Mercury 305 CID, Service Manual, Page: 216 / 967

3A-24 - ENGINES 90-823225--1 1096
Rocker Arm Cover
Removal
It may be necessary to remove exhaust manifold be-
fore removing rocker arm cover. Refer to Section 7B
for removal. Also remove any component that will in-
terfere with the removal of the manifold or rocker arm
cover.
1. Disconnect crankcase ventilation hoses.
2. Remove any items that interfere with the removal
of rocker arm covers.
3. Remove rocker arm cover.
Installation
1. Clean sealing surfaces on cylinder head and
rocker arm cover with degreaser.
2. Place new rocker arm cover gasket in position in
rocker arm cover.
72324
a - Rocker Arm Cover Gasket
a
3. Install rocker arm cover. Torque screws to 90 lb.
in. (10 N·m).
4. Reinstall exhaust manifolds, if removed.
5. Reinstall any items which were removed to allow
removal of rocker arm covers.
6. Connect crankcase ventilation hoses to rocker
arm covers.
7. Start engine and check for oil leaks.
Intake Manifold
Removal
1. Drain engine cooling system.
2. Disconnect hoses from thermostat housing.
3. Disconnect electrical leads interfering with re-
moval.
4. Disconnect crankcase ventilation hoses from
rocker arm covers.
5. Disconnect throttle cable from carburetor. Re-
move fuel line and sight tube running between
fuel pump and carburetor.
6. Remove distributor cap and mark position of rotor
on distributor housing. Also, mark position of dis-
tributor housing on intake manifold. Remove dis-
tributor.
IMPORTANT: Do not crank engine over after dis-
tributor has been removed.
7. Remove other ignition components.
8. Remove oil sending unit.
9. Disconnect any other miscellaneous items that
will prevent removal of manifold.
IMPORTANT: It may be necessary to pry intake
manifold away from cylinder heads and block, in
next step. Use extreme care to prevent damage to
sealing surfaces.
10. Remove intake manifold bolts, then remove in-
take manifold and carburetor assembly.
NOTE: If intake manifold requires replacement,
transfer all remaining parts to new manifold.
Cleaning and Inspection
1. Clean gasket material from all mating surfaces.
IMPORTANT: When cleaning cylinder head mat-
ing surface, do not allow gasket material to enter
engine crankcase or intake ports.
2. Inspect manifold for cracks or scratches. Ma-
chined surfaces must be clean and free of all
marks and deep scratches or leaks may result.
3. Check intake passages for varnish buildup and
other foreign material. Clean as necessary.