determine bearing clearance by subtracting the
crankshaft connecting rod journal outer diameter from the inner diameter of the bearing from step 5.

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.033–0.088 mm
Production 0.033–0.078 mm (0.0013–0.0031 in.)
(0.0013–0.0035 in.)
Journal clearance
0.025–0.076 mm
Service limit 0.025–0.063 mm (0.0010–0.0025 in.)
(0.0010–0.0029 in.)
11. If the clearance exceeds specifications, select a new, correct size bearing, and recheck the bearing clearance.

90-879288300 AUGUST 2012 Page 3A-87

Engine Mechanical

Connecting Rod Bearing Clearance, Plastic Gauge Method

The plastic gauge method is an optional method of determining connecting rod bearing clearance. Micrometer measurement is
the preferred method.
1. Wipe both upper and lower bearings and the crankshaft connecting rod journal with a clean soft cloth. Remove any oil film.
2. Install the bearings in the connecting rod and cap.
IMPORTANT: To obtain accurate measurements the connecting rod and upper bearing must be seated against the
connecting rod journal before installing the lower bearing and rod cap.
3. Rotate the crankshaft or move the connecting rod until the upper bearing is fully seated against the connecting rod journal
being measured.
IMPORTANT: Position the plastic gauge on the crankshaft journal so that it will be centered as it lays across the bearing
shell.
4. Place a piece of gauging plastic parallel to the crankshaft on the middle of the open crankshaft connecting rod journal
surface as shown.

30348

Plastic gauge placement

5. Install the bearing cap.

6. In a two‑pass sequence, tighten the bearing cap nuts to specification.

Description Nm lb–in. lb–ft

Connecting rod nut, First pass 27 20

5.0 L (305 cid) and 5.7 L (350 cid) Final pass (angle torque) + 70°

Connecting rod nut, First pass 27 20

6.2 L (377 cid) Final pass (angle torque) + 45°

IMPORTANT: Do not rotate the crankshaft while the gauging plastic is between the bearing and the journal.

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 Engine Mechanical
7. Without rotating the crankshaft, remove the bearing cap and use the scale on the gauging plastic envelope to measure the
gauging plastic width at the widest point.

a
b

19552

Measure clearance

Description 5.0 L (305 cid) and 5.7 L (350 cid) 6.2 L (377 cid)
0.033–0.088 mm
Production 0.033–0.078 mm (0.0013–0.0031 in.)
Connecting rod journal (0.0013–0.0035 in.)
clearance 0.025–0.076 mm
Service limit 0.025–0.063 mm (0.0010–0.0025 in.)
(0.0010–0.0029 in.)
8. If the clearance exceeds specifications, select a new, correct size bearing and recheck the clearance. A standard and
undersized connecting rod bearing combination may result in the proper clearance.
NOTE: If clearance cannot be brought to within specifications, the crankshaft connecting rod journal will have to be ground
undersized. If the connecting rod journal is already at maximum undersized, replace the crankshaft.
9. Ensure that all gauging plastic has been removed from the bearing and crankshaft surfaces.
10. Coat the selected bearing surface with oil.
11. Install the connecting rod cap.
12. In a two‑pass sequence, tighten the bearing cap nuts to specification.

Description Nm lb–in. lb–ft

Connecting rod nut, First pass 27 20

5.0 L (305 cid) and 5.7 L (350 cid) Final pass (angle torque) + 70°

Connecting rod nut, First pass 27 20

6.2 L (377 cid) Final pass (angle torque) + 45°

Connecting Rod Side Clearance

1. When all the connecting rod bearings have been installed, tap each rod lightly (parallel to the crankshaft) to establish
clearance.

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Engine Mechanical
2. Measure the side clearance between each pair of connecting rod caps.

6408

Measuring connecting rod side clearance

Connecting rod 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.15–0.68 mm
Side clearance 0.15–0.61 mm (0.006–0.024 in.)
(0.006–0.027 in.)

Piston Inspection
NOTE: Cylinder bore and taper must be within specifications before pistons can be considered for reuse.
1. Replace pistons that are damaged or show signs of excessive wear.
2. Inspect the piston for damage caused by pre‑ignition.

14394

Typical pre-ignition damage

Page 3A-90 90-879288300 AUGUST 2012

 Engine Mechanical

a b c d

30341

a- Pre‑ignition begins
b- Controlled ignition spark
c- Remaining fuel ignition
d- Flame front collision

NOTE: Engine failures that result from these conditions are beyond the control of Mercury MerCruiser. No warranty will
apply to failures that occur under these conditions.
3. If indicated, inspect the engine for causes of pre‑ignition damage to pistons.
• Combustion chamber hot spots caused by damaged components, foreign material, or combustion chamber deposits
• Overheated spark plug electrodes (improper heat range or defective plug)
• Inadequate engine cooling
4. Inspect the piston for damage caused by detonation (knock).

23037

Typical detonation damage

a b c d

23039

a- Controlled ignition spark

b- Combustion begins
c- Continued combustion
d- Detonation occurs

NOTE: The use of poor quality, contaminated or incorrect fuels will cause poor performance and engine damage.
5. If indicated, inspect the engine for causes of detonation damage to pistons:
• Use of low octane gasoline or neglecting engine maintenance
• Lean fuel mixture at or near full throttle (could be caused by leaking intake manifold)
• Cross‑firing ignition system
• The accumulation of deposits on piston or combustion chamber that result in a higher compression ratio

90-879288300 AUGUST 2012 Page 3A-91

Engine Mechanical
• Inadequate engine cooling
NOTE: Engine failures that result from these conditions are beyond the control of Mercury MerCruiser. No warranty will
apply to failures that occur under these conditions.
6. Inspect the piston for cracked ring lands, skirts and pin bosses, wavy or worn ring lands, scuffed or damaged skirts, and
eroded areas at the top of piston.
7. Inspect the ring grooves for nicks and burrs that may cause the rings to bind.
8. Inspect the piston for wear by checking piston to bore clearance:
a. Measure the piston diameter 11.0 mm (0.433 in.) from the bottom of the skirt at a right angle to the piston pin bore as
shown.

a Measuring piston diameter

b a - Piston diameter
b - Measurement location

22022

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
94.894–94.947 mm
Piston Diameter 101.618–101.643 mm (4.0007–4.0017 in.)
(3.7360–3.73881 in.)
b. Measure the cylinder bore diameter with a telescope gauge 64 mm (2‑1/2 in.) from the top of the cylinder bore at 90°
from the crankshaft center‑line.

30342
Measuring cylinder bore

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
94.894–94.947 mm
Diameter 101.618–101.643 mm (4.0007–4.0017 in.)
(3.7360–3.7381 in.)
Production 0.025 mm (0.0010 in.) maximum
Out‑of‑round
Service limit 0.05 mm (0.0020 in.) maximum
Production, thrust
0.012 mm (0.0005 in.) maximum
side
Taper Production, relief
0.025 mm (0.0010 in.) maximum
side
Service limit 0.025 mm (0.0010 in.) over production specification
c. Subtract the piston diameter from the cylinder bore diameter to determine piston‑to‑bore clearance.
d. Replace the piston if the piston‑to‑bore clearance is less than specified. For cylinder reconditioning and piston
replacement refer to Crankshaft, Main Bearings, and Engine Block.

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 Engine Mechanical

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.018–0.061 mm 0.018–0.053 mm 0.018–0.053 mm
Production
Piston‑to‑bore (0.0007–0.0024 in.) (0.0007–0.0021 in.) (0.0007–0.0021 in.)
clearance 0.018–0.068 mm 0.018–0.061 mm 0.018–0.068 mm
Service limit
(0.0007–0.0027 in.) (0.0007–0.0024 in.) (0.0007–0.0027 in.)
9. Insert the appropriate type of piston ring into each of the piston ring grooves.
10. Roll the ring around the groove to ensure that the ring moves freely around the entire piston.
• If the ring binds, check the piston ring groove for deposits. Clean out all deposits.
• If the ring binds, check the piston ring groove for nicks or burrs. Minor internal damage can be dressed with a fine file.
• If the ring binds, but the piston ring groove is clean and free of defects, it is possible that the ring used for the
inspection is bent. Recheck the groove with a different ring.

19616

Checking piston ring grooves

11. Using a feeler gauge, measure the clearance between the piston ring and the piston ring groove at several points around
the piston.

49888

Measuring piston-ring-to-piston clearance

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)

Top compression ring Production 0.030–0.070 mm (0.0012–0.0028 in.)

clearance Service limit 0.030–0.090 mm (0.0012–0.0035 in.)

90-879288300 AUGUST 2012 Page 3A-93

Engine Mechanical

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.030–0.074 mm 0.038–0.080 mm 0.0408–0.080 mm
Production
Second compression ring (0.0012–0.0029 in.) (0.0015–0.0031 in.) (0.0015–0.0030 in.)
clearance 0.030–0.090 mm 0.040–0.100 mm 0.040–0.100 mm
Service limit
(0.0012–0.0035 in.) (0.0016–0.0039 in.) (0.0015–0.0040 in.)
0.051–0.203 mm 0.046–0.096 mm 0.051–0.170 mm
Production
(0.0020–0.0080 in.) (0.0018–0.0038 in.) (0.0020–0.0067 in.)
Oil control ring clearance
0.051–0.220 mm 0.046–0.100 mm 0.051–0.195 mm
Service limit
(0.0020–0.0090 in.) (0.0018–0.0039 in.) (0.0020–0.0076 in.)
12. Replace the piston if the groove clearance exceeds the specified limit.

Piston Pin Inspection

IMPORTANT: Piston pin clearance is designed to maintain adequate clearance under all engine operating conditions. Because
of this, the piston and the piston pin are a matched set and not serviced separately.
NOTE: Piston pin bores and piston pins must be free of scuffing and deposits before they can be accurately measured.
1. Inspect the piston pin bores and piston pins for wear.
2. Measure the piston pin diameter with a micrometer.

22026

Measuring piston pin diameter

3. Measure the piston pin bore inside diameter with a dial bore gauge or inside micrometer.

30371

Measuring piston pin bore diameter

4. Subtract the piston pin diameter from the piston pin bore diameter to determine the clearance.

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
23.559–23.561 mm
Piston pin diameter 23.545–23.548 mm (0.9270–0.9271 in.)
(0.9275–0.9276 in.)
0.010–0.020 mm
Production 0.013–0.023 mm (0.0005–0.0009 in.)
Piston pin clearance (0.0004–0.0008 in.)
Service limit 0.013–0.025 mm (0.0005–0.0010 in.) maximum
5. Measure the connecting rod piston pin bore diameter with a dial bore gauge or inside micrometer.
6. Subtract the piston pin diameter from the connecting rod piston pin bore diameter to determine fit‑in‑rod clearance.

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 Engine Mechanical

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.021–0.040 mm
Piston pin fit‑in‑rod interference 0.012–0.050 mm (0.0005–0.0020 in.)
(0.00082–0.00157 in.)
7. If the clearance exceeds the service limit, replace the piston and piston pin assembly.

Piston Ring Gap Inspection

IMPORTANT: Fit each compression ring to the cylinder in which it is going to be used.
1. Insert a piston ring into the cylinder bore.
2. Use an inverted piston to push the piston ring 6.0 mm (1/4 in.) into the cylinder bore.
NOTE: Ensure that the piston and ring are square to the cylinder wall.
3. Remove the piston.
4. Using a feeler gauge, measure the piston ring gap.

30372

Measuring piston ring gap

Piston Ring Gap Specifications

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.25–0.51 mm 0.25–0.40 mm 0.25–0.51 mm
Production
Top compression ring (0.0098–0.020 in.) (0.0098–0.016 in.) (0.009–0.020 in.)
gap 0.25–0.65 mm 0.25–0.50 mm 0.30–0.68 mm
Service limit
(0.0098–0.026 in.) (0.0098–0.0197 in.) (0.012–0.027 in.)
0.46–0.66 mm 0.38–0.58 mm 0.46–0.66 mm
Production
Second compression ring (0.018–0.026 in.) (0.015–0.023 in.) (0.018–0.026 in.)
gap 0.46–0.90 mm 0.46–0.80 mm 0.51–0.94 mm
Service limit
(0.018–0.035 in.) (0.018–0.031 in.) (0.020–0.037 in.)
Production 0.25–0.76 mm (0.0098–0.0299 in.)
Oil control ring gap 0.25–0.89 mm 0.25–0.90 mm 0.28–0.81 mm
Service limit
(0.0098–0.0350 in.) (0.0098–0.0354 in.) (0.0110–0.0319 in.)
5. Replace the ring if the gap exceeds service limits. If the ring gap is below specifications, remove the ring and try another.

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Engine Mechanical

Assembly
IMPORTANT: When reassembling the pistons and connecting rods, the following must be kept in mind.
• The piston and pin are machine fitted to each other and must remain together as a matched set. Do not mix pistons and
pins.
• If the original pistons or connecting rods are being used, install them into the cylinder from which they were removed.
• The connecting rod bearing tangs are always oriented toward the outside of the engine block.
• The notch on the top of the piston must be positioned toward the front of the engine (water pump end).

a b Piston notch
a - 5.0 L (305 cid)
b - 5.7 L (350 cid) and 6.2 L (377 cid)

30378

1. Piston and Connecting Rod Assembly:

a. Assemble the piston and connecting rod using the piston pin press. Follow the tool manufacturer's instructions.

a a - Piston pin press

b - Piston pin
c - Piston and rod assembly
b

30339

Description SPX Part Number

Piston pin press J‑24086‑C (piston pin service set)
b. Check that the piston will pivot and slide freely on the piston pin. Piston and rod assemblies that bind have a piston
pin or bore out of specification and require replacement of the piston and pin assembly
c. If a new connecting rod has been installed, mark the connecting rod and cap (on the with slots for the connecting rod
bearing tangs) with cylinder number in which it will be installed.
2. Piston Ring Installation:
IMPORTANT: All compression rings are marked on the upper side of the ring. When installing compression rings, ensure
that the marked side is toward the top of the piston.
NOTE: Oil control rings are three‑piece type, consisting of two rings and a spacer.
a. Select rings appropriate for the cylinder bore and piston size.
b. Install the oil control ring spacer in its groove.

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 Engine Mechanical
c. Hold the spacer ends together and install the lower oil control ring with its gap properly located.

e Ring gap locations

b a a - Oil ring spacer gap
b - Oil ring gaps
c - Lower compression ring gap
d - Upper compression ring gap
c d e - Front of engine

b a
30387
d. Install the upper oil control ring with its gap properly located.
e. Flex the oil ring assembly to ensure that the rings move freely.
IMPORTANT: Use the piston ring expander for compression ring installation.

Piston Ring Expander 91‑24697

f. Using a piston ring expander, install the lower and upper compression rings with the marked side up.

Installation
IMPORTANT: Cylinder bores must be thoroughly cleaned before piston installation.
1. Cylinder bore preparation:
a. Clean cylinder bores with a light honing, as necessary.
b. Clean with hot water and detergent.
c. Rinse thoroughly.
d. Lightly oil the cylinder bores with a clean, lint free white cloth and engine oil. Repeat until the cloth remains clean.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Cylinder walls 92-858087K01
20W-40, NMMA FC-W
rated
e. Wipe down the cylinder bores a final time with a clean, lint free white cloth.
2. Rotate the crankshaft until the crankpin is at bottom dead center for the cylinder that is ready for the first piston to be
installed.
3. Carefully wipe any foreign material from the connecting rod bearings and the connecting rod bearing fitting surfaces.
IMPORTANT: Do not oil the back of the bearings or the connecting rod bearing mating surfaces.
4. Insert the bearing shells into the connecting rod and its matching rod cap.

a- Bearing tabs
a b- Connecting rod
c- Upper bearing half
d- Lower bearing half
e e- Rod cap

b
c

d 30388

5. Liberally lubricate the connecting rod bearings, pistons, rings, and cylinder walls with clean engine oil.

90-879288300 AUGUST 2012 Page 3A-97

Engine Mechanical

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Connecting rod bearings, pistons, rings, and cylinder walls 92-858087K01
20W-40, NMMA FC-W
rated
6. With the bearing caps removed, install bolt guides onto the connecting rod bolts. It is acceptable to use clean rubber tubing
for the bolt guides.

b a - Connecting rod bolt (2)

b - Bolt guides (2)

30338

Description SPX Part Number

Bolt guide set (3/8–24) J‑5239
7. Position ring gaps as shown.

e Ring gap locations

b a a - Oil ring spacer gap
b - Oil ring gaps
c - Lower compression ring gap
d - Upper compression ring gap
c d e - Front of engine

b a
30387
8. Use a piston ring compressor to compress the rings.

30399

Piston ring compressor use

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 Engine Mechanical
IMPORTANT: Be sure to install new pistons in the cylinders for which they were fitted and used pistons in the cylinders
from which they were removed. Each connecting rod and bearing cap should be marked, beginning at the front of the
engine (1, 3, 5, and 7 from the left bank and 2, 4, 6, and 8 from the right bank). Numbers on the connecting rod and
bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one
block or cylinder to another, new bearings should be fitted and the connecting rod should be numbered to correspond with
the new cylinder number.
9. Install each connecting rod and piston assembly in its respective bore with the connecting rod bearing tangs toward the
outside of the engine block and the piston notch toward the front of the engine.
10. Guide the connecting rod into place on the crankshaft journal with the connecting rod bolt guides installed.
11. Hold the piston ring compressor firmly against engine block until all piston rings have entered the cylinder bore.
12. Using a wooden or plastic hammer handle, lightly tap the piston into its bore.
13. Remove the connecting rod bolt guides.
14. Apply engine oil to the threads and mating faces of each connecting rod cap, bolt, and nut.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Connecting rod and rod cap 92-858087K01
20W-40, NMMA FC-W
rated

NOTICE
Connecting rods and end caps are matched sets. Mismatching the original pairs will result in catastrophic engine damage.
Install all connecting rods with their matched end caps.
15. Install the connecting rod cap.

a Installing connecting rod caps

b a - Connecting rod nuts (2)
b - Connecting rod cap
c c - Lower bearing half

19597

16. In a two‑pass sequence, tighten the bearing cap nuts to specification.

Description Nm lb‑in. lb‑ft

Connecting rod nut, First 27 20

5.0 L (305 cid) and 5.7 L (350 cid) Final + 70°

Connecting rod nut, First 27 20

6.2 L (377 cid) Final + 45°
17. Lightly tap each connecting rod assembly parallel to the crankpin to set the side clearance.

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Engine Mechanical
18. Measure all connecting rod side clearances between the connecting rod caps.

6408

Measuring connecting rod side clearance

Connecting rod 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.15–0.68 mm
Rod side clearance 0.15–0.61 mm (0.006–0.024 in.)
(0.006–0.027 in.)
19. Complete the engine assembly as follows. Refer to the appropriate procedures found in this service manual, as required.
a. Install the oil pump and crankshaft oil deflector.
b. Install the dipstick and oil pan.
c. Install the cylinder heads.
d. Install the intake manifold assembly.
e. Install the distributor.
f. Adjust the valves.
g. Install the rocker arm covers.
h. Install the exhaust elbow and manifold assemblies.
i. Fill the crankcase with the proper viscosity and quantity of oil. Refer to Section 1C.
j. Install all other external components removed from the front of the engine.

Crankshaft, Main Bearings, and Engine Block

Removal
If only the main bearings are being serviced, refer to Main Bearing Replacement without Crankshaft Removal.
NOTE: The engine port and starboard cylinder heads are removed for illustration clarity.
1. Remove components and empty fluids from the engine block as follows. Refer to the appropriate procedures found in this
manual (unless otherwise noted), as required.
a. Disconnect all electrical connections to the engine.
b. Disconnect the throttle and shift remote control cables (if equipped).
c. For sterndrive models, remove the sterndrive unit. Refer to the appropriate sterndrive service manual for details.
d. For inboard models, remove the transmission.
e. Drain the seawater‑cooling and closed‑cooling systems.
f. Remove the engine from the boat.
g. Mount the engine on a suitable engine stand.
h. Drain the engine oil.
i. Remove the starter.
j. Remove the flywheel housing.
k. Remove the coupler or drive plate.

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 Engine Mechanical
l. Remove the flywheel.
m. Remove the serpentine belt.
n. Remove the water circulating pump.
o. Remove the crankshaft pulley and the crankshaft balancer.
p. Remove the spark plugs.
q. Remove the dipstick tube and the oil pan.
r. Remove the crankshaft oil deflector and the oil pump.
s. Remove the crankshaft position sensor. Discard the O‑ring seal.
t. Remove the engine front cover.
2. Remove the crankshaft position sensor tone‑ring.

a - Engine front cover

b - Tone‑ring

a b
30410
3. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are in alignment, or turn the engine to
cylinder number 1 TDC, and mark both gears for alignment during reassembly.

a - Crankshaft timing sprocket

b - Camshaft timing sprocket
c c - Timing mark alignment
b

30411
4. Remove the camshaft sprocket.
NOTE: If the sprocket does not come off easily, a light tap on the lower edge of the sprocket with a plastic mallet should
dislodge it.
5. Remove the timing chain.

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Engine Mechanical
6. Remove the crankshaft sprocket using the crankshaft gear puller.

a- Bolt
b- Timing chain
c- Camshaft sprocket
c d- Crankshaft sprocket keys
e- Crankshaft sprocket

e d 30412

Description SPX Part Number

Crankshaft gear puller J‑5825‑A
7. Remove the rear main seal retainer and seal.
8. Remove the connecting rod and piston assemblies.
IMPORTANT: Inspect the bearing caps for orientation marks prior to removal. If no markings exist, make suitable marks
before disassembly so that they can be reinstalled in their original locations.
9. Ensure that all of the bearing caps are marked so that they can be installed in their original locations.

a - Main bearing cap

b - Bearing cap marks

1 b

30413
10. Remove the main bearing caps and carefully lift the crankshaft out of the engine block.

c Main bearing cap removal (typical)

a - Main bearings
b b - Main bearing caps
c - Main bearing cap bolts
d - Crankshaft
a

30414

Page 3A-102 90-879288300 AUGUST 2012

 Engine Mechanical
11. If new main or connecting rod bearings are to be installed, remove the main bearing inserts from the engine block and the
bearing caps or connecting rod bearing inserts from the connecting rods and caps. Install new bearings.

Cleaning
Crankshaft
1. Clean the crankshaft in cleaning solvent. Ensure that the oil passages are clear of sludge and restriction.
2. Dry with compressed air.

Main Bearings
1. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth. Do not scratch the
crankshaft bearing surfaces.
2. Dry with compressed air.

Engine Block
1. Remove all engine components.
2. Remove the camshaft rear bearing hole expansion cup plug.

a a - Rear of engine block

b - Rear camshaft expansion plug

30415

3. Remove the oil pressure sender and oil gallery plugs.

b a - Oil pressure sender location

b - Upper oil gallery plug
c - Rear oil gallery plugs (3)
c

a
30416

4. Insert a 3/8 in. x 26 in. rod into the rear oil gallery holes and drive out (remove) the front oil gallery plugs. Discard the plugs.

30417

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Engine Mechanical

NOTE: Expansion plugs may be removed with a sharp punch or drilled and pried out.
5. Remove and discard the engine block core hole expansion plugs.

30419

Expansion plug removal

6. Clean all sealing surfaces.

7. Remove all gasket and sealant residue.
8. Clean the engine block with cleaning solvent.
9. Flush the engine block with clean water or steam clean.
10. Clean the cylinder bores.
11. Clean the oil galleries and oil passages.
12. Clean scale and deposits from coolant passages.
13. Clean the engine block cylinder head bolt holes and dry with compressed air.
14. After cleaning the engine block, spray or wipe the cylinder bores and other machined surfaces with clean engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Cylinder bores and other machined surfaces 92-858087K01
20W-40, NMMA FC-W
rated

Crankshaft Inspection
1. Inspect the machined surfaces of the crankshaft for deep grooves, scratches, pitted surfaces, or uneven wear.
2. Inspect the crankshaft rear oil seal surface for scoring or damage.
3. Inspect the crankshaft oil passages for restrictions.
4. Inspect the thrust journal surface for wear or damage.
5. Inspect the crankshaft threaded bolt holes for damage.
6. Inspect the crankshaft balancer keyway for damage.
7. Measure the main bearing journals with a micrometer for out‑of‑round, taper, and undersized diameter.
IMPORTANT: The crankshaft journal diameter must be measured in multiple locations approximately 90° apart. Calculate
the average of the resulting measurements for comparison to the specification.

Main Bearing Journal Specifications

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Number 1 62.189–62.212 mm (2.4484–2.4493 in.)
62.182–62.207 mm
Number 2, 3, and 4 62.189–62.212 mm (2.4484–2.4493 in.)
Diameter (2.4481–2.4491 in.)
62.182–62.212 mm
Number 5 62.185–62.207 mm (2.4479–2.4491 in.)
(2.4481–2.4493 in.)

Page 3A-104 90-879288300 AUGUST 2012

 Engine Mechanical

Main Bearing Journal Specifications

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Production 0.005 mm (0.0002 in.) maximum
Taper
Service 0.025 mm (0.0010 in.) maximum
Production 0.005 mm (0.0002 in.) maximum
Out‑of‑round
Service 0.025 mm (0.0010 in.) maximum
8. Measure the connecting rod bearing journals with a micrometer for out of round, taper and undersized diameter.

Connecting Rod Journal Specifications

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Diameter 53.284–53.335 mm (2.0978–2.0998 in.)
Production 0.007 mm (0.0003 in.) maximum
Taper
Service 0.025 mm (0.0010 in.) maximum
Production 0.007 mm (0.0003 in.) maximum
Out‑of‑round
Service 0.025 mm (0.0010 in.) maximum
9. To check the crankshaft for runout, support the front and rear main bearing journals in V‑blocks.
10. Check crankshaft runout at the front and rear intermediate journals with a dial indicator.

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
0.05–0.20 mm
Crankshaft runout 0.038 mm (0.0015 in.)
(0.0020–0.0079 in.)
11. Replace or recondition the crankshaft if not within specifications.

Main Bearing Inspection

These MerCruiser engines use precision insert type main bearings. If an installed bearing clearance exceeds the specification,
then the bearing assembly must be replaced. Service bearings are available in standard size and 0.0254 mm (0.001 in.),
0.254 mm (0.010 in.), and 0.508 mm (0.020 in.) undersized.
Selective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances. For this reason you
may find one half of a standard insert with one half of a 0.0254 mm (0.001 in.) undersized insert, which will decrease the
clearance 0.0127 mm (0.0005 in.) over using a complete standard size bearing set.
When a production crankshaft cannot be precision fitted by this method, it is then ground 0.229 mm (0.009 in.) undersized, on
only those main journals that cannot be properly fitted. All journals will not necessarily be ground undersized. A 0.229 mm
(0.009 in.) undersized bearing and 0.254 mm (0.010 in.) undersized bearing may be used for precision fitting in the same
manner as previously described.

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Engine Mechanical
Due to loading factors, the lower half of a crankshaft bearing set will generally exhibit the most wear. If inspection indicates the
lower bearing half is suitable for reuse, it can be assumed that the upper bearing half can also be reused. If the lower bearing
half shows evidence of wear or damage, replace the entire bearing set. Never replace one half of a bearing set without
replacing the other half.

Main bearing failure

example
a - Contamination
scratches
b - Contamination
c particles
a b c - Tapered journal
d - Oil starvation
e - Radius ride
f - Improper seating
g - Fatigue failure

d e

f g
6354

Main Bearing Tension

IMPORTANT: Ensure that the main bearing is installed under tension. It should require firm pressure to fit the bearing into
position.

30447

Main bearing tension

Main Bearing Clearance, Plastic Gauge Method

To obtain accurate measurements while using Plastigauge® or its equivalent, the engine must be out of the boat and upside
down so the crankshaft will rest on the upper bearings and the total clearance can be measured between the lower bearing and
journal.
To ensure the proper seating of the crankshaft, all bearing cap bolts should be at their specified torque. In addition, the surface
of the crankshaft journal and bearing must be wiped clean of oil.

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 Engine Mechanical
NOTE: When checking the number 1 main bearing, loosen the accessory drive belt to prevent obtaining a tapered reading with
the gauging plastic.
1. Remove the bearing cap and wipe any oil from the journal and bearing cap to be inspected.
2. Place a piece of gauging plastic the full width of the bearing and parallel to the crankshaft center‑line as shown.

Main bearing plastic gauge measurement

a a - Gauging plastic
b - Bearing journal

b 19550

IMPORTANT: The bearing caps must be tightened to specification to ensure correct measurements. Do not rotate the
crankshaft with the plastic gauge installed.
3. Install the bearing cap and evenly tighten the main bearing cap bolts or stud nuts to specification.

Description Nm lb‑in. lb‑ft

Crankshaft main bearing cap bolt and stud, First pass 20 15

preferred method Final pass (angle torque) + 73°

Description Nm lb‑in. lb‑ft

Crankshaft main bearing cap bolt and stud, One pass with all bolts
105 77
alternate method tightened evenly
4. Remove the bearing cap. The flattened gauging plastic will be found adhering to either the bearing cap or the journal.
5. On the edge of the gauging plastic envelope there is a graduated scale that is correlated in thousandths of an inch. Without
removing the gauging plastic from the crankshaft bearing or journal, measure its compressed width at the widest point with
the graduated scale.

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Engine Mechanical
NOTE: Normally main bearing journals wear evenly and are not out‑of‑round.
• If a bearing is being fitted to an out‑of‑round journal of 0.0254 mm (0.001 in.) maximum, be sure to fit to the maximum
diameter of the journal.
• If the bearing is fitted to the minimum diameter and the journal is out‑of‑round 0.0254 mm (0.001 in.) maximum,
interference between the bearing and journal will result in rapid bearing failure.
• If the flattened gauging plastic tapers toward the middle or ends, the difference in clearance indicates taper or an other
irregularity of the bearing or journal.
• Measure the journal with a micrometer if the flattened gauging plastic indicates more than 0.0254 mm (0.001 in.)
difference.

Measuring clearance with gauging plastic

a - Compressed gauging plastic
b - Scale

a
b

19552

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Number 1 0.018–0.053 mm (0.0007–0.0021 in.)
Main bearing Numbers 2, 3, 0.022–0.061 mm
0.030–0.068 mm (0.0012–0.0027 in.)
clearance, and 4 (0.00087–0.0024 in.)
production
0.025–0.069 mm
Number 5 0.020–0.060 mm (0.0008–0.0024 in.)
(0.00098–0.0027 in.)
Number 1 0.025–0.051 mm (0.0010–0.0020 in.)
Main bearing Numbers 2, 3,
0.025–0.064 mm (0.0010–0.0025 in.)
clearance, and 4
service limit
0.038–0.076 mm
Number 5 0.038–0.064 mm (0.0015–0.0025 in.)
(0.0015–0.0030 in.)
6. If the bearing clearance is within specifications, the bearing insert is satisfactory. If the clearance is not within
specifications, replace the insert. Always replace both upper and lower inserts as a set.
7. A standard or 0.025 mm (0.001 in.) undersized bearing may produce the proper clearance. If not, it will be necessary to
regrind the crankshaft journal for use with the next undersized bearing.
IMPORTANT: After selecting a new bearing, recheck the clearance.
8. Check the clearance with a newly selected bearing. If the bearing clearance is within specifications, the bearing insert is
satisfactory. If not, repeat the previous steps.
9. Proceed to the next bearing. After all bearings have been checked, oil and install the selected bearings and rotate the
crankshaft to check for excessive drag.

Crankshaft End Play

1. Firmly force the crankshaft rearward.
2. Firmly force the crankshaft forward.

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 Engine Mechanical
3. Measure the clearance at the front end of the rear main bearing with a feeler gauge as shown.

19553

Measuring crankshaft end play

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
End play (thrust clearance) 0.05–0.20 mm (0.0020–0.0079 in.)

Engine Block Inspection

1. Inspect the engine block for cracks in coolant jackets.
2. Inspect the cylinder bores for scratches or gouging.
3. Inspect the valve lifter bores for excessive scoring or wear.
4. Inspect the threaded holes, crankshaft bearing caps, bearing bores, and engine block core hole expansion plug bores for
damage.
5. Inspect the engine block, engine mount bosses and crankshaft bearing webs for cracks or damage.
6. Check the engine block head gasket surfaces for warp with a machinist's straight‑edge and a feeler gauge. Take
measurements diagonally across the surface (both ways) and straight down center. If warp exceeds specification, the
engine block must be resurfaced by a machine shop.

30448

Checking engine block head gasket surfaces for warp

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Cylinder head gasket surface flatness 0.10 mm (0.0040 in.)
7. Check the cylinder bore:

90-879288300 AUGUST 2012 Page 3A-109

Engine Mechanical
a. Measure cylinder bore diameter with a dial indicator or inside micrometer.

30342
Measuring cylinder bore

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
94.894–94.947 mm
Cylinder Diameter 101.618–101.643 mm (4.0007–4.0017 in.)
(3.7360–3.7381 in.)
b. Measure cylinder bore taper with a dial indicator or inside micrometer, measuring the diameter at the top and bottom
of the cylinder at positions "a" and "b." Cylinder taper will be the difference between the top and bottom
measurements.
c. Measure cylinder out‑of‑round with a dial indicator or inside micrometer, measuring the diameter at positions "a" and
"b." Cylinder out‑of‑round is the difference between the two measurements.

6386

Measuring cylinder out-of-round

a
a - At a right angle to the center‑line of the engine
b - Parallel to the center‑line of the engine

b b

a 19678

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Production, thrust side 0.012 mm (0.0005 in.) maximum
Cylinder Taper Production, relief side 0.025 mm (0.0010 in.) maximum
Service limit 0.025 mm (0.0010 in.) over production

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 Engine Mechanical

Description 5.0 L (305 cid), 5.7 L (350 cid), and 6.2 L (377 cid)
Production 0.025 mm (0.0010 in.)
Cylinder out‑of‑round
Service Limit 0.05 mm (0.0020 in.)
d. Remove any ridge at the top of ring travel.
8. If the cylinder does not meet specifications, honing, or boring and honing will be necessary.

Cylinder Reconditioning
NOTE: The effectiveness of cylinder reconditioning depends upon engine condition at time of repair.
NOTE: If engine block inspection indicates that the block is suitable for continued service, out of round or tapered cylinders can
be reconditioned by honing or boring and honing.
1. If cylinders have less than 0.127 mm (0.0050 in.) wear they can be reconditioned with a hone and fitted with high limit
standard size pistons. If there is more than 0.127 mm (0.0050 in.) wear, bore and hone to fit the smallest oversized piston
that will permit the complete resurfacing of all cylinders.
2. Clean cylinder bores with hot soapy water. Rinse thoroughly. After cleaning, lightly lubricate the cylinder walls with engine
oil and a clean cloth. Wipe off excess oil with a clean dry cloth.

Cylinder Boring
IMPORTANT: Before using any type of boring bar, file the top of the engine block to remove dirt or burrs. This prevents boring
bar tilt (the bored cylinder wall is not at right angles to crankshaft.)
1. File the top of the engine block to smooth any irregular surface and remove any deposits or burrs.
2. Clean the cylinders with warm water and detergent. Rinse thoroughly.
3. Measure the piston to be fitted with a micrometer. Take measurements at the center of the piston skirt and at right angles
to the piston pin.
NOTE: Hone cylinders as outlined under Cylinder Honing and Piston Selection.
4. Bore the cylinder to same diameter as the piston and hone to provide the specified clearance.
5. Carefully observe equipment manufacturer's instructions.

Cylinder Honing
1. Follow the instructions provided with the cylinder hone kit.

Description SPX Part Number

Cylinder hone kit J‑5902‑O1
2. Frequently clean the cylinder bore and recheck piston for a correct fit in the cylinder.
3. When finish‑honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to obtain fine uniform
surface finish marks in a 30° cross hatch pattern. Finish marks should be clean but not sharp, and free from imbedded
particles and torn or folded metal.
4. As each piston is fitted to a cylinder, permanently mark each with its corresponding cylinder number.
IMPORTANT: Handle pistons with care and do not attempt to force them into a cylinder until it is honed to the correct size.
5. Thoroughly clean cylinder bores with hot soapy water. Scrub each cylinder with a stiff, synthetic bristle brush, and rinse
thoroughly with hot water. Lightly lubricate the cylinders with light engine oil on a clean cloth, then wipe clean with a clean
dry cloth. Repeat this process several times until the oiled cloth remains clean and free of machining debris. The cylinder
should not be cleaned with kerosene or gasoline. Clean the engine block to remove dirt and debris left by the
reconditioning process.

Piston Selection
1. Check the piston‑to‑cylinder‑bore clearance on used pistons:

90-879288300 AUGUST 2012 Page 3A-111

Engine Mechanical
a. Measure the cylinder bore diameter with a telescope gauge 64 mm (2‑1/2 in.) from top of the cylinder bore.

30342
Measuring cylinder bore diameter

b. Measure the piston diameter at the skirt, 11 mm (0.4331 in.) from the bottom of the skirt at a right angle to the piston
pin bore.

a a - Piston diameter
b b - Measurement location

22022

c. Subtract the piston diameter from the cylinder bore diameter to determine the piston‑to‑bore clearance.
d. Determine if the piston‑to‑bore clearance is in the acceptable range.

Description 5.0 L (305 cid) 5.7 L (350 cid) 6.2 L (377 cid)
Piston‑to‑bore clearance, 0.018–0.061 mm 0.018–0.053 mm 0.018–0.053 mm
production (0.0007–0.0024 in.) (0.0007–0.0020 in.) (0.0007–0.0021 in.)
Piston‑to‑bore clearance, service 0.018–0.068 mm 0.018–0.061 mm 0.018–0.068 mm
limit (0.0007–0.0026 in.) (0.0007–0.0024 in.) (0.0007–0.0027 in.)
2. If a used piston is not satisfactory, determine if a new piston can be selected to fit the cylinder bore within the specified
range.
3. If the cylinder bore must be reconditioned, measure the new piston diameter, then hone the cylinder bore to correct the
clearance.
4. Mark each piston to identify the cylinder for which it was fitted.

Engine Block Plug Installation

1. Apply Loctite 242 to the outside diameter of each new engine block expansion plug.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Engine block expansion plug 92-809821

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 Engine Mechanical
2. Install the engine block core hole expansion plugs flush with the inside chamfer of the engine block core hole.

a - Inside chamfer
b - Expansion plug
c - Core hole

b
a
c

30451

3. Apply Loctite 242 to the outside diameter of the new camshaft rear bearing hole expansion plug.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Camshaft rear bearing hole expansion plug 92-809821
4. Install the camshaft rear bearing hole expansion plug.

a Camshaft plug installation

a - Rear of block
b - Expansion plug

30415

5. Apply Loctite 242 to the threads of the oil pressure sender and rear oil gallery plugs.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Oil gallery plugs and oil pressure sender 92-809821
6. Install the oil pressure sender and the indicated rear oil gallery plugs.

b a - Upper oil gallery plug

b - Rear oil gallery plug (3)
c - Oil pressure sender
c

a
30416

7. Tighten the rear oil gallery plugs to specification.

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Engine Mechanical

Description Nm lb‑in. lb‑ft

Oil gallery plug 20 15
8. Coat the threads of the front oil gallery plugs with Loctite 567.

Tube Ref No. Description Where Used Part No.

Loctite 567 PST Pipe
9 Oil gallery plug 92-809822
Sealant
9. Install the front oil gallery plugs recessed 0.11 mm (0.004 in.) into the engine block.

30417

Front oil gallery plugs

10. Tighten the front oil gallery plugs to specification.

Description Nm lb‑in. lb‑ft

Oil gallery plug 20 15
11. Coat the threads of the engine block coolant drain plugs with Loctite 567.

Tube Ref No. Description Where Used Part No.

Loctite 567 PST Pipe
9 Coolant drain plug 92-809822
Sealant
12. Install and tighten the engine block coolant drain hole plugs to specification.

Description Nm lb‑in. lb‑ft

Coolant drain hole plug 20 15

Main Bearing Replacement without Crankshaft Removal

1. Remove the cap on the main bearing requiring replacement.
2. Remove the lower bearing from the cap.
3. Install the main bearing shell remover in the oil hole in the crankshaft journal. If this tool is not available, a cotter pin may
be bent as shown and used.

a - Main bearing shell remover

b - Cotter pin

b
a

6379

Page 3A-114 90-879288300 AUGUST 2012

 Engine Mechanical

Description SPX Part Number

Main bearing shell remover J‑8080
4. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll the upper bearing out of the engine block
5. Lubricate a new upper bearing with clean engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Main bearing 92-858087K01
20W-40, NMMA FC-W
rated
6. Insert the plain (not notched) end between the crankshaft and the indented or notched side of the engine block.
7. Rotate the crankshaft clockwise, turning the bearing into place. Remove the tool from the oil hole in the crankshaft journal.
8. Lubricate a new lower bearing with engine oil. Install the bearing in the bearing cap.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Main bearing 92-858087K01
20W-40, NMMA FC-W
rated
9. Install the main bearing cap in its original location with the markings pointing toward the front of the engine.

1 b

30413

Main bearing cap markings

10. Tighten all main bearing caps to specification, except the rear main bearing cap.

Crankshaft main bearing cap bolt and stud, preferred method Nm lb‑in. lb‑ft
First pass 20 15
Two bolt main caps
Final pass (angle torque) + 73°

Description Nm lb‑in. lb‑ft

Two bolt main caps One pass with all bolts tightened evenly 105 77
11. Tighten the rear main bearing cap to specification.
a. Preferred method: Perform the first pass on the rear main bearing cap bolts and stud

Crankshaft main bearing cap bolt and stud, preferred method Nm lb‑in. lb‑ft
Two bolt main caps First pass 20 15
b. Preferred method: Tap the end of the crankshaft shifting the crankshaft to the rear and then to the front with a lead
hammer.
c. Preferred method: Perform the final pass on the rear main bearing cap bolts and studs.

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Engine Mechanical

Crankshaft main bearing cap bolt and stud, preferred method Nm lb‑in. lb‑ft
Two bolt main caps Final pass (angle torque) + 73°
d. Optional method: Tap the end of the crankshaft to the rear and then to the front with a lead hammer.
e. Optional method: Tighten the rear main bearing cap bolts and studs as specified.

Crankshaft main bearing cap bolt and stud, optional method Nm lb‑in. lb‑ft
Two bolt main caps One pass with all bolts tightened evenly 105 77

Main Bearing and Crankshaft Replacement

1. Remove the timing sprocket from the old crankshaft and install it on the replacement crankshaft.
2. On driveshaft extension models, if the old pilot bushing is to be reused, it can be removed without damage with the
following procedure:
a. Fill the pilot bushing cavity with grease.
b. Insert an old transmission input shaft into the pilot bushing and strike the shaft with a hammer. The resulting hydraulic
pressure will force the old pilot bushing out of the crankshaft.
IMPORTANT: Ensure that all bearings and crankshaft journals are clean.
3. Install the upper main bearing inserts into the engine block.

a - Upper main bearing inserts

c b - Upper thrust bearing insert
c - Oil grooves on upper main bearing insert

30634

4. Install the lower main bearing inserts into the main bearing caps.

a - Lower main bearing inserts

b - Lower thrust bearing insert

b
30635
5. Carefully lower the crankshaft into place. Be careful not to damage bearing surfaces.

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 Engine Mechanical
6. Install the main bearing caps in their original locations, with markings pointing toward the front of the engine.

a - Main bearing cap

b - Main bearing cap markings
1

b a

30636

7. Verify the clearance of each main bearing. Refer to Main Bearing Clearance, Plastic Gauge Method.
8. Lubricate the main bearings and crankshaft bearing journals with clean engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Main and crankshaft bearing journals 92-858087K01
20W-40, NMMA FC-W
rated
9. Install the main bearing caps.
10. Tighten all of the main bearing caps, except the rear main cap, to specifications.

Description Nm lb‑in. lb‑ft

First pass 20 15
Two bolt main caps (preferred method)
Final pass (angle torque) + 73°

Description Nm lb‑in. lb‑ft

Two bolt main caps (alternate method) One pass 105 77
11. Tighten the rear main bearing cap to specification.
a. Preferred method: Perform the first pass on the rear main bearing cap bolts and stud.

Description Nm lb‑in. lb‑ft

Two bolt main caps First pass 20 15
b. Preferred method: Tap the end of the crankshaft shifting the crankshaft to the rear and then to the front with a lead
hammer.
c. Preferred method: Perform the final pass on the rear main bearing cap bolts and studs.

Description Nm lb‑in. lb‑ft

Two bolt main caps Final pass (angle torque) + 73°
d. Optional method: Tap the end of the crankshaft to the rear and then to the front with a lead hammer.
e. Optional method: Tighten the rear main bearing cap bolts and studs as specified.

Description Nm lb‑in. lb‑ft

Two bolt main caps One pass 105 77
12. Check the crankshaft end play.
13. Install the rear main seal retainer and seal.
14. Verify clearance for each connecting rod bearing. Refer to Connecting Rod, Bearings, and Piston Assembly.
15. Coat the connecting rod bearing surface with clean engine oil.

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Engine Mechanical

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Connecting rod bearings 92-858087K01
20W-40, NMMA FC-W
rated
16. Install the connecting rod bearings.
17. Install the connecting rod cap.

a
a - Connecting rod nuts
b - Connecting rod cap

30638
18. In a two pass sequence, tighten the connecting rod cap nuts to specification.

Description Nm lb‑in. lb‑ft

Connecting rod nut 5.0 L (305 cid) and 5.7 L First pass 27 20
(350 cid) Final pass (angle torque) + 70°

Description Nm lb‑in. lb‑ft

First pass 27 20
Connecting rod nut 6.2 L (377 cid)
Final pass (angle torque) +45°
19. Reassemble the remaining components to the engine block as follows. Refer to the appropriate procedures found in this
service manual, as required.
a. Install the timing chain.
IMPORTANT: The crankcase front cover is not reusable per manufacturer's specification. It must be replaced if
removed.
b. Install a new front cover and gasket.
c. Install the oil pump and crankshaft oil deflector.
d. Install the dipstick tube and oil pan.
e. Install the spark plugs.
f. Install the crankshaft balancer and crankshaft pulley.
g. Install the water circulating pump.
h. Install the serpentine belt.
i. Install the flywheel and the drive coupler or drive plate.
j. Install the flywheel housing.
k. Install the starter.
l. Install a new oil filter.
m. Fill the crankcase with oil.
20. Install the engine in the boat.

Rear Oil Seal Retainer

Removal
The rear oil seal retainer can only be replaced with the oil pan removed.
1. Remove the oil pan.

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 Engine Mechanical
2. Remove the oil seal retainer fasteners.

a- Stud
a b c b- Gasket
c- Oil seal retainer
d- Nut
e- Screw

e
30698

3. Remove the oil seal retainer.

4. Remove and discard the the old oil seal retainer gasket.

Cleaning
1. Remove all gasket material form the seal retainer, oil pan, and engine block.
2. Clean all sealing surfaces.
3. Wash all removed parts in solvent and dry with compressed air.

Inspection
1. Inspect the oil seal retainer for cracks or any scored surface.
2. Inspect the oil seal for worn, dry, or torn rubber. Replace if necessary.
3. Inspect the flywheel locator pin for damage. Replace if necessary.

Installation
IMPORTANT: Always use a new oil seal retainer gasket.
1. Install the rear oil seal retainer stud, if removed previously. Tighten the stud to specification.

Description Nm lb‑in. lb‑ft

Rear Oil Seal Retainer Stud 6 53 –
2. Install a new rear oil seal retainer gasket.
3. Install the rear oil seal retainer on the stud.

a- Stud
a b c b- Gasket
c- Oil seal retainer
d- Nut
e- Screw

e
30698

4. Install the retainer nut and bolt and tighten to specification.

Description Nm lb‑in. lb‑ft

Rear oil seal retainer fasteners 12 106 –
5. If not already installed, install the rear oil seal.
6. Install the oil pan.

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Engine Mechanical

Oil Filter, Bypass Valve, and Block Adapter

Oil Filter Block Adapter
IMPORTANT: Inspect the oil filter by‑pass valve and block adapter assembly whenever the engine is disassembled for major
repair or when inadequate oil filtration is suspected.

a- Engine block
b- Block adapter with bypass valve
c- Screw (2)
d- Oil filter

a b

30700

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 Engine Mechanical

Remote Oil Filter, Front Bracket Applications

2 3
4

9
30701

1- Remote oil filter components

2- Remote oil supply line
3- Block adapter with bypass valve
4- Screw (2)
5- Seal
6- Remote oil filter adapter
7- Quad ring seal
8- Outlet fitting
9- Remote oil return line

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Engine Mechanical

Remote Oil Filter, Front Lifting Eye Applications

6
5 8

1
7

10
9

30702

1- Remote oil line routing

2- Remote oil filter base
3- Oil filter fitting
4- Remote oil return line
5- Remote oil return fitting
6- Remote oil supply line
7- Remote oil supply fitting
8- Remote oil filter adapter
9- Remote oil supply line
10 - Remote oil return line

Remote Oil Filter Adapter Removal

1. Remove the inlet oil line from the oil filter adapter.
2. Remove the outlet oil line from the outlet fitting.
3. Remove the outlet fitting and the quad ring seal from the oil filter adapter. Discard the quad ring seal.
4. Remove the oil filter adapter and seal. Discard the seal.

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 Engine Mechanical
5. Remove the block adapter with bypass valve.

d a- Remote oil supply line

e b- Remote oil filter adapter
c- Seal
c d- Block adapter with bypass valve
e- Screw (2)
f- Quad ring seal
b g- Outlet fitting
h- Remote oil return line
f
g

a h
30703

Cleaning
1. Clean the bypass valve and block adapter assembly in solvent.
2. Dry with compressed air.
3. Clean the outlet fitting and oil filter adapter in solvent.
4. Dry with compressed air.

Inspection
1. Inspect the block adapter for cracks, thread wear, or other damage.
2. Inspect the fiber bypass valve for cracks or other damage.
3. Ensure that the bypass valve fits tightly against its seat.
4. Push the bypass valve down and release it. The bypass valve should cycle smoothly and spring back to its original
position. If bypass valve operation is questionable, replace the block adapter assembly.

Typical
a - Block adapter
b b - Bypass valve

a
30704

5. Inspect the oil filter adapter and fitting for cracks, thread wear, or other damage.

Remote Oil Filter Adapter Installation

1. Install the block adapter with bypass valve on the engine block. Tighten the block adapter screws to specification.

a - Block adapter
b - Block adapter screw (2)

b
30705

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Engine Mechanical

Description Nm lb‑in. lb‑ft

Block adapter screw 27 20
2. Place a new seal in the oil filter adapter and lightly lubricate the sealing surfaces with engine oil.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Oil filter adapter seal 92-858087K01
20W-40, NMMA FC-W
rated
3. Install the oil filter adapter and new seal on the engine block.
4. Lightly lubricate a new quad ring seal with engine oil and slide it onto the fitting.

Tube Ref No. Description Where Used Part No.

Mercury MerCruiser Full-
Synthetic Engine Oil
154 Quad ring seal 92-858087K01
20W-40, NMMA FC-W
rated
5. Install the fitting with the new quad ring seal. Tighten the fitting to specification.

a- Oil filter adapter fitting

b- Adapter
c- Seal
d- Quad ring seal

d
a 30706

Description Nm lb‑in. lb‑ft

Oil filter adapter fitting 31 23

NOTE: Ensure that the remote oil delivery line is connected to the fitting of the remote oil filter adapter and to the center
port of the remote oil filter assembly.
6. Install the oil lines and tighten their fittings to specification.

Description Nm lb‑in. lb‑ft

Oil line fittings 27 20

Page 3A-124 90-879288300 AUGUST 2012