Mercury Mercruiser Marine Engine 4.3 5.0 MPI & Seacore 4.3 5.0 Installation Manual - PDF DOWNLOAD

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

4.3, 5.0 MPI & SEACORE 4.3, 5.0 MODELS INSTALLATION MANUAL Models Covered Alpha Models covered

Serial Number

4.3 MPI

1A300000 and above

5.0 MPI

Bravo Models covered

Serial Nnumber

4.3 MPI 5.0 MPI

1A300000 and above

SeaCore 4.3 SeaCore 5.0

Notice NOTICE After completing installation, these instructions should be placed with the product for the owner's future use.

NOTICE Predelivery preparation instructions must be performed before delivering boat to the product owner.

Notice to Boat Manufacturer/Installer Throughout this publication, dangers, warnings, cautions, and notices, (accompanied by the International Hazard Symbol) are used to alert the manufacturer or installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials. Observe Them Carefully!

These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures.

! DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Page i

© 2007 Mercury Marine

90-899883178 NOVEMBER 2007

! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

NOTE: Refer to the appropriate Mercury MerCruiser Product Applications Manual for application recommendations.

This installation manual has been written and published by Mercury MerCruiser to aid the boat manufacturer (OEM) in the installation of the products described herein.

It is assumed that these personnel are familiar with marine product installation.

Furthermore, it is assumed that they are familiar with, if not trained in, the recommended installation procedures of Mercury MerCruiser product.

We could not possibly know of or advise the marine trade of all conceivable installations and of the possible hazards and/or results of each installation. Therefore, the OEM is responsible for any installation that does not fulfil the requirements of this manual.

It is the responsibility of the boat manufacturer to select the appropriate engine/transom/ drive package (including the correct gear ratio and propeller) for a given boat. Mercury MerCruiser recommends that any new or unique hull/power package combination be thoroughly water tested prior to sale, to verify that the boat performs as desired, and that the engine operates in the appropriate RPM range.

It is recommended that a Mercury MerCruiser Product Application Engineer (PAE) be contacted for assistance. For assistance outside the United States, contact the local Mercury Marine office or authorized distributor.

All information, illustrations and specifications contained in this manual are based on the latest product information available at time of publication. Mercury Marine reserves the right to make changes at any time without obligation. As required, revisions to this manual will be sent to all OEM boat companies.

Page ii

Manual Outline

Important Information

1 - Important Information 2 - Boat Construction 3 - Exhaust System 4 - Fuel System 5 - Cooling System

Boat Construction

Exhaust System

6 - Drive System and Engine Installation 7 - Electrical System

Fuel System

8 - Remote Controls 9 - Predelivery Preparation and Storage

Cooling System

Drive System and Engine Installation

Electrical System

Remote Controls

Predelivery Preparation and Storage

1 2 3 4 5 6 7 8 9

Page iii

Page iv

SECTION - 1

IMPORTANT INFORMATION

SECTION 1 - IMPORTANT INFORMATION

1

Table of Contents Torque Specifications.............................................................................................................................................. 2 Quicksilver Products................................................................................................................................................ 2 Accessories ...................................................................................................................................................... 2 Remote Controls and Instrumentation for the DTS System.................................................................................... 3 Identification............................................................................................................................................................ 3 Serial Number Decal Placement.......................................................................................................................3 Bravo Sterndrive Serial Number and Identification...........................................................................................3 Bravo Transom Serial Number..........................................................................................................................4 Bravo Three Notice: Trim‑in Limit Insert.................................................................................................................. 5 Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 5 Internal Power Steering With Internal Tie Bar Only ......................................................................................... 6 Internal Power Steering With Internal and External Tie Bar ............................................................................. 6 External Power Steering .................................................................................................................................. 6 External Power Steering With Low External Tie Bar ........................................................................................ 6 SeaCore Components and Castings....................................................................................................................... 6 Stainless Steel Fasteners........................................................................................................................................ 6 Corrosion Protection................................................................................................................................................ 7 Anti‑fouling Paint..................................................................................................................................................... 7 Emission Control Information Label........................................................................................................................ 9 Owner Responsibility ...................................................................................................................................... 10 Star Label.............................................................................................................................................................. 10 Hang Tag............................................................................................................................................................... 11

90-899883178 NOVEMBER 2007

Page 1 / 12

IMPORTANT INFORMATION

SECTION - 1

Lubricants, Sealants, Adhesives Tube Ref No. 34

Description Special Lubricant 101

Where Used

Part No.

Threads of stainless steel fasteners

92-802865Q02

Torque Specifications NOTE: Securely tighten all fasteners not listed below.

NOTE: The propeller torque stated is a minimum torque value.

Description

Nm

lb‑in.

Exhaust tube clamp

3

26

–

Exhaust pipe bolts

34

–

25

Exhaust block‑off plate bolts

34

–

25

75

–

55

Bravo One propeller nut Bravo Two propeller nut

lb‑ft

Then align tabs with grooves 81

–

60

Then align tabs with grooves

Bravo Three front propeller nut

136

–

100

Bravo Three rear propeller nut

81

–

60

Rear engine mounting bolts

47

–

35

Steering cable coupler nut

47

–

35

Steering system pivot bolts

34

–

25

Sterndrive unit fasteners

68

–

50

Transom assembly fasteners

34

–

25

Mounting clip screw

12.2

108

–

Hose clamps

2

26

–

Water inlet fitting bolts

5

45

–

Water inlet block‑off screw

5

45

–

Fuel inlet fitting

Finger tight + 1‑3/4 to 2‑1/4 turns with a wrench. Do not overtighten.

Gen III Cool Fuel Module captured nut

19

168

–

Battery stud

8‑11

71‑91

–

Propeller shaft anode screw

19

168

–

Quicksilver Products Accessories Quicksilver gauges, remote controls, steering systems, propellers, and other accessories are available for this product. Mercury MerCruiser recommends the use of Quicksilver parts on all applications. Refer to Mercury Precision Parts Accessories Guide for a complete listing.

This Guide is available from: Attn: Parts Department Mercury Marine W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside of U.S.A., order through Distribution Center or Distributor.

Page 2 / 12

90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

Remote Controls and Instrumentation for the DTS System The Digital Throttle and Shift system (DTS) requires the use of specialized helm components, including a command module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

Identification Serial Number Decal Placement There are 3 sets of engine, transom assembly, and sterndrive serial number decal strips provided with each power package. One should be used for each of the following: • Engine Specification Decal • Warranty Registration Card • Operation, Maintenance and Warranty Manual identification page Affix engine serial number decal to specification / serial number decal.

8331

a a - Specification/serial number decal

Bravo Sterndrive Serial Number and Identification The sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive.

a

b

c d

25906

a - Bar code b - Serial Number

90-899883178 NOVEMBER 2007

c - Gear ratio d - Model number

Page 3 / 12

IMPORTANT INFORMATION

SECTION - 1

The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers.

a

25907

Bravo sterndrive serial number stamping a - Serial number stamping

Bravo Transom Serial Number The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.

a

25904

Bravo transom assembly U‑bolt plate a - Transom assembly serial Number

Page 4 / 12

90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers.

a

25905

Gimbal housing with serial number stamping a - Transom assembly serial Number

Bravo Three Notice: Trim‑in Limit Insert NOTE: Bravo One, Two and Three Models are equipped with a trim‑in limit insert.

It has been brought to our attention that some boats (predominantly deep‑Vee heavy boats) will roll up on their side under certain, specific, operating conditions. The roll can be either to port or starboard and may be experienced while moving straight ahead, or while making a turn. The roll occurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near full trim‑in. While the boat will not roll completely over, the roll may be sufficient to unseat the operator or passengers, and thereby create an unsafe situation.

The roll is caused by stern‑lift created from excessive sterndrive unit trim‑in. Under these extreme stern‑lift / bow‑down conditions, instability can be created, which may cause the boat to roll. Weight distribution to the stern can reduce stern‑lift and, in some circumstances, help to control the condition. Weight distribution in the bow, port or starboard, may worsen the condition.

The trim‑in limit insert reduces stern‑lift by preventing the sterndrive unit from reaching the last few degrees of full trim under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The need for this trim‑in limit insert, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.

! WARNING On some boats, increased trim‑in range can cause handling problems at high speeds, resulting in personal injury or death. We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for handling problems.

Multiple Sterndrive Steering Tie Bar Arrangements With multiple sterndrives you must select one of several possible steering systems.

NOTICE Incorrect tie bar installation can damage the drive and steering system. Do not let the tie bar contact other components during severe turning conditions. Always calculate sufficient turning clearances, observe recommended tie bar arrangements, and check for proper installation before operating the boat.

90-899883178 NOVEMBER 2007

Page 5 / 12

IMPORTANT INFORMATION

SECTION - 1

Internal Power Steering With Internal Tie Bar Only At the lower end of the performance spectrum, boats not capable of speeds in excess of 97 km/ h. (60 MPH), the basic internal tie bar is recommended. It connects the slave sterndrive to the sterndrive that is directly connected to the factory power steering output. This internal tie bar is available in a variety of lengths from the sterndrive manufacturer.

Internal Power Steering With Internal and External Tie Bar As a boat moves into the moderate performance range of 97‑113 km/h. (60‑70 MPH) or for a reduction in steering backlash, an external tie bar should be added. External tie bars are usually designed to attach at the aft power trim cylinder bosses. This location is an excellent choice because of its proximity to the propeller. HOWEVER, because of the potential overstress that can occur if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part Number 90362A3) should be installed to limit this potential tilt differential to about 20 degrees.

IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with no internal tie bar when using the internal power steering system. This can cause excessive loads on the steering components on the sterndrive connected to the internal power steering system.

These increased loads can damage the steering components, resulting in increased play in the steering of the boat.

External Power Steering When boat speeds move past 113 km/h (70 MPH) or if additional steering backlash reduction is desired, external power steering is recommended. This normally will include an external tie bar mounted at the same general location as the power steering cylinders, which are generally attached at the top of the sterndrive's drive shaft housing. With this steering system, no internal tie bar should be used. These steering cylinders can be attached either inboard (between) or outboard of the sterndrives.

External Power Steering With Low External Tie Bar For the fastest boats, over 129 km/h (80 MPH) , or for the ultimate in steering backlash reduction, use external power steering, BUT (where mechanically possible) with the external tie bar mounted at the trim cylinder boss location (as previously described in "Internal Power Steering with Internal and External Tie Bar" statements). Again, this system does not use an internal tie bar.

SeaCore Components and Castings Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with special coatings. Do not replace SeaCore components with non‑SeaCore. Use only the specified Mercury MerCruiser SeaCore components and castings on these power packages.

Stainless Steel Fasteners SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in salt water environments.

Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction, improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads.

Apply a lubricant, such as Special Lubricant 101 or an equivalent, on the threads of stainless steel fasteners during installation to avoid galling. Lubricate at least the first 8 mm (1/4 in.) of the threads before installation.

Tube Ref No. 34

Page 6 / 12

Description Special Lubricant 101

Where Used

Part No.

Threads of stainless steel fasteners

92-802865Q02

90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

Corrosion Protection Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions or if using a stainless steel propeller, it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System with 2 additional transom mounted anode assemblies be installed (some models have a MerCathode System as standard equipment). A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. (Refer to Mercury Precision Parts Accessories Guide for part numbers.)

Boats that are connected to AC shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while still providing a path to ground for dangerous fault (shock) currents. (Refer to Mercury Precision Parts Accessories Guide for part number.)

IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.

Anti‑fouling Paint IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the limited warranty.

Painting Boat Hull or Boat Transom: Anti‑fouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

90-899883178 NOVEMBER 2007

Page 7 / 12

IMPORTANT INFORMATION

SECTION - 1

IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper base paint, if not prohibited by law, can be used. If using copper based anti‑fouling paint, observe the following: • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) UNPAINTED area on transom of the boat around these items.

a

b 8107

a - Painted boat transom

b - Minimum 40 mm (1‑1/2 in.) unpainted area around transom assembly

NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint or an anti‑fouling paint that DOES NOT contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, MerCathode system or items specified by boat manufacturer.

NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.

Page 8 / 12

90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

Do not wash the sterndrive unit with a power washer as this can damage the coating on the reference wire of the MerCathode assembly, if equipped, and increase corrosion.

c

a

b a - MerCathode reference electrode b - Do not paint

6211

c - Do not pressure wash

Emission Control Information Label A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement. Please note that the low emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information.

EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD. XX.X g/kW-hr

D.O.M. DISP

MMM YYYY

X.XL

Emission Control Label—California Emissions–Compliant

0575

31656

"SERIAL#"—Engine Serial Number "FAMILY"—Engine Family "STD."—Emissions Standard "D.O.M."—Date of Manufacture

90-899883178 NOVEMBER 2007

Page 9 / 12

IMPORTANT INFORMATION

SECTION - 1

"DISP"—Piston Displacement

EMISSION CONTROL INFORMATION

NOT FOR SALE IN CALIFORNIA REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD. XX.X g/kW-hr

D.O.M.

MMM YYYY

DISP

X.XL 31657

Emission Control Label—Not for Sale in California "SERIAL#"—Engine Serial Number "FAMILY"—Engine Family "STD."—Emissions Standard "D.O.M."—Date of Manufacture "DISP"—Piston Displacement

Owner Responsibility The operator must have routine engine maintenance performed to maintain emission levels within prescribed certification standards.

The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed their factory specifications.

Star Label The 4.3 models meet the California Air Resources Board's Three‑Star Sterndrive and Inboard marine engine 2003 exhaust emission standards. The Three‑Star label will be affixed on the left side of the hull as shown.

a

XX 1234 XX

a - Recommended location

Page 10 / 12

b 32973

b - Secondary location

90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION One Star - Low emission

mc79569-1

The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

Two Stars - Very Low emission

IDA

FO

mc79570-1

The two‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star ‑ Low‑Emission engines.

Three Stars - Ultra Low emission

SS D

A

mc79571-1

The three‑star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines.

Four Stars - Super Ultra Low emission

F RN

T

mc79572-1

The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star ‑ Low Emission engines.

Hang Tag On 4.3 models, the Dealer must mark the appropriate box on one hang tag to match the Star label affixed to the boat. The dealer is responsible for displaying the hang tag in a visible location on the boat on display in California. Failure to properly display the hang tag could result in a citation and possible fine to the dealer from the California Air Resources Board.

If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying the boat.

90-899883178 NOVEMBER 2007

Page 11 / 12

IMPORTANT INFORMATION

SECTION - 1

NOTES:

Page 12 / 12

90-899883178 NOVEMBER 2007

SECTION - 2

BOAT CONSTRUCTION

SECTION 2 - BOAT CONSTRUCTION Table of Contents Boat Construction.................................................................................................................................................... 2 Transom Thickness and Surface Plane............................................................................................................2 Transom Cutout.................................................................................................................................................2 Checking Transom Thickness...........................................................................................................................2 Engine Bed........................................................................................................................................................2

90-899883178 NOVEMBER 2007

2

Page 1 / 2

BOAT CONSTRUCTION

SECTION - 2

Boat Construction Transom Thickness and Surface Plane IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.

Transom Specifications Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical center line Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.)

Flatness

Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.) Outer Surface ‑ Flat within 2 mm (1/16 in.)

Angle

10 ‑16 degrees

e

a

d

d

b

c

7508

a - Transom thickness b - Inner surface c - Outer surface

d - Transom plate coverage ‑ 203 mm (8 in.) from center e - Transom angle

Transom Cutout Refer to Section 6 - Drive System And Engine Mounting.

Checking Transom Thickness Refer to Section 6 - Drive System And Engine Mounting.

Engine Bed IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.

This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer (structure) to obtain the 6 mm (1/4 in.) dimension.

Description

Specification

Difference between starboard and port engine mount

57.2 cm (22‑1/2 in.)

Mount adjustment up and down (minimum)

6 mm (1/4 in.)

NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure that the front and rear mount locations in the vessel are parallel and in the same plane. This may be checked by tying a string from the left front mount location to the right rear mount location and another from right front to left rear. The strings should touch where they cross.

Page 2 / 2

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

SECTION 3 - EXHAUST SYSTEM Table of Contents Exhaust System....................................................................................................................................................... 2 Important Information........................................................................................................................................2 Carbon Monoxide Poisoning.............................................................................................................................2 Good Ventilation ........................................................................................................................................ 2 Poor Ventilation ......................................................................................................................................... 3 Measuring Exhaust Elbow Height........................................................................................................................... 3 General Information...........................................................................................................................................3 Exhaust Angle Measurement ..................................................................................................................... 4 Boat Requirements............................................................................................................................................4 Loading Requirements......................................................................................................................................5 Loading the Boat with a Capacity Plate.............................................................................................................5 Example ..................................................................................................................................................... 6 Loading the Boat—Without a Capacity Plate....................................................................................................7 Example ..................................................................................................................................................... 8 Clear Hose Measurement Method..................................................................................................................10 Clear Hose Measurement Method from Seacock or Muffler Drain.................................................................. 11

90-899883178 NOVEMBER 2007

3

Page 1 / 12

EXHAUST SYSTEM

SECTION - 3

Exhaust System Important Information

NOTICE Improperly designing, installing, or modifying the engine’s exhaust system can introduce seawater or water from condensation into the combustion chambers, damaging the engine. The installing dealer or boat builder is responsible for proper installation of the exhaust system as explained in the installation instructions for the product. Engine damage resulting from water ingestion is not covered by the product warranty, unless the damage is the result of a defective part supplied by the engine manufacturer.

The exhaust system must be installed in accordance with the information contained in this section to prevent water intrusion problems. Special care is required on the transom or hull exhaust applications, as these custom‑designed exhaust systems can create a tuning effect that can cause water to be forced back into the engine. The instructions under Checking for Water Intrusion must be performed to ensure that water intrusion is not occurring. It is the boat manufacturer's responsibility for ensuring that water intrusion does not exist with their unique exhaust system.

Engines with through propeller exhaust have been carefully designed and tested to avoid water intrusion problems and no additional testing is required. These applications require that only that exhaust elbow height be checked as outlined under Measuring Exhaust Elbow Height.

! WARNING Installing the exhaust system incorrectly can lead to serious injury or death. When installing or designing exhaust systems, follow all federal, state, and local boating and safety standards for the market in which the boat will be sold.

Exhaust system design and installation can affect: • Noise level.

• Performance.

• Water Intrusion.

• Carbon monoxide levels.

• Component longevity.

Carbon Monoxide Poisoning IMPORTANT: The following important information is covered in the owner's operation, maintenance and warranty manuals. You may also want to include this information in the boat owner's manual.

Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives, and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless, and tasteless.

Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea.

! WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

Page 2 / 12

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

1. Example of desired air flow through the boat.

mc79553-1

POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install 1 or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide.

1. Examples of poor ventilation while a boat is stationary:

a

b

a - Operating the engine when the boat is moored in a confined space.

b - Mooring close to another boat with its engine operating.

mc79554-1

2. Examples of poor ventilation while a boat is moving:

a a - Operating the boat with the trim angle of the bow too high.

b

mc79556-1

b - Operating the boat with no forward hatches open (station wagon effect).

Measuring Exhaust Elbow Height General Information The height of the exhaust elbows must be within the dimensions specified to prevent water intrusion problems. Exhaust elbow risers must be installed, if needed, to obtain the proper exhaust elbow height and exhaust angle. Risers are limited to 152.4 mm (6 in.) on all 4.3 and 5.0 models.

Measurement must be taken with the boat in the water. Load the boat as outlined to simulate the maximum loading conditions likely to be encountered in normal operation.

IMPORTANT: Exhaust elbow height is measured to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. Refer to Water Lift Muffler.

IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer.

Any load distribution conditions that will affect the exhaust system must be clearly communicated to the operator in the owner's manual. For example, the number of people that can be located on the swim platform simultaneously should be included in the manual if this could pose a problem.

Measurements under all loading conditions must be within the following specifications.

Minimum Exhaust Elbow Height Model

Specifications

4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models

330 mm (13 in.)

90-899883178 NOVEMBER 2007

Page 3 / 12

EXHAUST SYSTEM

SECTION - 3 Minimum Exhaust Hose Slope Specification within 45.7 cm (18 Specification for the remainder of in.) of the engine system (if applicable)

Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models

10°

3°

If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers.

The maximum exhaust riser height is specified in the table below.

Riser Options Model

Low

4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models

76 mm (3 in.) and 43 mm (1.7 in.)

Medium

High

76 mm (3 in.) and 43 mm (1.7 in.)

152 mm (6 in.)

EXHAUST ANGLE MEASUREMENT Measure the exhaust angle of each section of the exhaust system using an inclinometer as shown in the diagram below. Begin the measurement at the exhaust elbow outlet continuing along each section to the exhaust exit point of the boat. All exhaust angle measurements must be performed with the boat at rest in the water. Perform the first set of measurements without a load in the boat.

Perform the second set of measurements with the boat fully loaded. See Loading Requirements.

c a

b 18582

Typical Exhaust a - Inclinometer b - Exhaust hose or tube

c - Minimum 305 mm (12 in.)

Boat Requirements IMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height measurement. No prototype hulls or light layup hulls should be considered. Any measurement performed on non‑production boats, prototype hulls, or light layup hulls could be inaccurate and could result in product damage.

• All boats that display a CE certification capacity plate must use the maximum capacity as stated on the CE certification capacity plate to perform the exhaust elbow waterline measurement.

•

Page 4 / 12

All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on the USCG capacity plate to perform the exhaust elbow waterline measurement.

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

• •

•

For boats that do not have a capacity plate, the maximum capacity load is the number of persons that can sit on designated seating plus cargo excluding cabin space.

Measurements used for official Mercury MerCruiser audit at the OEM boat builder must be performed on current production boats. No prototype hulls or light layup hulls will be considered for official audit purposes.

Measurements used for official Mercury MerCruiser audit at OEM boat builders must use the CE certification maximum load for any boat model that will be sold outside of the United States.

Loading Requirements 1. Fill the fuel tanks, fresh water tanks or holding tanks, ballast tanks, and heater tanks to simulate fully loaded condition.

2. Weights can be used to simulate these load conditions if desired. Place weights in the corresponding area for which the load is being replaced. Refer to the following conversions.

• 1 U.S. gallon of water = 8.3 lb.

• 1 liter of water = 1 kg • 1 U.S. gallon of gasoline = 6 lb.

• 1 liter of gasoline = 0.72 kg 3. For the purpose of MerCruiser waterline height measurements: • One person is equivalent to 74.84 kg (165 lb.)

• Cargo per person is equivalent to 11.34 kg (25 lb.)

4. Add weight for any additional boat options: extra battery, battery charger, tower, arch, generator, ballast tanks, ballast sacks, television, carpet, anchor, stereo/entertainment equipment, washer/dryer, safe, etc.

5. If a swim platform is an option, the swim platform must be installed for the waterline height measurement. Use the following guide to determine the correct swim platform load: a.

Boats less than 8.84 m (29 ft.) long, not including boats that are 8.84 m (29 ft.) long, must add the maximum rated swim platform weight capacity to the swim platform. b.

Boats less than 8.84 m (29 ft.) long, not including boats that are 8.84 m (29 ft.) long that do not have a maximum rated swim platform weight capacity, must add181.45 Kg (400 lb.) to the swim platform . c.

Boats 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, must add the maximum rated swim platform weight capacity to the swim platform. d.

Boats 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, that do not have a maximum rated swim platform weight capacity must add 226.80 kg (500 lb.) to the swim platform.

Loading the Boat with a Capacity Plate For boats with a capacity plate, use the maximum load for persons and gear as listed on the capacity plate to determine the number of persons to place onto the boat for exhaust elbow waterline height measurements.

IMPORTANT: Use 20 inches for average passenger seat width when measuring bench seating.

Round up or down at 0.5 to obtain a whole person. See the examples listed below.

• 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons.

• 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.

1. Take the maximum capacity weight as listed on the capacity plate (XXXX lb. Persons, Gear) and subtract the swim platform load, if applicable.

2. Next divide the weight by 74.84 kg (165 lb.) per person. This gives the whole number and remainder of 74.84 kg (165 lb.) persons to load onto the boat.

90-899883178 NOVEMBER 2007

Page 5 / 12

EXHAUST SYSTEM

SECTION - 3

3. Put the remainder of a person in the next available seat. See Boat loading diagram.

24860

CE Capacity Plate

24861

USCG Capacity Plate

IMPORTANT: If there is not enough seating for the number of people, treat the leftover weight as cargo. Load cargo weight onto the boat before loading passenger weight.

4. If applicable, load cargo (leftover persons weight) onto the boat. Distribute cargo as described below.

IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage application from the Optional Cargo Distribution table that best applies to your boat configuration.

Preferred Cargo Distribution Aft storage

Center storage

Bow storage

25%

50%

25%

Optional Cargo Distribution Aft storage

Center storage

Bow storage

25%

75%

None

None

75%

25%

50%

None

50%

None

100%

None

100%

None

None

None

None

100%

5. Perform the first measurement with the swim platform loaded and the person taking the waterline measurement on the boat.

6. Load the swim platform if equipped.

7. Measure the exhaust elbow waterline height.

IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.

8. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight is loaded onto the boat. Repeat until a person weight is is loaded into each seat in that row.

9. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded into each seat.

NOTE: The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity plate.

NOTE: The following example is provided as a reference.

EXAMPLE NOTE: This example uses a boat that is less than 8.84 m (29 ft.) long, not including a boat that is 8.84 m (29 ft.) long that does not have a maximum rated swim platform weight capacity, and must add 181.45 Kg (400 lb.) to the swim platform NOTE: Use 0.50 lb. as the break point to round up or down to obtain a whole pound.

Page 6 / 12

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

1. Maximum load (persons and gear) from capacity plate – swim platform load = remaining weight to be placed in the boat.

• 1100 lb. – 400 lb. = 700 lb.

2. Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the boat • 700 lb. ÷ 165 lb. = 4.24 persons 3. Total number of persons – number of whole persons = remaining persons • 4.24 persons – 4 persons = 0.24 remaining persons 4. Remainder persons ÷ MerCruiser person weight = remainder MerCruiser person weight • 0.24 × 165 lb. = 40 lb.

IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.

5. Using the totals in this example, load four 165‑lb. persons and one 40‑lb. person onto boat seating with 400 lb. on the swim platform.

• 400 lb. + 165 lb. = 565 lb.

• 565 lb. + 165 lb. = 730 lb.

• 730 lb. + 165 lb. = 895 lb.

• 895 lb. + 165 lb. = 1060 lb.

• 1060 lb. + 40 lb. = 1100 lb.

d

e

b

a

c f 24862

Boat loading diagram a - Swim platform load b - MerCruiser person weight (one) c - MerCruiser person weight (two)

d - MerCruiser person weight (three) e - MerCruiser person weight (four) f - Remainder MerCruiser person weight (five)

Loading the Boat—Without a Capacity Plate For boats that do not display a capacity plate, the number of persons to be loaded onto the boat for measuring purposes is the number of persons that can sit on designated seating excluding cabin space. An additional weight of 25 lb. per person is to be added to the boat before loading passenger weight onto the boat.

IMPORTANT: Use 20 inches for average passenger seat width when measuring bench seating.

Round up or down at 0.5 to obtain a whole person. See the examples below.

• 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons.

• 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.

1. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person weight = maximum passenger load for measurement.

90-899883178 NOVEMBER 2007

Page 7 / 12

EXHAUST SYSTEM

SECTION - 3

•

Number of persons × 165 lb. (MerCruiser person weight) = XXXX lb. maximum passenger load.

2. Maximum passenger load from the calculation above – swim platform load if applicable.

3. Divide the weight by 165 lb. per person. This gives the number of 165‑lb. persons to load onto the boat. Round up to next whole number. See Example 3.

IMPORTANT: To account for cargo, add a weight of 25 lb. per person to the boat before loading passenger weight onto the boat.

4. Calculate the cargo by multiplying 25 lb. by the number of persons that can sit on designated seating excluding cabin space. See Example.

5. Load the cargo onto the boat. Distribute cargo as described below.

IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage application from the Optional Cargo Distribution table that best applies to your boat configuration.

Preferred Cargo Distribution Aft storage

Center storage

Bow storage

25%

50%

25%

Optional Cargo Distribution Aft storage

Center storage

Bow storage

25%

75%

None

None

75%

25%

50%

None

50%

None

100%

None

100%

None

None

None

None

100%

6. Perform the first measurement with the swim platform loaded and the person measuring the waterline on the boat.

7. Load the swim platform if equipped.

8. Measure the exhaust elbow waterline height.

IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.

9. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight is loaded onto the boat. Repeat until a person weight is is loaded into each seat in that row.

10. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded into each seat.

EXAMPLE NOTE: The following example is provided as a reference.

This example uses a boat that is 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, that does not have a maximum rated swim platform weight capacity, and must add 226.80 Kg (500 lb.) to the swim platform .

Page 8 / 12

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on designated seating excluding cabin space.

6 9 2 1 3

4

7

5

8 24863

Designated Seating Diagram This example uses 9 persons as the maximum passenger load.

NOTE: Use 0.50 lb. as the break point to round up or down to obtain a whole pound.

1. To determine the maximum cargo load multiply the maximum passenger load by the maximum cargo weight per passenger.

• 9 passengers × 25 lb. = 225 lb.

2. To determine the preferred cargo distribution for aft, center, and bow storage: a.

To determine the maximum aft storage cargo weight, multiply the maximum cargo weight by 25% 3. To determine the maximum center storage cargo weight, multiply the maximum cargo weight by 50% a.

225 lb. × 50% = 112.50 lb. b.

112.50 lb. rounded up = 113 lb.

4. To determine the maximum bow storage cargo weight, multiply the maximum cargo weight by 25% • 225 lb. × 25% = 56.25 lb.

• 56.25 lb. rounded down = 56 lb.

5. To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb. (MerCruiser person weight) to get a 1485 lb. (total passenger load) • 9 passengers × 165 lb. = 1485 lb.

6. Subtract the swim platform load from the total passenger load to get the remaining weight to be placed in the boat.

• 1485 lb. – 500 lb. = 985 lb.

7. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat.

• 985 lb. ÷ 165 lb. = 5.9 passengers • 5.90 passengers rounded up = 6 passengers 8. Using the totals in this example load 56 lb. cargo in the aft storage, 113 lb. cargo in the center storage, and 56 lb. cargo in the bow storage onto the boat before adding passenger weight.

Then, load six 165 lb. passengers, onto the boat with 500 lb. on the swim platform.

• 500 lb. + 225 lb. = 725 lb.

• 725 lb. + 165 lb. = 890 lb.

• 890 lb. + 165 lb. = 1055 lb.

• 1055 lb. + 165 lb. = 1220 lb.

• 1220 lb. + 165 lb. = 1385 lb.

• 1385 lb. + 165 lb. = 1550 lb.

90-899883178 NOVEMBER 2007

Page 9 / 12

EXHAUST SYSTEM

SECTION - 3

•

1550 lb. + 165 lb. = 1715 lb.

g c

a

b d

h

i

e

j

f 24864

Cargo, swim platform, and passenger weight loading diagram a - Swim platform load f - MerCruiser person weight (five) b - MerCruiser person weight (one) g - MerCruiser person weight (six) c - MerCruiser person weight (two) h - Aft storage d - MerCruiser person weight (three) i - Center storage e - MerCruiser person weight (four) j - Bow storage

Clear Hose Measurement Method 1. Obtain an 8–10 mm (5/16–3/8 in.) ID (inner diameter) clear hose approximately 4.5 m (15 ft.) long. Install a metal fitting or a weight on one end of the hose to keep that end of the hose below the waterline. The fitting or weight must not restrict water from filling the clear hose.

b b

c

a

24865

a - Clear hose b - Fitting

c - Unrestricted opening

IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water.

2. Put the weighted end of the clear hose over the side of the boat (port or starboard) that is sitting lower in the water.

3. Submerge the clear hose until completely filled with water.

4. Place a finger over the open end of the clear hose before removing it from the water.

5. Coil the excess clear hose into the bottom of the boat bilge. Keep the coil of clear hose below the waterline.

6. Keeping the clear hose in line with the engine's exhaust elbow, lift the end of the clear hose up to the highest point of the exhaust elbow.

Page 10 / 12

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

7. Slowly take the finger off of the end of the clear hose to let the water level stabilize. The water will seek the level of the water outside of the boat. Keep the clear hose close to the exhaust elbow and as vertical as possible.

b

c e

a d

8340

9142

a - Waterline b - Top of exhaust elbow c - Clear hose

d - Weight e - Measurement, waterline to top of exhaust elbow

Clear Hose Measurement Method from Seacock or Muffler Drain IMPORTANT: Measure the exhaust elbow height to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped.

IMPORTANT: The engine must have been operated previously to fill the muffler with water.

IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water.

1. Attach a clear hose to the muffler drain point or seacock drain point.

2. Start the engine to fill the muffler and hose.

3. If attached to the seacock drain, open the seacock.

4. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that this open end section of the hose is as vertical as possible from the boat's bilge to the top of the exhaust elbow.

5. Coil excess hose in the bilge of the boat, keeping it below the water line.

6. Lower the open end of the hose and siphon water until it starts to come out of the hose. Put a finger over the hose and lift open end until it is at the top of the exhaust elbow.

7. Slowly take the finger off of the end of the hose to let the water level stabilize. The water will seek the level of the water outside the boat. Keep the hose close to the exhaust elbow and as vertical as possible.

90-899883178 NOVEMBER 2007

Page 11 / 12

EXHAUST SYSTEM

SECTION - 3

8. The measurement between the water in the hose and the top of the exhaust elbow is the exhaust elbow height. The maximum riser height is 15.2 cm (6 in.).

a

b 24866

Typical vertical water lift muffler a - Minimum exhaust elbow height with b - Clear hose for measuring waterline maximum load

a

b

24867

Typical horizontal water lift muffler a - Minimum exhaust elbow height with b - Clear hose for measuring waterline maximum load

Page 12 / 12

90-899883178 NOVEMBER 2007

SECTION - 4

FUEL SYSTEM

SECTION 4 - FUEL SYSTEM Table of Contents Fuel Delivery System .............................................................................................................................................. 2 California Regulations for 2007—Low‑Permeation Fuel Hose..........................................................................2 Fuel Lines and Fittings......................................................................................................................................2 Fuel Delivery System .......................................................................................................................................3 Special Information About Electric Fuel Pumps ......................................................................................... 4

4

90-899883178 NOVEMBER 2007

Page 1 / 4

FUEL SYSTEM

SECTION - 4

Fuel Delivery System California Regulations for 2007—Low‑Permeation Fuel Hose California Regulations for New 2007 and Later Spark-Ignition Inboard/Sterndrive Pleasurecraft (3) Requirements of engine manufacturers and boat manufacturers under Option 2 and using Low Permeation Fuel Line Hose: (A) Each manufacturer that chooses Option 2 must provide written instructions, as part of the installation materials provided to purchasers of the engine, to use Low Permeation fuel Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale, sold, or offered for sale in California, or that is introduced, delivered or imported into California for introduction into commerce.

(B) Each boat manufactured must install Low Permeation Fuel Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale, sold, or offered for sale in California that uses an engine from a manufacturer that chooses Option 2.

Low Permeation Fuel Line Hose is USCG Type A1‑15, defined as not exceeding 15 g/m²/24 h with CE10 fuel at 23° C as specified in SAE J 1527—Marine Fuel Hoses.

Fuel Lines and Fittings We recommended that you measure the exact route and length of the fuel lines before the first installation of the engine to prevent problems later in connecting them to the engine.

Only a few points related to function and safety are listed here. Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines.

• Use fuel lines that are Coast Guard approved USCG Type A1. The U.S. boating standards and regulations specify the sole use of USCG Type A1 fuel lines in the engine compartment or in any location in the boat where a break in the line could result in a discharge of 150 cc (5 oz.) of fuel in 2½ minutes.

• Ensure that the fuel pickup is at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities.

• Using a digital vacuum gauge, measure the vacuum at the engine's fuel inlet. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg) throughout engine operating range.

IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels. It can also cause poor engine performance because of fuel starvation.

• Follow the minimum fuel line diameter specification listed below.

Description

Specification

Minimum fuel line diameter on single‑engine gasoline installations

10 mm (3/8 in.)

Minimum fuel line diameter on multi‑engine gasoline installations with single pickup and line

13 mm (½ in.) ID or larger

•

On multi-engine gasoline installations, use a fuel pickup and fuel tank supply line for each engine. If a single pickup and line is used, the line must be 13 mm (½ in.) ID or larger.

•

On installations that require long lines or numerous fittings, use the fuel lines and fittings with an ID greater than 10 mm (3/8 in.).

Use the Engine Compartment/Fuel System Pressure and Temperature Test to determine if the fuel pressure and temperature are within an acceptable range. If the temperature is excessive, reduce the fuel line length, reduce the number of fittings or insulate the components. Refer to the Engine Compartment/Fuel System Pressure and Temperature Test in the Mercury MerCruiser Product Applications Manual.

•

•

Page 2 / 4

Route the fuel lines as low as possible in the engine compartment to keep them in the coolest region. Temperature increases significantly with increased engine compartment height.

90-899883178 NOVEMBER 2007

SECTION - 4

FUEL SYSTEM

•

Route the slope of the fuel line as consistent as possible to avoid high spots that can trap vapor and contribute to vapor locking problems.

• Ensure that the holes where the fuel lines run through the bulkheads are carefully rounded off or protected with grommets to prevent damage from vibration and chafing.

• Keep the fuel line free of stress and firmly secured to prevent vibration and chafing. Secure the fuel line with clamps that will not pinch or kink the line.

• Do not route the fuel line with sharp bends.

• Use a flexible fuel line to connect the fuel supply line to the fuel inlet fitting on the engine. The flexable line will absorb deflection between the engine and the hull structure when the engine is running.

• Keep all the fuel lines well secured.

IMPORTANT: If the engine is equipped with a boost pump, an in‑line filter must be installed between the fuel tank and the boost pump. This filter is provided with the engine package. The 100 Vazer model is equipped with a fuel pre‑filter already installed on the engine. Do not install a in‑line fuel filter on Vazer models.

The fuel delivery system must be designed to deliver the fuel to the engine with minimal restriction and at the lowest temperature. Gasoline is extremely sensitive to vaporizing if placed under a vacuum (low pressure) and exposed to moderate or high temperatures. This is particularly true if winter blend fuels with a high RVP (Reid Vapor Pressure) are encountered in warmer temperature areas. Excessive restriction in the fuel delivery system may cause a condition known as vapor locking. This typically occurs after the engine has been operated at high RPM and then shut off and allowed to sit for 15 minutes to 2 hours. During this time the engine heat soaks, causing the temperature of the fuel system to increase. Upon restart, the combination of heat and vacuum in the fuel system causes the fuel to vaporize. The fuel system cannot handle this vapor and therefore, fuel starvation results when the boater attempts to resume operation. Depending upon the degree of vapor locking, this can range from a hesitation or bog when accelerating to a complete stalling of the engine. To minimize the potential for this problem, the guidelines should be observed to limit fuel delivery restriction to 6.9 kPa (2 in. Hg) or less and fuel inlet temperature to 44° C (110° F) or less.

The fuel delivery system is an integral part of the boat. Mercury MerCruiser makes no attempt in this manual to cover all aspects of design and integration of the fuel delivery system, due to a broad range of possible configurations and the numerous regulations and standards that cover this area. The applicable standards and regulations for the markets where your product will be sold should be observed, along with any information from the fuel system component manufacturers. The following general guidelines are provided:

! WARNING Improper boat design and construction may result in serious injury or death. Adhere to all applicable marine regulations (United States Coast Guard [USCG], European Union– Recreational Craft Directive [EU‑RCD], etc.) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], etc.) when designing and constructing the boat and other components, such as the engine compartment, fuel delivery system, or exhaust system.

The main concern of a boat's fuel system is safety; this must be achieved through a technically sound installation and constant inspection.

The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.

The fuel tank is an integrated component of the boat. Refer to the special information on service and maintenance, which you have received from the tank manufacturer.

Only a few points related to function and safety are listed here [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: • All connections should be on the upper side of the tank.

90-899883178 NOVEMBER 2007

Page 3 / 4

FUEL SYSTEM

SECTION - 4

•

The drain plug at the lowest point on the tank serves to permit the removal of water and sediment.

• The tank breather pipe must have an inner diameter of at least 13 mm (1/2 in.) and must be fitted with a swan neck to prevent water from entering the tank.

It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine.

All fuel lines must be well secured. The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets. This prevents damage to the lines from abrasion.

The following, but not limited to the following, additional fuel connection related points, applying to all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: 1. Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities.

2. Using a digital vacuum gauge, measure the vacuum at the engine's fuel inlet. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg) through out engine operating range.

IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels. It can also cause poor engine performance because of fuel starvation.

3. Use fuel lines that are Coast Guard approved (USCG Type A1).

Description

Specification

Minimum fuel line diameter on single‑engine gasoline installations

10 mm (3/8 in.)

Minimum fuel line diameter on multi‑engine gasoline installations with single pickup and line

13 mm (½ in.) ID or larger

4. On multi-engine gasoline installations, use a fuel pickup and fuel tank supply line for each engine. If a single pickup and line is used, the line must be 13 mm (½ in.) ID or larger.

5. On installations that require long lines or numerous fittings, use the fuel lines and fittings with an ID greater than 10 mm (3/8 in.).

6. Install the fuel lines so they are free of stress and firmly secured to prevent vibration and/or chafing.

7. Avoided sharp bends in the fuel lines.

8. Use a flexible fuel line to the fuel inlet fitting on the engine to absorb deflection when engine is running.

SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS

! WARNING Improper boat design and construction may result in serious injury or death. Adhere to all applicable marine regulations (United States Coast Guard [USCG], European Union– Recreational Craft Directive [EU‑RCD], etc.) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], etc.) when designing and constructing the boat and other components, such as the engine compartment, fuel delivery system, or exhaust system.

The installation of additional filters may cause: • Fuel vapor locking.

• Difficult warm‑starting.

• Piston detonation due to lean fuel mixture.

• Poor driveability.

Page 4 / 4

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

SECTION 5 - COOLING SYSTEM Table of Contents General Information................................................................................................................................................. 2 Seawater Supply System........................................................................................................................................ 2 Seawater Supply Hose......................................................................................................................................2 Seawater Inlet Hose..........................................................................................................................................2 Through‑Hull Seawater Pickup System............................................................................................................. 3 Seawater Pickup...............................................................................................................................................4 Seacock.............................................................................................................................................................5 Sea Strainer......................................................................................................................................................6 Sterndrives With Closed Cooling Engines............................................................................................................... 7 Bravo Models with Closed Cooling.................................................................................................................... 7 SeaCore Models................................................................................................................................................7 SeaCore Bravo One and Bravo Three Models .......................................................................................... 7 SeaCore Bravo Two Models ...................................................................................................................... 7 Seawater Pickups for SeaCore Sterndrive Engine Models ....................................................................... 8 Installing the Y‑Fitting........................................................................................................................................9 Installing the Seawater Supply Hose.................................................................................................................9 Closed Cooling...................................................................................................................................................... 10 Description......................................................................................................................................................10 Antifreeze Recommendations.........................................................................................................................10 Coolant Recovery System...............................................................................................................................11 Hot Water Heater Hose Connections ‑ MPI Models ............................................................................................. 11 Supply Hose Connection ................................................................................................................................ 12 Return Hose Connection ................................................................................................................................ 13 Water Flow Diagrams............................................................................................................................................ 14 V‑6 and V‑8.....................................................................................................................................................14 V‑8 Bravo Models With Closed Cooling and Risers ................................................................................ 14 V‑6 Alpha Models With Closed Cooling and Risers ................................................................................. 15 V‑8 Bravo Models With Closed Cooling ................................................................................................... 16 V‑6 Sterndrive Models With Closed Cooling ............................................................................................ 17 V‑6 Bravo MPD Models With Seawater Cooling ...................................................................................... 18 V‑8 Bravo MPD Models With Seawater Cooling ...................................................................................... 19 V‑8 Bravo Models With Seawater Cooling (Except MPD Models) ........................................................... 20 V‑6 Bravo Models With Seawater Cooling (Except MPD Models) ........................................................... 21 V‑6 and V‑8 Alpha MPD Models With Seawater Cooling ........................................................................ 22 V‑6 and V‑8 Alpha Models With Seawater Cooling (Except MPD Models) ............................................. 23

90-899883178 NOVEMBER 2007

5

Page 1 / 24

COOLING SYSTEM

SECTION - 5

Lubricant, Sealant, Adhesives Tube Ref No.

Description

Where Used

9

Loctite 567 PST Pipe Sealant

116

RTV 587 Ultra Blue Silicone Sealer

Part No.

Hose fitting threads and plastic plug threads 92-809822 Sealing surfaces and screw shaft

92-809825

General Information Mercury MerCruiser engines have either a seawater cooling system or a closed cooling system.

Seawater cooling systems are sometimes called raw water cooling or standard cooling, while closed cooling systems are sometimes called fresh water cooling. On engines with seawater cooling, the engine is cooled entirely by the seawater in which the boat is being operated. Closed cooling systems use a combination of fresh water (antifreeze and water) and seawater for cooling.

Both types of systems are designed to keep the engine operating temperature at approximately 71 degrees C (160 degrees F) for optimum performance, fuel economy and durability. (Refer to cooling system flow diagrams at end of section.)

To monitor the cooling system, a temperature switch is incorporated into the audio warning system, which alerts the operator of an abnormal condition if the temperature exceeds approximately 93 degrees C (200 degrees F). A temperature sender is also employed to operate a temperature gauge at the dash. On dual helm applications, this sender must be replaced with a dual station sender to obtain the proper temperature reading at both stations. Refer to the Instrumentation and Controls section for more information.

The cooling system must receive a sufficient amount of seawater under all operating conditions to operate properly. The design and installation of the seawater supply system is the boat manufacturer's responsibility. Cooling system components must be constructed, sized, and installed in accordance with the following guidelines.

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.

Seawater Supply System Seawater Supply Hose Seawater Supply Hose Specifications Seawater inlet hose

32 mm (1‑1/4 in.) I.D. (wire reinforced)

Seawater pickup Seacock (ABYC requirement)

Low restriction with 32 mm (1‑1/4 in.) connections

Sea strainer (optional)

Seawater Inlet Hose • • • •

Page 2 / 24

A reinforced hose capable of supporting 10 in. Hg vacuum must be used to prevent the seawater inlet hose from collapsing from pump suction.

The hose should be oil and seawater resistant.

Use the shortest hose length possible with the least number of bends to minimize restriction.

All connections must be secured with a hose clamp.

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

•

Fasten hose as appropriate to maintain proper routing and to prevent chafing or contact with other moving parts.

a

a

7638

9361

Typical composite seawater pickup pump a - Seawater inlet hose connection

Typical brass seawater pickup pump

Through‑Hull Seawater Pickup System IMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction is created by seawater pump impeller.

g

c f b

e

b

b d

a 7924

Typical installation shown with a through the hull seawater pickup a - Quicksilver seawater pickup and e - Seawater hose to engine seacock f - Seawater pump hose connector (if b - Hose clamp equipped) c - Seawater hose to seawater strainer g - Below seawater pump level d - Quicksilver seawater strainer IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as the pickup may create turbulence and allow air to flow into the propeller slipstream. This will cause propeller ventilation and will adversely affect boat performance.

IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come in contact with steering system components, engine coupler, or drive shaft.

90-899883178 NOVEMBER 2007

Page 3 / 24

COOLING SYSTEM

SECTION - 5

• • •

The seawater pickup must be large enough to permit sufficient seawater flow to engine seawater pickup pump for adequate engine cooling.

The seawater pickup also must supply a positive head while underway.

The seawater pickup should be located as close to the seawater pump inlet as possible and in an area where an uninterrupted, solid stream of seawater will flow past when the boat is underway.

Seawater Pickup Either a through‑transom or through‑hull seawater pickup can be used. Select pickup location to minimize seawater inlet hose length while providing an optimum location for seawater pickup. The location should be in an area that will provide a solid, air‑free flow of seawater under all operating conditions. Avoid areas with a disturbed seawater flow, such as those behind or in close proximity to the propeller. Locations that are too far forward or outboard should also be avoided as these are prone to aeration problems at high boat trim angles and in turns. Check for aeration as outlined under Seawater Supply Test.

IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as pickup may create turbulence and allow air to flow into the propeller slip‑stream. This will cause propeller ventilation and will adversely affect boat performance.

Openings in seawater pickup should be approximately 3 mm (1/8 in.) maximum to prevent larger debris from entering and clogging the cooling system.

IMPORTANT: Use a seawater strainer if the seawater pickup openings exceed 3 mm (1/8 in.).

Provisions should be made to minimize galvanic corrosion, given the hull material being used and the composition of the surrounding components. Some industry standards and regulations also require that the pickup be connected into the boat's bonding system to minimize stray current corrosion. Refer to applicable standards and regulations for more details.

IMPORTANT: External seawater pickup must have an integral seacock.

7532

Typical seacock

Page 4 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

b a

d

c

e

f

g

h i j

7558

Typical transom pickup a - Hose fitting b - Nut (4) c - Gasket d - O‑ring (4) e - Washer (4)

f - Screw (4) g - Plastic plug h - Pickup i - Screen j - Screw (2)

Tube Ref No.

Description

Where Used

Part No.

9

Loctite 567 PST Pipe Sealant

Hose fitting threads and plastic plug threads

92-809822

Tube Ref No.

Description

Where Used

Part No.

RTV 587 Ultra Blue Silicone Sealer

Sealing surfaces and screw shaft

92-809825

116

Seacock The ABYC and other industry standards and regulations require the use of a seacock on certain types of applications to stop the entry of seawater in the event of a leak in the cooling system.

Refer to applicable standards and regulations for specific requirements. The seacock also allows the seawater to be shut off when servicing the engine.

90-899883178 NOVEMBER 2007

Page 5 / 24

COOLING SYSTEM

SECTION - 5

The seacock must provide minimum restriction to seawater flow (see Specifications). A ball valve or gate valve is recommended. The ball valve is most common and is typically equipped with a lever type handle that operates in a 90 degree arc. This design gives a clear indication of whether the valve is open or shut. Industry standards and requirements typically require that the seacock be rigidly attached to the hull at the seawater pickup. Seacock location should be readily accessible for quick, easy operation.

7532

Typical seacock

Sea Strainer A sea strainer is recommended if the boat is to be operated in an area with a high debris content.

The strainer must be sized to minimize restriction (See Specifications) and to provide a reasonable service interval. Locate the strainer in an area that will be easily accessible for servicing. If the boat is not equipped with a seacock, the strainer should be located above the seawater‑line to prevent seawater entry into boat when servicing. The strainer must have provision to allow draining in freezing temperature periods.

7533

Typical Sea Strainer

Page 6 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

Sterndrives With Closed Cooling Engines Bravo Models with Closed Cooling NOTE: Closed cooled Bravo models require a through the hull or through the transom pickup in addition to the sterndrive water inlets in order to meet the minimum flow specifications.

When additional water inlets are used, a Y‑fitting is installed to the engine seawater pump.

a

c b d

8485

Dual seawater pickup for Bravo closed cooled engines a - Engine seawater pump c - Y‑ fitting port to Bravo drive b - Hose from seawater pump inlet port d - Y‑fitting port to additional water inlet to Y‑fitting Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere do not require the dual seawater pickup with a bravo sterndrive on closed cooling models.

Remove the Y‑fitting at the seawater pump inlet. Install a seawater suppy hose that meets MerCuiser specifications. Cut the hose to fit from the transom inlet fitting to the seawater pump inlet.

SeaCore Models Some SeaCore models do not require a through‑the‑hull or through‑the‑transom seawater pickup to meet the minimum flow specifications. See the chart, Seawater Pickups for SeaCore Sterndrive Engine Models.

SEACORE BRAVO ONE AND BRAVO THREE MODELS The SeaCore Bravo One and Bravo Three engine packages do not require a through‑the‑hull or through‑the‑transom seawater pickup in addition to the sterndrive water pickups if: • The sterndrive gearcase has dual water pickups.

• The boat is capable of 64 km/h (40 MPH) with the boat fully loaded and operated within the specified operating range.

NOTE: When not installing the through‑the‑hull or through‑the‑transom seawater pickup, see Installing the Seawater Supply Hose.

SEACORE BRAVO TWO MODELS The SeaCore Bravo Two engine packages must have a through‑the‑hull or through‑the‑transom seawater pickup in addition to the sterndrive side water pickups. Install the Y‑fitting at the engine's seawater pump inlet. See Installing the Y-Fitting.

90-899883178 NOVEMBER 2007

Page 7 / 24

COOLING SYSTEM

SECTION - 5

SEAWATER PICKUPS FOR SEACORE STERNDRIVE ENGINE MODELS Seawater Pickups for SeaCore Sterndrive Engine Models Boat speed with the boat fully loaded and operated within the specified operating range

SeaCore Bravo has side water pickup

SeaCore Bravo has dual water pickup

Through‑the‑hull or through‑the‑transom seawater pickup

Not required See Installing the Seawater Supply Hose

64 km/h (40 MPH) or greater

30180

Required See Installing the Y-Fitting

Less than 64 km/h (40 MPH) 30181

30180

Required See Installing the Y-Fitting

64 km/h (40 MPH) or greater

30181

Greater or Less than 64 km/h (40 MPH) Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere.

Page 8 / 24

Not required See Installing the Seawater Supply Hose 30181

30180

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

Installing the Y‑Fitting Engine models that require a through‑the‑hull or through‑the‑transom seawater pickup, require a Y‑fitting at the engine seawater pump inlet port. The Y‑fitting directs the seawater from the sterndrive and through‑the‑hull or through‑the‑transom seawater pickup to the engine's seawater pump to meet the minimum flow specifications.

a

c b d

8485

Typical Y‑fitting installation a - Engine seawater pump b - Hose 101.6 mm (4 in.) from seawater pump inlet to Y‑fitting port c - Y‑fitting port to water inlet at transom d - Y‑fitting port to through‑the‑hull or through‑the‑transom seawater pickup

NOTE: For models not factory equipped with a Y‑fitting, refer to Mercury Parts Catalog, Closed Cooling Systems (Bravo) to order the specified Y‑fitting, seawater supply bulk hose, and hose clamps that meets MerCruiser specifications.

1. Cut a 101.6 mm (4 in.) leneth piece of the supply hose and install it to the seawater pump inlet and the Y‑fitting port.

2. Install a seawater supply hose to the Y‑fitting port and the sterndrive's water inlet at the transom. Cut off any excess hose as needed.

3. Install a seawater supply hose to the Y‑fitting port and the through‑the‑hull or through‑the‑transom seawater pickup. Cut off any excess hose as needed.

4. Properly secure all hoses to all fittings to prevent water leaking into the boat.

Installing the Seawater Supply Hose For engine models not using through‑the‑hull or through‑the‑transom seawater pickup: 1. If applicable, remove the Y‑fitting at the seawater pump inlet.

2. Install a seawater supply hose that meets MerCruiser specifications to the engine's seawater pump inlet.

3. Route the seawater supply hose directly to the seawater inlet fitting on the transom. Cut off any excess hose as needed.

4. Properly secure the hose at both ends to prevent water leaking into the boat.

NOTE: For models not factory‑equipped with a seawater supply hose, refer to the Mercury Parts Catalog, Standard Cooling Systems (Bravo) to order the specified bulk hose, hose clamps, and

quick connect fittings that meet MerCruiser specifications.

NOTE: For models with quick connection fittings and pull test information, refer to Section 6, Seawater Inlet Fitting Connection .

90-899883178 NOVEMBER 2007

Page 9 / 24

COOLING SYSTEM

SECTION - 5

Closed Cooling Description Closed cooling is a standard feature on some models and is available as an accessory or a factory installed option on others. When closed cooling is used, a mixture of antifreeze and water is circulated through the water jackets in the engine block, cylinder heads, and—on some applications—the exhaust manifolds to dissipate the heat. Refer to Water Flow Diagrams. This coolant is then passed though a heat exchanger. Here the coolant rejects heat to seawater (water in which the boat is being operated), which is simultaneously being passed through the exchanger.

The heat is then carried away by the seawater and discharged overboard via the exhaust elbows.

The design of the heat exchanger allows for the transfer of heat, while ensuring that the two coolants are separated. In this manner, the expensive engine components are never exposed to seawater, which can be corrosive in salty, polluted, or mineral laden water areas.

Mercury MerCruiser's closed cooling systems are developed by the same people who design our engines to ensure compatibility and the same high quality standards. Our systems employ several exclusive features to provide unsurpassed cooling efficiency and durability. An exclusive double‑acting thermostat is used on V6 and V8 models, which provides increased coolant velocity through the engine and heat exchanger to prevent hot spots and improve performance. Mercury MerCruiser's heat exchangers also incorporate several state‑of‑the‑art designs to enhance the heat transfer between the coolants for an additional margin of cooling capacity. Features like these allow our systems to continually operate at WOT in water temperatures up to 38 °C (100 °F), where most after‑market systems fall short of this mark. This additional cooling capacity translates into longer cooling system life with fewer problems regardless of where the boat is operated. Contact your sales representative to order your closed cooling systems factory installed or refer to the Mercury Precision Parts and Accessories Guide to obtain the part numbers for the accessory kits.

The term full closed cooling, also known as full fresh water cooled or full FWC refers to the use of an ethylene glycol mixture in the engine and the exhaust water jackets. The ethylene glycol coolant mixture is circulated through the exhaust cooling passages as well as the engine cooling passages.

Antifreeze Recommendations

NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.

Factory installed closed cooling systems come filled with an extended life antifreeze. This coolant allows for a service interval of 5 years or 1000 hours (whichever occurs first), versus 2 years or 400 hours for standard antifreeze. When adding coolant to these systems (i.e. when filling coolant recovery bottle, installing hot water heater), we recommend that only an extended‑life antifreeze be used. Mixing this coolant with even a small amount of regular antifreeze will require that the service interval be reduced 2 years. If you are installing closed cooling kits at your facility, we would also encourage you to use the extended Life coolant to allow your customer to take advantage of the reduced maintenance costs.

Pre‑mixed extended life coolant is available from Quicksilver or can be purchased at most automotive stores and other locations where antifreeze is sold. Extended‑life coolant is available from Texaco under the name Havoline Extended Life Dex Cool. Prestone also offers a version of this antifreeze called Extended Life 5/100. Only coolants that state that they are compatible with Dex Cool should be used. Extended‑life coolants can be identified by their orange color (vs. green for standard coolant) and their corresponding orange cap on the container.

All antifreeze should be mixed 50/50 with pure water (Quicksilver coolant is already pre‑mixed).

If installing closed cooling kits at your facility, be sure to observe the special filling procedure in the installation instructions.

Closed Cooling System Capacity

Page 10 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM 8.1S Models

18 liters (19 quarts)

All Other Models

19 liters (20 quarts)

Coolant Recovery System This system is equipped with a coolant recovery system that must be installed by the boat manufacturer. Coolant recovery bottle mounting location must meet these requirements: • Within approximately 122 cm (4 ft.) of heat exchanger filler neck to allow connection with tubing provided.

• Even with or slightly above heat exchanger filler neck.

NOTE: This differs from the previous recommendation and has been changed to ensure that air does not enter the cooling system upon cool down.

• Accessible for observing level and servicing coolant.

c

c

a b

e

f

d 12838

d

12837

e

a - Recovery bottle b - Mounting bracket c - Screw and flat washer (2 each provided)

d - Plastic tubing e - Tubing clamp f - Heat exchanger fill neck

Hot Water Heater Hose Connections ‑ MPI Models IMPORTANT: When connecting a cabin heater or hot water heater: • Supply hose (from engine to heater) and return hose (from heater to engine) Must Not Exceed 16 mm (5/8 in.) inside diameter (ID).

• Make heater connections only at locations shown.

• Refer to manufacturers' instructions for complete installation information and procedures.

• Do not reposition engine temperature switch.

NOTICE Blocking the coolant flow at the heater can cause reduced engine performance or overheating.

Check for continuous coolant flow from the engine intake manifold to the water circulating pump.

90-899883178 NOVEMBER 2007

Page 11 / 24

COOLING SYSTEM

SECTION - 5

NOTICE Prevent engine damage from overheating. In models equipped with closed cooling, low coolant levels may allow an air pocket to form when the hot water heater or cabin heater is mounted higher than the fill cap on the heat exchanger. Mount the heater lower than the fill cap of the heat exchanger and maintain the recommended coolant level.

Supply Hose Connection NOTE: Some models may be equiped with additional fittings.

a

9255

Seawater cooled models with air or manual drain a - Location for hot water supply

a 9256

Closed cooled models a - Location for hot water supply

Page 12 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

a 9257

Seawater cooled models with multi‑point drain a - Location for hot water supply

Return Hose Connection

a

b

9258

a - Return hose connection for hot water heater

b - Water circulating pump housing

IMPORTANT: A special fitting 22‑865526 may be used if the hex of the standard hose barb fitting contacts the water pump housing not allowing the fitting to turn before the fitting is tight.

a b

25133

a - Standard fitting

90-899883178 NOVEMBER 2007

b - Special fitting

Page 13 / 24

COOLING SYSTEM

SECTION - 5

Water Flow Diagrams V‑6 and V‑8 V-8 BRAVO MODELS WITH CLOSED COOLING AND RISERS

h b

j

a i

c

d

k

p

e g

c

f

n o

l

8182

m a - Seawater inlet b - Power steering cooler c - Gen III cool fuel module d - Exhaust and seawater outlet e - Exhaust manifold f - Distribution housing g - Water circulating pump h - Thermostat housing

Page 14 / 24

i - Exhaust elbow j - Seawater pump k - Heat exchanger l - To power steering pump m - From seawater pump n - Seawater o - Ethylene glycol mix p - Check valve

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-6 ALPHA MODELS WITH CLOSED COOLING AND RISERS

i

b

a

k

j e c

l

d f h

9393

m g a - Seawater inlet b - Power steering cooler c - Check valve d - Fuel cooler e - Exhaust and seawater outlet f - Exhaust manifold g - Distribution housing

90-899883178 NOVEMBER 2007

n h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - Heat exchanger m - Seawater n - Ethylene glycol mix

Page 15 / 24

COOLING SYSTEM

SECTION - 5

V-8 BRAVO MODELS WITH CLOSED COOLING

i a h b

j

c

k

p

d

e g c

n f

o

l m

9385

a - Y‑fitting b - Power steering cooler c - Gen III cool fuel module d - Exhaust and seawater outlet e - Exhaust manifold f - Distribution housing g - Water circulating pump h - Thermostat housing

Page 16 / 24

i - Exhaust elbow j - Seawater pump k - Heat exchanger l - To power steering cooler m - From seawater pump n - Seawater o - Ethylene glycol mix p - Check valve

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-6 STERNDRIVE MODELS WITH CLOSED COOLING

a j

i b

k

l

c

e

d f h

g a - Y‑fitting b - Power steering cooler c - Check valve d - Fuel cooler e - Exhaust and seawater outlet f - Exhaust manifold g - Distribution housing

90-899883178 NOVEMBER 2007

m n

9386

h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - Heat exchanger m - Seawater n - Ethylene glycol mix

Page 17 / 24

COOLING SYSTEM

SECTION - 5

V-6 BRAVO MPD MODELS WITH SEAWATER COOLING

j b a

k i e

c d h

g

f

9388

a - Seawater inlet b - Power steering cooler c - Drain plug d - Fuel cooler e - Exhaust and seawater outlet f - Exhaust manifold

Page 18 / 24

g - Check valve h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-8 BRAVO MPD MODELS WITH SEAWATER COOLING

j

b a

d

k

e

c

i

h

g

f

d

l

9387

m a - Seawater inlet b - Power steering cooler c - Drain plug d - Gen III Cool Fuel Module e - Exhaust and seawater outlet f - Exhaust manifold g - Check valve

90-899883178 NOVEMBER 2007

h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - To power steering cooler m - From seawater pump

Page 19 / 24

COOLING SYSTEM

SECTION - 5

V-8 BRAVO MODELS WITH SEAWATER COOLING (EXCEPT MPD MODELS)

i

b

c a n

h

d

j c

g

e

k l

f m

9389

a - Seawater inlet b - Power steering cooler c - Gen III cool fuel module d - Exhaust and seawater outlet e - Exhaust manifold f - Distribution housing g - Water circulating pump

Page 20 / 24

h - Thermostat housing i - Exhaust elbow j - Seawater pump k - Drain from starboard exhaust manifold l - To power steering cooler m - From seawater pump n - Check valve

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-6 BRAVO MODELS WITH SEAWATER COOLING (EXCEPT MPD MODELS)

j b

a e

c

i k d

h

f

g a - Seawater inlet b - Power steering cooler c - Check valve d - Fuel cooler e - Exhaust and seawater outlet f - Exhaust manifold

90-899883178 NOVEMBER 2007

9390

g - Distribution housing h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump

Page 21 / 24

COOLING SYSTEM

SECTION - 5

V-6 AND V-8 ALPHA MPD MODELS WITH SEAWATER COOLING

j

a

b

i e

c

d h

g

f 9391

a - Seawater inlet (from transom) b - Power steering cooler c - Drain plug d - Fuel cooler e - Exhaust and seawater outlet

Page 22 / 24

f - Exhaust manifold g - Check valve h - Water circulating pump i - Thermostat housing j - Exhaust elbow

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-6 AND V-8 ALPHA MODELS WITH SEAWATER COOLING (EXCEPT MPD MODELS)

a j b

c

i

e

d

h

f

9392

g a - Seawater inlet (from transom) b - Power steering cooler c - Check valve d - Fuel cooler e - Exhaust and seawater outlet

90-899883178 NOVEMBER 2007

f - Exhaust manifold g - Distribution housing h - Water circulating pump i - Thermostat housing j - Exhaust elbow

Page 23 / 24

COOLING SYSTEM

SECTION - 5

NOTES:

Page 24 / 24

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION 6 - DRIVE SYSTEM AND ENGINE INSTALLATION Table of Contents Transom Cutout....................................................................................................................................................... 5 Finding The Crankshaft Vertical Center Line....................................................................................................5 Single Engine ............................................................................................................................................. 5 Dual Engine ............................................................................................................................................... 6 Finding Crankshaft Horizontal Center Line (X‑dimension)................................................................................6 90 Degree Tool Method ............................................................................................................................. 7 Tape Measure Method ............................................................................................................................... 7 Cutting Out the Transom...................................................................................................................................8 Checking The Transom Thickness..................................................................................................................10 General Information............................................................................................................................................... 11 Drive Shaft Extension Models.........................................................................................................................11 Rear Engine Mounts........................................................................................................................................11 All Bravo Models.............................................................................................................................................12 SeaCore and Closed Cooling Engine Models Seawater Inlets.......................................................................12 Alternative Mounting Of Gear Lube Monitor On Transom...............................................................................12 Air Pump..........................................................................................................................................................13 Transom Assembly Installation.............................................................................................................................. 13 Installing Gimbal Housing Assembly...............................................................................................................13 Installing the Alpha Inner Transom Plate........................................................................................................14 Installing Inner Transom Plate ........................................................................................................................ 14 Connecting Speedometer Pickup....................................................................................................................16 Water Inlet Block‑Off Plate Installation.................................................................................................................. 17 Models With Alpha Sterndrive and Alternative Water Pickups........................................................................17 Alpha Models ........................................................................................................................................... 18 Water Inlet Block‑Off Plate Installation............................................................................................................20 Alternative Water Pickups ........................................................................................................................ 20 Bravo Models ........................................................................................................................................... 20 Exhaust Preparation........................................................................................................................................22 Seawater Inlet Fitting and Gear Lube Monitor Fitting............................................................................................ 23 Alpha Gear Lube Monitor Connection At Gimbal Housing..............................................................................23 Seawater Inlet Fitting Installation....................................................................................................................24 Gear Lube Monitor Connection At Gimbal Housing........................................................................................25 Exhaust at Transom.............................................................................................................................................. 26 Transom Exhaust Connections.......................................................................................................................26 Power Trim Pump Installation................................................................................................................................ 27 Power Trim Pump............................................................................................................................................ 27 Power Trim Pump Connections and Filling.....................................................................................................27 Filling ....................................................................................................................................................... 28 Trim Limit Switch Connection..........................................................................................................................29 Steering System Installation.................................................................................................................................. 29 Hydraulic (Helm) Steering...............................................................................................................................29 Steering Helm and Cable................................................................................................................................29 Steering Cable Specifications.........................................................................................................................30 Installing Steering System...............................................................................................................................30 Sensor Steering Assembly.................................................................................................................................... 34 Installing the Pitot Sensor...................................................................................................................................... 35 Preliminary Transom Harness Connections.......................................................................................................... 36 Transom Harness............................................................................................................................................36

90-899883178 NOVEMBER 2007

6

Page 1 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Engine Installation................................................................................................................................................. 37 Transom Preparation.......................................................................................................................................37 Shift Cable Routing.........................................................................................................................................37 Engine Preparation .........................................................................................................................................38 Gen II Cool Fuel with Boost Pump Inlet Fitting................................................................................................ 39 Gen III Cool Fuel Module Inlet Fitting..............................................................................................................40 Engine Installation ..........................................................................................................................................41 Exhaust System Hose Connections................................................................................................................44 Engine Alignment Sterndrive Models..............................................................................................................45 Electrical Connections........................................................................................................................................... 47 Boat Harness and Instrumentation Connections.............................................................................................48 SmartCraft Product .................................................................................................................................. 49 Audio Warning System Connections...............................................................................................................49 MerCathode Connections................................................................................................................................50 Power Trim Electrical Connection...................................................................................................................50 Power Trim Pump Connections....................................................................................................................... 51 Battery Cables Connection..............................................................................................................................51 Fluid Connections.................................................................................................................................................. 51 Gear Lube Monitor Connection.......................................................................................................................51 Power‑Assisted Steering Hoses......................................................................................................................52 Alpha Seawater Inlet Hose Connection...........................................................................................................53 Seawater Inlet Fitting Connection...................................................................................................................53 Coolant Recovery System...............................................................................................................................56 Alpha Shift Cable Installation................................................................................................................................ 57 Alpha Sterndrive Shift Cable Installation.........................................................................................................57 Shift Cable Travel .................................................................................................................................... 58 Separate Shift and Throttle Controls ....................................................................................................... 58 Installation ................................................................................................................................................ 59 Bravo Shift Cable Installation and Adjustment...................................................................................................... 62 Bravo Models Shift Cable Installation.............................................................................................................. 62 Bravo Models Shift Cable Adjustment.............................................................................................................63 DTS System Installation........................................................................................................................................ 66 Shift Cable Installation For DTS System............................................................................................................... 66 Throttle Cable Installation...................................................................................................................................... 67 Throttle Cable Installation And Adjustment.....................................................................................................67 Alpha Sterndrive Installation.................................................................................................................................. 68 Trim Cylinder Installation ......................................................................................................................... 73 Speedometer Connection ‑ Alpha Models.......................................................................................................74 Alpha Notice: Increased Trim‑in Range Capability.......................................................................................... 75 Alpha Trim Cylinder Spacer Removal.............................................................................................................75 Alpha Trim Cylinder Disassembly...................................................................................................................76 Alpha Trim Cylinder Reassembly....................................................................................................................77 Alpha Trim Cylinder Installation....................................................................................................................... 78 Bravo Sterndrive Installation................................................................................................................................. 80 Trim Cylinder Installation ......................................................................................................................... 87 Speedometer Connections ‑ Bravo Models..................................................................................................... 89 Trim Limit and Trim Position Settings.............................................................................................................. 90 Bravo Sterndrive Shift Check (Engine Running).............................................................................................90 Troubleshooting Shift Problems......................................................................................................................91 Paddle Wheel Speed Sensor Installation (If Equipped)..................................................................................94 Parts Provided ......................................................................................................................................... 94 Selecting Location ................................................................................................................................... 94 Transom Angle Requirements ................................................................................................................. 94 Installing Bracket ..................................................................................................................................... 95 Routing the Cable .................................................................................................................................... 95 Drilling Hole Through Transom (optional) ......................................................................................... 95 Without Drilling Hole Through Transom (optional) ............................................................................ 96

Page 2 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Installing and Removing the Paddle Wheel ............................................................................................. 96 Wiring Connections .................................................................................................................................. 96 Template ‑ Paddle Wheel Speed Sensor ................................................................................................ 97

90-899883178 NOVEMBER 2007

Page 3 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Lubricants, Sealants, Adhesives Tube Ref No.

Description Liquid soap

Where Used

Part No.

Exhaust tubes

Obtain Locally

Trim cylinder bolt threads

92-809819

Fuel inlet fitting

92-809822

7

Loctite 271 Threadlocker

9

Loctite 567 PST Pipe Sealant

25

Liquid Neoprene

Battery terminals All electrical connections

92- 25711 3

27

Bellows Adhesive

Exhaust bellows mounting surface

92-86166Q1

92-802865Q02

Obtain Locally

34

Special Lubricant 101

Gimbal housing studs Power steering bushings Upper and lower pivot bolts Clevis pin Steering cable end Rear engine mounting bolts Shift cable stud Trim cylinder end cap

80

SAE Engine Oil 30W

Shift cable pivot points

87

High Performance Gear Lubricant

91

Engine Coupler Spline Grease

95

2-4-C Marine Lubricant with Teflon

114

Power Trim and Steering Fluid

Gear lube monitor Gear Lube Monitor Coupler splines Ujoint O-rings Drive shaft splines U-joint O-rings Driveshaft splines Bell housing studs Trim cylinder hardware Trim cylinder O-ring Water passage seals Shift cable end Power trim pump

92-858064K01

92-802869A1

92-802859A1

92-858074K01

Special Tools Tapered insert tool

91‑43579 Removes and installs the tapered insert retainer into the water inlet hose.

9197

Alignment Tool Assembly

91‑805475A 1 Aligns the engine and the sterndrive unit during installation.

9183

Shift Cable Adjustment Tool

91‑12427

9186

Page 4 / 98

Attaches over the shift cable, and aids in proper shift cable adjustment at the shift plate.

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION Shift Slide Stabilizer

91‑865232

Holds the shift slide in the proper position as the sterndrive is installed onto the bell housing studs.

9184

Trim Cylinder End Cap Tool

91‑821709T

Allows easy removal of the trim cylinder end caps. Required if tilt limit spacers are to be installed or if the trim in limit spacer is to be removed (to allow additional trim in range).

9191

Dual Water Pick‑up Flush Gearcase Seal Kit

91‑881150K 1

Blocks off the front water inlet holes on the dual water inlet gearcases.

9194

Flushing Device

91‑44357Q 2

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

9192

Flushing Kit

91‑849996T 1

Use for flushing gearcases with low water inlets.

9195

Transom Cutout Finding The Crankshaft Vertical Center Line SINGLE ENGINE 1. Locate and mark the vertical center line on the transom, if known. This is also the crankshaft vertical center line.

2. If unknown, a compass can be used to locate the vertical center line: a.

Mark identical locations on each side of the boat 304 mm (12 in.) from the bottom of the hull.

90-899883178 NOVEMBER 2007

Page 5 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

b. c.

a

SECTION - 6

Position the fixed end of a compass at the marks and draw arcs on the transom.

Draw the crankshaft vertical center line through the intersection points of the 2 arcs.

b

e c

b

e

d

7687

Single engine installation a - 304 mm (12 in.) b - Identical side marks c - Compass arc

d - Arc intersection points e - Crankshaft vertical center line

DUAL ENGINE 1. Locate and mark the vertical center line on the transom. Refer to Single Engine procedure.

2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical center lines on either side of the vertical center line.

Minimum Distance Between Crankshaft Vertical Center lines (Dual Side‑By‑Side) Model

Measurement

V6 and V8 Sterndrive

838 mm (33 in.)

IMPORTANT: Crankshaft vertical center lines must be an equal distance from boat vertical center line.

3. Draw the 2 crankshaft vertical center lines through the intersection of the marks.

b b

c

c

a Dual installation a - Vertical center line b - 1/2 minimum distance between crankshaft center line marks

7688

c - Crankshaft vertical center lines

Finding Crankshaft Horizontal Center Line (X‑dimension) X‑dimension can be measured by the 90 Degree Tool Method or by the Tape Measure Method.

Page 6 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

90 DEGREE TOOL METHOD 1. Construct the 90 degree tool.

90

a

b a - 34.5 cm (13‑9/16 in.)

7689

b - 1.2 m (4 ft)

IMPORTANT: The 34.5 cm (13‑9/16 in.) dimension should only be raised or lowered after proper testing.

• ‑To lower drive unit - Subtract from dimension "a".

•

To raise drive unit - Add to dimension "a".

2. Place the 90 degree tool along the boat bottom at the vertical center line.

3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical center line. This is the crankshaft horizontal center line or X‑dimension.

4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

c b

b

c a

7690

Single engine a - 90 degree tool along boat bottom at vertical center line b - Contact point

a

7691

Dual engine c - Crankshaft horizontal center line

TAPE MEASURE METHOD 1. Determine the X‑dimension from the following chart.

IMPORTANT: This dimension should only be raised or lowered after proper testing.

90-899883178 NOVEMBER 2007

Transom Angle (degrees)

X‑dimension

16

36.4 cm (14‑5/16 in.)

15

36.2 cm (14‑1/4 in.)

14

36.0 cm (14‑3/16 in.)

13

35.9 cm (14‑1/8 in.)

12

35.7 cm (14‑1/16 in.)

11

35.6 cm (14 in.)

10

35.4 cm (13‑15/16 in.)

Page 7 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. On the vertical crankshaft center line, measure up from the bottom of the transom to the X‑dimension selected previously. This is the crankshaft horizontal center line at the X‑dimension.

3. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

a

a c

c

b

b

7692

Single engine a - Vertical center line b - X‑dimension that corresponds to transom angle

7693

Dual engine c - Crankshaft horizontal center line

Cutting Out the Transom IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is suitable for most boats. Best mounting location for a particular boat, however, can be determined only by testing.

1. Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from X‑Dimension.

2. Heavy duty applications: Subtract 25 mm (1 in.) from X‑Dimension.

3. Above 40 km/h (25 mph): Use X‑Dimension shown.

4. Above 80 km/h (50 mph): The X‑Dimension can be increased to improve performance in some applications. However, pulling power for skiing will decrease. During testing, X‑Dimension should be increased 13 mm (1/2 in.) at a time until desired performance is achieved but in no case should it ever be increased by more than: Maximum Increase In X‑Dimension Bravo One and Three

76 mm (3 in.)

Bravo Two

25 mm (1 in.)

Extreme care should be taken when raising drive unit to ensure that water supply does not become aerated. Use clear water inlet hose to monitor incoming water and monitor engine temperature gauge to ensure engine does not overheat.

In applications where cooling water to the engine is supplied by a through the hull or through the transom fitting, the sterndrive height will not cause cooling water aeration.

IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed height will not be covered by Mercury MerCruiser warranty.

Page 8 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

1. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately).

7694

7893

Transom cutout template Transom drilling fixture kit 2. Follow instructions indicated on template or provided with drilling fixture.

3. Ensure that centerline on either the template or transom drilling fixture align with lines previously marked on transom.

4. Drill two 6 mm (1/4 in.) pilot holes at a 60 degree angle for hole saw guides.

5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole saw cutout is made incorrectly, drive unit steering lever may contact transom causing limited steering travel.

a b

7695

a - 51 mm (2 in.) hole saw holes (steering lever cutout)

b - 60 degrees versus transom angle

6. Cut the transom on the cut line at a 90 degree angle. If the transom cutout is made incorrectly the gimbal housing or exhaust system may improperly contact the boat transom causing transom mounting problems.

90-899883178 NOVEMBER 2007

Page 9 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water absorption and deterioration of the transom.

b

d

a c 7696

a - Cut line b - 90 degrees to transom

c - Exhaust pipe area d - Mounting holes perpendicular to transom (8)

Checking The Transom Thickness IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.

1. Ensure that transom thickness and surface conform to specifications.

Transom Specifications Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical center line Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.)

Flatness

Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.) Outer Surface ‑ Flat within 2 mm (1/16 in.)

Angle

10 ‑16 degrees

a

b

c 7697

a - Measuring thickness b - Measuring flatness

Page 10 / 98

c - Suitable mandrel to check for uniform transom thickness

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

General Information Drive Shaft Extension Models If the power package is equipped with a drive shaft extension, refer to the Drive Shaft Extension Installation Instructions (90‑866039) included with the engine package.

Extensions for the gear lube monitor and MerCathode quick connects are used with drive shaft extention installations. Refer to your parts catalog for replacement part numbers.

Rear Engine Mounts A fiber washer is cemented to the transom plate where the rear engine mount is attached to the transom plate. Verify the washer is in place before installing the engine.

Normally the engine attaches to the transom plate with only the fiber washer in place. If the front engine mounts cannot be adjusted low enough to achieve proper engine alignment, spacer kit (12‑892619A01) can be ordered and installed as shown to raise the rear of the engine. Do not use the spacer unless alignment cannot be achieved with the front engine mount adjustment.

IMPORTANT: The fiber washer must be used.

NOTE: Engine alignment is usually obtained using only the rear engine mount and the fiber washer.

1. Ensure that the fiber washer is in place.

b

a

16584

a - Transom plate

b - Fiber washer

2. Place the stainless steel washer on top of the transom plate mount only if needed to obtain proper alignment.

b

a c

a

b c

a - Transom plate b - Stainless steel washer

90-899883178 NOVEMBER 2007

16583

c - Stainless steel washer position to raise engine

Page 11 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

All Bravo Models IMPORTANT: The trim‑in limit insert must be properly positioned before installing the trim cylinder anchor pin.

NOTE: When removing the sterndrive, note the position of the insert for reference when reinstalling the sterndrive.

1. Ensure that the trim‑in limit insert is positioned correctly for the appropriate Bravo model.

a

8548

Bravo One and Two (positioned forward) a - Trim‑in limit insert

a

8557

Bravo Three (positioned aft) a - Trim‑in limit insert IMPORTANT: The position of the trim‑in limit insert on the Bravo Three sterndrive should only be changed after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a particular boat application.

SeaCore and Closed Cooling Engine Models Seawater Inlets Refer to Section 5, Sterndrives With Closed Cooling Engines for seawater pickup requirements and inlet connections.

Alternative Mounting Of Gear Lube Monitor On Transom IMPORTANT: The mounting location specified must be above the steering lever on the transom assembly. Hose must be positioned to avoid moving parts (steering system, engine coupler).

1. Install the gear lube monitor bracket in the specified location and secure with lag screws and flat washers.

Page 12 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Install the gear lube monitor in the bracket. Secure the monitor with the retaining strap.

a c d b

7706

a - Bracket b - Lag screw and flat washer

c - Gear lube monitor and cap d - Retaining strap

Air Pump NOTE: Some models have air pump mounted on the engine and other models have the air pump in a parts bag.

1. Select an easily accessible mounting location for the air pump.

2. Mount the air pump.

8992

Transom Assembly Installation Installing Gimbal Housing Assembly 1. Carefully remove transom assembly from shipping carton.

2. Remove and read all tags attached to transom assembly.

a

b

7713

a - Shipping hardware 3.

4.

5.

6.

b - Trim cylinder suppport

Remove the shipping hardware.

Remove the dust cover if boat will be shipped with drive installed.

Do not remove the Shift Slide Installation Tool.

Retain the serial number envelope.

90-899883178 NOVEMBER 2007

Page 13 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Installing the Alpha Inner Transom Plate 1.

2.

3.

4.

5.

Insert the wires, hoses, and shift cable through appropriate openings in inner transom plate.

Position the gimbal housing on the transom and hold in place.

Temporarily secure with hardware.

Attach continuity wires.

Place the transom harness ground ring terminal on top of the continuity circuit wire on transom bolt.

6. Secure the transom assembly with the hardware as shown. Torque the hardware.

Description

Nm

Transom assembly hardware

34

lb. in.

lb. ft.

25

IMPORTANT: Tighten the transom assembly fasteners using an X‑pattern torque sequence, starting from the middle fasteners. Tighten in small increments and go around the pattern several times until the proper torque is achieved.

IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves.

5

d

7

3

e

f

2

a 1

i

h

j

5

4 8

c b

i

6

g

7

3

2

1

4 8

6

24401

a - Locknuts and flat washers (8) b - Hydraulic hoses c - Drive unit shift cable d - Trim limit and trim position sender wires e - Inner transom plate

f - Transom harness ground wire g - Mercathode wires (if equipped) h - J‑clip i - Torque sequence j - Steering lever continuity circuit wire

Installing Inner Transom Plate 1. Insert wires, hoses, and shift cable through appropriate openings in inner transom plate.

2. Position gimbal housing on transom and hold in place.

3. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the gimbal housing studs.

Page 14 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION Tube Ref No. 34

Description Special Lubricant 101

Where Used

Part No.

Gimbal housing studs

92-802865Q02

IMPORTANT: Tighten the transom assembly fasteners using an X‑pattern torque sequence, starting from the middle fasteners. Tighten in small increments and go around the pattern several times until the proper torque is achieved.

4. Secure transom assembly with fasteners. Torque the fasteners.

Description

Nm

Transom assembly hardware

34

lb. in.

lb. ft.

25

IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves.

90-899883178 NOVEMBER 2007

Page 15 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

IMPORTANT: Transom harness ground must be attached as shown.

g d c a

f

a

5

a

7

a 3

2

1

4

b

e a - Locknuts and flat washers (8) b - Hydraulic hoses and MerCathode wire c - Steering lever continuity wires d - Transom plate continuity wires

8

6

e - Torque sequence f - Trim sender and trim limit wires g - Ground from transom harness

23138

Connecting Speedometer Pickup

NOTICE Removing the plug from the speedometer pickup fitting can introduce water into the bilge. Do not remove the the plug unless you intend to make a connection to a speedometer pickup.

1. Remove the protective cap from the male quick connect.

Page 16 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Connect a 4 mm (5/32 in.) speedometer hose (not provided) from speedometer to barb fitting.

Secure hose with tie strap.

a

b c

c

e

d

b

7703

Typical a - Male quick connect b - Female quick connect c - Barbed fitting

d - Hose e - Tie strap

! CAUTION A ruptured speedometer hose can introduce water into the bilge, causing boat damage or possible sinking. Position or install the speedometer hose away from moving parts or pinch points, such as steering system components, engine coupler, or driveshaft, which could damage the hose.

3. Secure the hose to the transom with the hose clip and screw that are provided in the parts bag. Ensure that the hose does not contact the steering system components or the engine coupler and drive shaft.

Water Inlet Block‑Off Plate Installation Models With Alpha Sterndrive and Alternative Water Pickups A water inlet block‑off kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine. When installing the block‑off plate, it is necessary to cut the water hose that is located between the bell housing and the gimbal housing. This allows water to continue to circulate through the sterndrive unit for cooling.

NOTICE Obstructions in the water passages will keep cooling water from circulating through the engine, resulting in damage to the sterndrive. When using a block‑off plate ensure that the water hose between the bell housing and gimble housing is cut and removed.

90-899883178 NOVEMBER 2007

Page 17 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

ALPHA MODELS 1. Cut water tube off close to cover. Remove and discard the screws and cover.

a

b c

a b 9260

a - Water Tube Cover b - Screws

c - Water Tube

2. Remove rubber grommet from cavity around tube.

a

b 9283

a - Water Tube (Cut Off In Previous Step)

b - Rubber Grommet

3. Remove and discard bell housing sta‑strap and clip that retains wires and speedometer hose.

f

d

c a b e a - Sta‑Strap b - Clip c - Bell Housing Hose

Page 18 / 98

9281

d - Bell Housing Assembly e - Speedometer Hose f - Trim Limit Switch Wire Harness

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Cut the bell housing hose close to the bell housing as shown.

a

b 9285

a - Bell Housing Hose

b - Cut Line

5. Pull on hose to withdraw water tube through gimbal housing opening. Remove hose with remaining piece of water tube from gimbal housing.

b

a

a

9286

a - Bell Housing Hose

b - Water Tube (Cut Off Previously)

6. Sta‑strap (obtain locally) speedometer hose and trim limit switch wire harness together onto piece of hose remaining on bell housing.

7. Install the block‑off plate with new gasket. Secure with screws and lockwashers. Torque the screws.

c

d

a

b

7262

a - Block‑off plate b - Gasket

90-899883178 NOVEMBER 2007

c - Screw d - Lockwasher

Page 19 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Description

Nm

lb. in.

Water inlet block off screw

5

45

lb. ft.

8. Install a through the hull or through the transom seawater pickup, seawater strainer, and seacock.

9. Connect the seawater inlet hose between seawater pump and seawater strainer.

10. Secure all hoses with hose clamps.

ALTERNATIVE WATER PICKUPS A water inlet block‑off kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine. When installing the block‑off plate, it is necessary to cut the water hose that is located between the bell housing and the gimbal housing. This allows water to continue to circulate through the sterndrive unit for cooling.

NOTICE Obstructions in the water passages will keep cooling water from circulating through the engine, resulting in damage to the sterndrive. When using a block‑off plate ensure that the water hose between the bell housing and gimble housing is cut and removed.

BRAVO MODELS 1. Remove the tapered insert in the gimbal housing using the tapered insert tool. Discard the insert.

a c

b d

a - Tapered insert location in the gimbal housing b - Rachet and extension Tapered insert tool

Page 20 / 98

17857

c - Tapered insert d - Tapered insert tool

91‑43579

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Install the block‑off plate with new gasket. Secure with screws and lockwashers. Torque the screws.

a d

a

c

b

21683

a - Block‑off plate b - Gasket

c - Screw d - Lockwasher

Description

Nm

lb. in.

Water inlet block off screw

5

45

lb. ft.

3. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2.

a d e c b 8489

a - Trim limit switch wires b - Speedometer hose c - Gimbal housing

d - Water hose e - Tapered insert

! WARNING Improper reassembly of the U‑joint and pinion gear assembly can damage the sterndrive or sink the boat. The U‑joint bellows must provide a watertight seal to prevent water from entering the boat. Assemble and install the U‑joint and pinion gear as specified.

NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. The existing tie strap and clip can be reused if they are moved and repositioned after the hose is cut.

4. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where it is fitted into the bell housing in the area shown. Do not damage the U‑joint bellows.

5. Discard loose hose piece.

90-899883178 NOVEMBER 2007

Page 21 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

6. Secure the trim limit switch wires and speedometer hose to the remaining section of water hose using existing tie strap and clip.

e

c

f b d a - Tie strap b - Clip c - Water inlet hose

a 8490

d - Speedometer hose e - Trim limit wire harness f - Cutting area

7. Install a through the hull or through the transom seawater pickup, seawater strainer, and seacock.

8. Connect the seawater inlet hose between seawater pump and seawater strainer.

9. Secure all hoses with hose clamps.

Exhaust Preparation IMPORTANT: When installing through the transom exhaust, it is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats.

1. If required, remove and discard clamps and bellows from gimbal housing.

IMPORTANT: When installing through the propeller exhaust: • With Bravo One and Bravo Two Sterndrives, an exhaust tube may be installed for a slight increase in performance.

• With most Bravo Three Sterndrive Models, an exhaust tube may be installed for a slight increase in performance.

• With a Silent Choice Exhaust System, the exhaust bellows must be removed and an exhaust tube must be installed.

• With any application, installation of an exhaust tube will increase exhaust noise.

2. If required, install exhaust tube on gimbal housing as follows: a.

Remove and discard clamps and exhaust bellows.

IMPORTANT: Failure to install the grounding clip can damage the exhaust tube due to corrosion.

Always install the grounding clip. b.

Install grounding clip on tube. c.

Apply adhesive to exhaust bellows/tube mounting surface.

Tube Ref No. 27

d. e.

Page 22 / 98

Description Bellows Adhesive

Where Used

Part No.

Exhaust bellows mounting surface

92-86166Q1

Allow bellows adhesive to dry until no longer tacky (approximately 10 minutes).

Position tube so that "SIDE" markings on tube are facing toward the right and left sides.

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

f.

Install and torque the clamp.

e

d

c a a - Exhaust tube b - Clamp c - "SIDE" marking

b 8406

d - Exhaust tube e - Grounding clip

Description

Nm

lb‑in.

lb‑ft

Exhaust tube clamp

3

26

–

Seawater Inlet Fitting and Gear Lube Monitor Fitting Alpha Gear Lube Monitor Connection At Gimbal Housing NOTE: The gear lube monitor hose is now in the parts bag on the engine.

1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal housing.

d

a

b

c

7704

a - Hose b - Quick release 90 degree fitting

c - Gimbal housing fitting d - Quick connect fitting

NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting, or block‑off plate if equipped. Release button must not contact water fitting or block‑off plate, if equipped.

90-899883178 NOVEMBER 2007

Page 23 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Position quick release button on hose fitting away from water inlet fitting. Release button must not contact water fitting.

a

e

b d

f

c d 7705

Alpha transom a - Water inlet fitting b - Star washer and screw c - 90 degree hose fitting

d - Quick release button e - ACCEPTABLE positions f - NOT ACCEPTABLE position

Description

Nm

lb. in.

Water inlet fitting bolts

5

45

lb. ft.

NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.

Seawater Inlet Fitting Installation 1. Install a new gasket, seawater inlet fitting, and screws. Torque screws.

a

a

b

c d Seawater inlet fitting shown with gear lube hose J‑clip a - Seawater inlet fitting c - Gasket b - Screw (2) d - Star washers

Page 24 / 98

21634

Description

Nm

lb. in.

Seawater inlet fitting screws

5

45

lb. ft.

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Gear Lube Monitor Connection At Gimbal Housing 1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal housing.

a

d a c

b Model with block‑off plate a - Hose b - Quick release 90 degree fitting

21623

c - Seawater inlet fitting d - J‑clip

NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting, or block‑off plate if equipped. Release button must not contact water fitting or block‑off plate, if equipped.

2. Position quick release button on hose fitting away from water inlet fitting. Release button must not contact water fitting.

b

a

c

21624

Model with Quick connect seawater inlet fitting a - Gear lube monitor hose c - Quick release button b - Seawater inlet fitting

NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.

90-899883178 NOVEMBER 2007

Page 25 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Exhaust at Transom Transom Exhaust Connections IMPORTANT: Exhaust pipe or block‑off plate and gimbal housing mating surface must be clean and free of nicks and scratches and O‑ring must be properly seated in groove or water may leak into boat.

a 21630

a - Seal 1. For through the transom exhaust installations, install a block‑off plate using four bolts and lockwashers. Tighten the bolts to the specified torque.

b c a a a - Block‑off plate b - Bolts

21625

c - Lockwashers

Description

Nm

Exhaust block‑off plate bolts

34

lb. in.

lb. ft.

25

2. For through the propeller exhaust installations, install the exhaust pipe. Tighten the bolts to the specified torque.

a a - Engine exhaust pipe

Page 26 / 98

16231

Description

Nm

Exhaust pipe to gimbal housing bolts

34

lb. in.

lb. ft.

25

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Power Trim Pump Installation Power Trim Pump 1. Select an appropriate mounting location (floor or transom) for the trim pump that: • Is within length limits of BLACK and GRAY hydraulic hoses coming from gimbal housing assembly.

• Is close to the battery so that trim pump battery leads can be connected.

• Allows easy access to trim pump oil fill and vent locations.

• Is in an area where pump will not be exposed to water.

• Prevents the power steering booster cylinder from coming in contact with the trim pump when the steering wheel is turned in either direction (right or left).

NOTE: Template 90‑863152 provides mounting hole location for floor or transom mounting.

2. Mount the pump in the desired location.

Power Trim Pump Connections and Filling IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking from the system.

1. Connect hydraulic hoses to the trim pump. Ensure that the quick‑ connect fittings completely seat when connecting the hoses.

a c g

h f b

d a - Positive battery lead b - Negative battery lead c - Harness connector d - BLACK hydraulic hose (UP hose)

90-899883178 NOVEMBER 2007

7698

e e - GRAY hydraulic hose (DOWN hose) f - Fill/vent cap g - Dual mount trim pump bracket h - Trim limit switch connected and secured

Page 27 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Connect power trim pump control harness to trim pump.

a b

7699

a - Control harness

b - Trim pump connector

FILLING 1. If the oil level is below the "MIN" line specified fluid must be added.

2. Remove the fill cap from the reservoir.

NOTE: Fill cap is vented.

a

b

7701

Power tim pump reservoir showes the oil level is below "MIN" line a - Fill cap assembly b - Fill cap installed 3. Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir.

a

b 7876

a - Reservoir

Page 28 / 98

b - "MIN" and "MAX" lines

Tube Ref No.

Description

Where Used

Part No.

114

Power Trim and Steering Fluid

Power trim pump

92-858074K01

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Install the fill cap.

Trim Limit Switch Connection 1. Connect the trim limit switch wires and secure with a wire retainer and tie strap.

a

b a - Trim limit switch wires

7700

b - Wire retainer and cable tie

Steering System Installation Hydraulic (Helm) Steering If your power package is equipped with Compact Hydraulic Steering, refer to the Compact Hydraulic (Helm) Steering Installation Instructions .

Steering Helm and Cable Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook.

The steering cable coupler nut must also have a means of locking it to the guide tube, as specified in ABYC requirements.

! WARNING Failure to use a steering cable locking device can cause serious injury or death due to loss of boat control. Use a locking device, such as a self‑locking coupler or external locking device when installing steering controls.

NOTE: All current production Quicksilver RideGuide steering cables have a self‑locking coupler nut and do not require an external locking device. (Other cable manufacturers also make cables with self‑locking coupler nut.)

a

7255

a - Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove) IMPORTANT: If using a steering cable that does not have a self‑locking coupler nut, an external locking device such as a locking sleeve must be used.

! WARNING Failure to use the correct cables or other steering system components can cause serious injury or death due to loss of boat control. Use only approved or required components when installing steering systems.

90-899883178 NOVEMBER 2007

Page 29 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

1. Steering cable must be the correct length, particularly when installed in larger boats.

2. Avoid sharp bends, kinks, or loops in cable.

3. Fully extended steering cable end dimension must be as specified.

Steering Cable Specifications IMPORTANT: Power‑assisted steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.

c

a b

d

e

g

f

C L

j

k

h i

l

7254

a - Coupler nut ‑ 7/8 ‑ 14 UNF ‑ 28 thread b - 298 mm (11‑3/4 in.) minimum c - Interface point d - 12.7 mm (1/2 in.) maximum e - 10.7 mm (27/64 in.) minimum flat f - 3.1 mm (7/64 in.) minimum radius

g - 15.9 mm (5/8 in.) maximum diameter end fitting h - 9.5 mm (3/8 in.) i - 9.8 mm (3/8 in.) diameter through hole (chamfered each side) j - 34.9 mm (1‑3/8 in.) maximum k - 15.9 mm (5/8 in.) diameter tube l - Cable travel: mid‑travel position ‑ 429 mm (16‑7/8 in.) total travel to be 203 mm (8 in.) minimum to 228 mm (9 in.) maximum travel each side of mid‑travel position ‑ 102 mm (4 in.) minimum to 114 mm (4‑1/2 in.) maximum

Installing Steering System NOTE: For dual installations, power‑assisted steering unit can be mounted on port or starboard transom assembly. Measure exact distance between power package center lines. Select a tie bar from Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar installation instructions before proceeding.

1. Remove the protective shipping caps.

2. Inspect the bushings for debris. Lubricate the power steering bushings.

3. a

7709

a - Bushings

Page 30 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION Tube Ref No.

Description Special Lubricant 101

34

Where Used

Part No.

Power steering bushings

92-802865Q02

4. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.

a

b 21631

a - Upper pivot bolt Tube Ref No.

b - Lower pivot bolt

Description Special Lubricant 101

34

Where Used

Part No.

Upper and lower pivot bolts

92-802865Q02

5. Position the steering assembly so that the pivot bolts will enter the bushings in the power‑assisted steering control valve.

6. Install the upper and lower pivot bolts along with tab washers. Ensure that the tab washer tangs straddle the ridge on the inner transom plate.

a b

a

a

b 21632

Upper Pivot Bolt And Tab Washer Shown (Lower Similar) a - Tab washer tang b - Ridge 7. Turn the pivot bolts all the way in, by hand, to ensure proper steering assembly alignment.

8. Ensure that the steering assembly pivots freely.

9. Torque the pivot bolts. Bend the tab washer tabs against the corresponding flats on the bolt heads.

90-899883178 NOVEMBER 2007

Page 31 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTE: It may be necessary to tighten the pivot bolts further to align the flats on bolt head with the tabs on the washer.

a

b

b

a 21691

a - Pivot bolt

b - Bent tab

Description

Nm

Upper and lower pivot bolt

34

lb. in.

lb. ft.

25

! CAUTION Contents under pressure. Moving the control valve cable guide tube with the hoses disconnected expels fluid from the ports. Wear eye protection while servicing the system.

10. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tube as shown, so that it will be less difficult to pull it out or push it in during connection.

a

a

b b

8496

a - Port

b - Control valve cable guide tube

11. Connect the clevis to the steering lever. a.

Lubricate the clevis pin.

Tube Ref No. 34

Page 32 / 98

Description

Where Used

Part No.

Special Lubricant 101

Clevis pin

92-802865Q02

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

b.

Insert the clevis pin.

b a

20396

a - Clevis c. d.

b - Clevis pin

Insert the cotter pin.

Spread both ends of the cotter pin.

c

b c

a

a

a - Cotter pin b - Clevis pin

20399

c - Steering lever

IMPORTANT: Quicksilver RideGuide steering cable has a self‑locking coupler nut and does not require an external locking sleeve or locking plate.

a

7255

a - Self‑locking coupler nut

90-899883178 NOVEMBER 2007

Page 33 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTICE Fastening any items to the steering cables or outer casings prevents normal operation. The steering cable and outer casing must be free to move back and forth. Do not fasten any items to the steering cable and outer casing.

a

7827

a - Steering cable and outer casing 12. Connect the steering cable as follows: a.

Coat the steering cable end with a liberal amount of lubricant.

Tube Ref No.

Description Special Lubricant 101

34

Where Used

Part No.

Steering cable end

92-802865Q02

b.

Install the steering cable and secure with hardware as shown.

IMPORTANT: Cable guide tube flat surfaces must be positioned vertically or slight feedback in the steering system could be encountered. c.

Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical position. Torque the coupler nut. Ensure that the flat surfaces are still aligned vertically after torque is applied to the coupler nut.

d g

h e

f

a b

c

d 7830

a - Steering cable b - Grease fitting c - Cable coupler nut d - Cable guide tube

e - Steering cable end f - Clevis g - Clevis pin h - Cotter pin

Sensor Steering Assembly 1. Remove nuts from upper 2 transom studs.

Page 34 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Remove cotter pin and clevis pin from steering lever.

3. Install new clevis pin and secure with existing cotter pin.

c a

h d

a f

e

b

g

8403

a - Transom stud holes b - Pitot tube connection c - Plug d - Guide 4.

5.

6.

7.

8.

9.

e - Cotter pin f - Clevis pin g - Tie strap h - Alignment mark

Slide guide onto the groove in the clevis pin.

Bolt the steering assembly to the transom.

Remove the brass plug from the transom.

Install pitot barbed fitting.

Attach pitot tube to barbed fitting and secure with a tie strap.

Plug sensor into transom harness.

Installing the Pitot Sensor IMPORTANT: The pitot hose must not come into contact with the steering system components or the engine coupler.

1. Remove the yellow cap from the quick‑connect fitting at the transom.

b

a

mc79613-1

a - Male quick‑connect fitting

b - Yellow plug

IMPORTANT: Ensure that the fittings snap into place.

90-899883178 NOVEMBER 2007

Page 35 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Connect the quick‑connect pitot hose to the fitting on the transom.

a

b mc79614-1

a - Female quick‑connect fitting

b - Male quick‑connect fitting

3. Connect the pitot hose quick‑connect fitting on the transom.

b

a

12119

a - Pitot sensor

b - Quick‑connect fitting on transom

Preliminary Transom Harness Connections Transom Harness The Transom harness connects to the engine harness and the following transom connections; engine to transom ground, analog trim, and the MerCathode. Wires are color coded and connections are tagged for easy installation.

IMPORTANT: Secure ground ring terminal (black wire) to screw on port side of transom plate.

1. Ensure that the transom harness ground ring is secured with the continuity circuit wire on transom plate.

2. If equipped, connect the transom harness MerCathode connector to the MerCathode connector from transom.

3. Analog trim: Connect transom harness analog connector to the analog connector from transom.

4. Make all transom wiring connections and secure with clamps. Transom harness connector should be placed in a safe location and will be connected to the engine after the engine is installed.

Page 36 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Engine Installation Transom Preparation

NOTICE Mismatched flywheel housing mounts and inner transom plate mounting hardware will result in improper engine alignment and possible engine damage. Ensure that the flywheel housing mounts and the inner transom plate mounting hardware, port and starboard, are the correct parts and match before installing the engine.

1. When installing mounts with knurled bottoms, use only the fiber washer. Do not install double‑wound lockwashers to knurled mounts.

b

a 7960

Typical flywheel housing, all similar a - Late‑style mount: knurled surface b - Fiber washer 2. Position rear engine mount attaching hardware on the inner transom plate mounts as shown.

a

b 7839

a - Fiber Washer (2)

b - Locknut (2)

Shift Cable Routing 1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:

90-899883178 NOVEMBER 2007

Page 37 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

a.

b. c.

SECTION - 6

The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing.

The cable should then be routed under the starboard rear engine mount and turn toward the transom.

The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine.

NOTE: Following this routing will prevent the engine coupler from damaging the cable.

8995

Refer to Section 8 - Remote Control.

Engine Preparation 1. Remove and read all tags attached to engine.

2. Remove all hardware that secures engine to shipping container.

3. Connect battery cables to engine. Observe the following: a.

Ensure that the grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection. b.

Install battery positive (+) wire directly to the large starter solenoid stud. c.

Install negative (‑) battery cable to the ground stud on the flywheel housing. d.

After battery cables are connected, apply a thin coat of sealant to the terminals.

Description

Nm

lb. in.

Battery stud

8‑11

71‑97

Tube Ref No. 25

Description Liquid Neoprene

lb. ft.

Where Used

Part No.

Battery terminals

92- 25711 3

e.

Slide rubber boot over positive (+) terminal after making connection.

4. Drape battery cables over top of engine to prevent interference during installation.

Page 38 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

IMPORTANT: There is a fuse located at the starter solenoid. Do not remove this fuse.

c

a

b

8501

a - Positive (+) battery cable location b - Starter solenoid

c - 90 amp fuse ‑ Do not remove

5. If not already done, remove shipping plug from coupler and lubricate splines.

a

7767

Typical a - Shipping plug Tube Ref No.

Description

Where Used

Part No.

91

Engine Coupler Spline Grease

Coupler splines

92-802869A1

Gen II Cool Fuel with Boost Pump Inlet Fitting ! WARNING Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting, causing a fuel leak and possible fire or explosion. Always install fittings and plugs correctly, and do not tighten with power tools.

1. Remove the shipping plug from the brass inlet fitting.

2. Install an adapter or a fitting to the brass inlet fitting of the boost pump. To prevent cracking the casting or causing fuel leaks, turn the fuel inlet adapter or fitting in by hand until finger‑tight.

Tighten the fitting an additional 1‑3/4 to 2‑1/4 turns with a wrench. DO NOT OVERTIGHTEN.

90-899883178 NOVEMBER 2007

Page 39 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

IMPORTANT: Hold the brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet adapter fittings.

a

b c 25007

Typical fuel boost pump a - Fuel inlet fitting b - Shipping plug

c - Boost pump

Tube Ref No.

Description

Where Used

Part No.

9

Loctite 567 PST Pipe Sealant

Fuel inlet fitting

92-809822

Description

Procedure Finger‑tight + 1‑3/4 to 2‑1/4 turns with a wrench. Do not overtighten.

Fuel inlet adapter or fitting

Gen III Cool Fuel Module Inlet Fitting ! WARNING Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting, causing a fuel leak and possible fire or explosion. Always install fittings and plugs correctly, and do not tighten with power tools.

1. Install an adaptor or a fitting to the brass inlet fitting of Gen III Cool Fuel Module. To prevent cracking the casting or causing fuel leaks, turn fuel inlet adaptor or fitting in by hand until finger‑tight. Tighten the fitting an additional 1‑3/4 to 2‑1/4 turns with wrench. DO NOT OVERTIGHTEN.

Page 40 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

IMPORTANT: Hold brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet adaptor fittings.

a

a

b 9360

a - Fuel inlet fitting

b - Gen III Cool Fuel Module

Tube Ref No.

Description

Where Used

Part No.

9

Loctite 567 PST Pipe Sealant

Fuel inlet fitting

92-809822

Description

Procedure Finger‑tight + 1‑3/4 to 2‑1/4 turns with a wrench. Do not overtighten.

Fuel inlet adaptor or fitting

NOTE: An installation jig (91‑806794A02) can be used to align and adjust engine mounts. Refer to instructions with fixture for proper use.

1. Remove the engine cover, if equipped.

a b

9289

Closed cool model shown, seawater cooled similar a - Engine cover knob b - Engine cover

90-899883178 NOVEMBER 2007

Page 41 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Attach a suitable sling to the front and rear lifting eyes on engine and adjust so that engine is level when suspended.

b

a

b

! CAUTION 9375

a - Center lifting eye (engine alignment only)

b - Lifting eye

3. Lift engine into position (in boat) using an overhead hoist.

4. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tube with exhaust pipe bellows.

Tube Ref No.

Description Liquid soap

Where Used

Part No.

Exhaust tubes

Obtain Locally

5. To help with installation, apply lubricant into the exhaust tubes.

IMPORTANT: The quick drain oil fitting clearance must be greater than 13 mm (1/2 in.) from the engine compartment and boat bottom.

6. If equipped with quick drain oil: Ensure that the quick drain oil fitting has a clearance of more than 13 mm (1/2 in.) from the engine compartment and boat bottom.

7. If clearance is 13 mm (1/2 in.) or less:Remove the quick drain oil fitting and install the oil drain plug from parts bag directly into the engine oil pan.

8. If clearance is greater than 13 mm (1/2 in.):

d e

a

b

f

a - Bilge drain plug b - Tether c - Quick oil drain hose plug a. b. c.

Page 42 / 98

c

7771

d - Flange e - Toward interior of boat f - Clip

Push end of oil drain hose out of boat hull through flange.

Pull oil drain hose out until it is 304 cm (12 in.) from the flange.

Move alignment clip on the oil drain hose and squeeze to position it on the hose just inside of the boat hull against the flange.

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

d.

Connect bilge drain plug to oil drain hose plug using clip.

b

a

c d

7618

a - Oil drain hose b - Alignment clip

c - Clip d - Bilge drain plug

e.

Push oil drain hose through flange into boat hull. f.

Install bilge drain plug in hull.

9. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the rear engine mounting bolts.

Tube Ref No.

Description Special Lubricant 101

34

Where Used

Part No.

Rear engine mounting bolts

92-802865Q02

10. Install both rear engine mounting bolts and hardware and torque. Do not relieve hoist tension.

c c e d e g

a

a

f

b 7961

b

f

a - Rear engine mount b - Inner transom plate mount c - Bolt d - Washer

7772

e - Spacer f - Fiber washer g - Stainless steel washer (optional spacer kit)

Description

Nm

Rear engine mounting bolts

47

lb. in.

lb. ft.

35

11. Loosen both adjusting nuts on front engine mounts to allow for adjustment during alignment.

12. Attach the front mounts to the stringers.

13. Remove the engine hoist.

90-899883178 NOVEMBER 2007

Page 43 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Exhaust System Hose Connections

NOTICE Hot spots in exhaust hoses can damage hoses and cause leaks. Ensure that discharge water from the exhaust elbow flows without restriction through all hoses and fittings.

Exhaust hoses must be properly installed on exhaust elbow outlets. Discharge water from the exhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots that could burn through the hose.

7629

7628

Correct

Incorrect

a c d e

b 9290

Exhaust connection a - Maximum misalignment +/‑ 5 degrees b - Exhaust outlet centerline (14 degrees vs. crankshaft centerline) c - Exhaust hose centerline

d - Angle vs. horizontal e - Horizontal (level surface)

IMPORTANT: Exhaust hoses/tubes should be secured at each connection with at least 2 hose clamps.

All exhaust connections, including those at the exhaust elbow, should be secured with 2 hose clamps. ABYC standards also specify the use of stainless steel clamps with a minimum 13 mm (1/2 in.) band width. Do not use spring tension clamps.

Page 44 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

1. Torque all exhaust hose or exhaust tube clamps.

a 7631

a - Hose clamps Description

Nm

lb‑in.

lb‑ft

Hose clamps

3

26

–

Engine Alignment Sterndrive Models 1. If applicable, open perforated area in bell housing dust cover.

a

8378

a - Dust cover

NOTICE Improper use of the alignment tool may result in personal injury or damage to the gimbal bearing or engine coupler. Do not operate the engine with the alignment tool installed. Do not attempt to force the alignment tool, raise or lower the engine with the tool inserted in the gimbal bearing or engine coupler, or raise the engine mount bracket above the top of the engine mount stud.

IMPORTANT: Alignment tools from other manufacturers may cause improper alignment and damage to the gimbal bearing or engine coupler. Use only the Quicksilver Alignment Tool.

2. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines.

Alignment Tool Assembly

91‑805475A 1

3. If the alignmet tool does not fit, remove it and carefully raise or lower the front end of the engine as necessary.

4. If applicable, attach the engine hoist to the engine aligment hook to raise or lower the front end of engine.

90-899883178 NOVEMBER 2007

Page 45 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTE: Models not equipped with engine alingment hooks; require adjusting the front engine mounts equally to raise and lower the front end of the engine.

5. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines.

NOTE: It may be necessary to hit the Alignment Tool with a synthane hammer to set the gimbal bearing to the coupler.

6. If necessary, firmly strike the sides of the Alignment Tool at 90 degree increments to help align the gimbal bearing.

d a

b

c

a

7784

e a - Alignment Tool b - Gimbal bearing c - Engine coupler

d - Hammer e - 90 degree increments

7. Repeat step 4. until the Alignment Tool installs easily (SLIDES FREELY WITH MINIMAL EFFORT) all the way into and out of engine coupler splines. Do not check by turning the alignment tool.

IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.

This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer (structure) to obtain the 6 mm (1/4 in.) dimension.

IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required to align engine.

8. Adjust front engine mounts until they rest on boat stringers.

9. Relieve hoist tension entirely and fasten both front mounts to boat stringer using 9 mm (3/8 in.) lag bolts.

Page 46 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

10. Recheck alignment with Alignment Tool. Tool must enter coupling splines freely. If not, readjust front mounts.

b a

8503

a - Alignment Tool (use only recommended Alignment Tool)

b - End to be inserted through gimbal housing assembly

11. When alignment is correct, tighten locknut securely. Recheck alignment.

12. Bend tab down on adjusting nut.

a b

c

d

8504

a - Nut and lockwasher b - Adjustment nut

c - Direction (counterclockwise) to raise front of engine d - Tab washer

13. Remove Alignment Tool. If not installing drive, fold bell housing dust cover flap back into place and tape shut for boat shipment. Dust cover flap will have to be removed before operating engine.

14. Remove the engine alignment hook from the engine.

Electrical Connections IMPORTANT: Refer to the following precautions when working on or around the electrical harness, or when adding other electrical accessories, to avoid damage to the electrical system.

• Do not tap accessories into the engine harness.

• Do not puncture wires for testing (probing).

• Do not reverse the battery leads.

• Do not splice wires into the harness.

• Do not attempt diagnostics without the proper, approved service tools.

90-899883178 NOVEMBER 2007

Page 47 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

IMPORTANT: When routing all wire harnesses and hoses, ensure that they are routed and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts.

Tube Ref No. 25

Description Liquid Neoprene

Where Used

Part No.

All electrical connections

92- 25711 3

Boat Harness and Instrumentation Connections We recommend the use of Quicksilver Instrumentation and Wiring Harnesses. On dual station applications, oil pressure and water temperature senders (on engine) must be changed. See Section 7-Boat Harness and Installation Connections.

The four basic gauges that must be used with the engine are: • Tachometer • Oil pressure • Water temperature • Voltmeter IMPORTANT: Maximum accessory load on the engine harness is 15 amps. If additional accessory load is needed, an accessory kit is available.

1. If an extension harness is required, connect the boat harness to the extension harness and connect the extension harness to the engine harness. Ensure that the harness does not rub or get pinched.

2. Fasten harnesses to boat at least every 46 cm (18 in.) using appropriate fasteners.

a

23135

Typical a - Engine harness plug 3. Connect 14‑pin harness to engine. Turn locking ring until firm snap is felt.

2

1

23136

Page 48 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine rpm, coolant temperature, water pressure, battery voltage, fuel consumption, and engine operating hours. The Smartcraft instrument package will also aid in engine diagnostics.

The SmartCraft instrument package will display critical engine alarm data and potential problems.

Refer to the Mercury SmartCraft Operator's Supplement (90‑10229023) for the warning functions monitored and basic operation of the SmartCraft Instrument package. Refer to the instructions included with the instruments for installation instructions.

Audio Warning System Connections ! WARNING Installing non‑potted electrical components in explosive environments can result in serious injury or death from fire or explosion. Install all non‑potted electrical components such as warning alarms away from environments where fuel or fuel vapor is present such as engine or fuel tank compartments.

1. Select a location for audio warning alarm that meets all of the following: • Alarm can be easily heard, yet is out of sight • Alarm can be easily accessed for installation and maintenance • Alarm will remain dry • Alarm is within length limits of the 46 cm (18 in.) purple alarm wire that connects to the "I" terminal or 12 volt source on switched side of ignition switch.

NOTE: The terminal to which wire is attached must have no voltage when ignition switch is in the OFF position.

2. Place alarm in desired location and secure to wire bundle with tie strap provided.

3. Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge or ignition switch. Tighten connection securely.

4. Connect TAN/BLUE wire from alarm to TAN/ BLUE wire from instrument harness.

5. Place the small (transparent) decals on the bottom of the water temperature and the oil pressure gauges.

6. Place the large decal on the instrument panel or other appropriate location easily viewed by the operator.

ALARM INDICATES LOW OIL OR OVERHEATING

a APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION:

b AUDIO WARNING HORN WILL SOUND WHEN: 1. ENGINE OIL PRESSURE IS TOO LOW 2. ENGINE TEMP. IS TOO HIGH, OR 3. DRIVE OIL LEVEL IS TOO LOW TO TEST AUDIO WARNING HORN: TURN KEY TO "ON" POSITION (ENGINE OFF)

7799

a - Small decal (transparent)

90-899883178 NOVEMBER 2007

b - Larger decal

Page 49 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7. Test audio warning system during Predelivery Preparation section.

MerCathode Connections The MerCathode controller assembly is located on the engine.

The engine harness supports the MerCathode system. The engine harness has a MerCathode connector which connects to a MerCathode connector on the transom harness.

1. Connect the battery wire the battery positive (+) terminal.

2. Spray the battery terminals with a battery connection sealant to help retard corrosion.

IMPORTANT: Opposite end of RED/PURPLE wire must be connected directly to battery positive (+) terminal. Do not connect it to a switched positive (+) circuit. MerCathode system must function continuously for proper corrosion protection.

a b f

d e

c 25180

a - MerCathode controller b - RED/PURPLE wire ‑ to positive (+) battery terminal c - Electrode on transom assembly

d - Ground wire (in the engine harness, no hookup needed) e - Connector on the transom harness f - Engine harness to the MerCathode controller

Power Trim Electrical Connection ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes.

(See ABYC for additional information) ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also specified.

MerCruiser has developed three methods to facilitate compliance with ABYC recommendations.

These come in the form of one standard production and two accessory kits.

• Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery.

• Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: a.

The red current conductor (for the trim pump) must be connected to the switched side of the battery switch and either:

Page 50 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

• •

Accessory Part Numbers

provided with circuit protection within 7 inches of the power source or Provided with circuit protection within 40 inches of the point of connection with the power source and sheathed the entire length of wire from the point of connection to the source and the circuit protection device. This will require the use of an Accessory cable kit.

Part Number

Description

Color

Length

Type

8M2000587

Cable Assembly – Trim Pump

Red

72 inches

Fused

8M2000588

Cable Assembly – Trim Pump

Red

40 inches

Sheathed

Power Trim Pump Connections 1. Connect power trim pump BLACK (–) battery cable to negative (–) battery terminal and pump's RED (+) battery cable to positive (+) battery terminal or to the switched side of the battery switch.

a

b 6842

a - Positive battery lead

b - Negative battery lead

Battery Cables Connection IMPORTANT: Engine electrical system is negative (‑) ground.

1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal.

2. Connect engine negative (–) battery cable (usually BLACK) to negative (–) battery terminal.

3. Tighten connections securely with a wrench.

4. Spray battery terminals with a battery connection sealant to help retard corrosion.

Fluid Connections Gear Lube Monitor Connection IMPORTANT: Route hoses to determine the minimum length of hose needed and trim off the excess to avoid low spots in the system. Avoid kinks and route in a straight path to avoid low spots (traps) in the system.

1. Locate the gear lube monitor quick connect at the rear of the engine.

2. Locate the gear lube monitor quick connect at transom.

IMPORTANT: Hose must not come in contact with steering system components, engine coupler, U‑joint shaft, or drive shaft.

90-899883178 NOVEMBER 2007

Page 51 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

3. Fasten the quick connect.

b

c

a

7800

a - Gear lube monitor hose assembly from transom b - Gear lube monitor hose assembly from gear lube monitor

c - Quick connect fitting

Power‑Assisted Steering Hoses IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks.

1. Disconnect the quick connect fittings on the power‑assisted steering hoses.

2. Connect the power‑assisted steering hoses to the control valve. Ensure that the quick connects snap into place.

3. Route hoses as appropriate to avoid contact with the steering system components.

4. Use extra hose clips to secure hose to transom.

a

a a a b

b 16225

a - Hydraulic lines

b - Power‑assisted steering control valve

NOTE: Steering Fluid can be added at this time if desired.

Page 52 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Alpha Seawater Inlet Hose Connection 1. 1. Connect water inlet hose to water inlet fitting on transom.

c

b

a

7802

a - Water inlet tube b - Hose clamp

c - Seawater inlet hose

2. Secure with hose clamp.

Seawater Inlet Fitting Connection IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly.

NOTE: The retainer clip must be in the closed position prior to installation.

1. Install the seawater inlet hose assembly to the water inlet fitting. a.

Position the retainer clip in the closed position.

c

a b

8512

Seawater inlet hose assembly a - Retainer clip closed c - Hose decal b - Quick connect fitting b.

Position the seawater inlet hose assembly with the center of the retainer clip and the hose decal toward the engine.

IMPORTANT: Tabs and slots are sized to only mate at the correct orientation. Mate the small tab with the small slot.

90-899883178 NOVEMBER 2007

Page 53 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

c.

SECTION - 6

Align the slots of the quick connect fitting to the tabs of the water inlet fitting.

g h

a

b

e

c

f

d 8513

a - Quick connect fitting b - Small slot c - Large slot d - Seawater inlet fitting

e - Small tab f - Large tab g - Center of retainer clip (toward engine) h - Centerline of water inlet fitting (toward engine)

d.

Ensure that the center line of the water inlet fitting and the center of the retainer clip are positioned toward the engine.

2. Push the seawater inlet hose assembly onto the water inlet fitting until connected.

NOTE: The retainer clip snaps into place and resumes the closed position when properly connected.

c

a

b 8514

Shown with engine removed for visual clarity a - Centerline of water inlet fitting c - Hose decal b - Retainer clip in closed position IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly.

3. Perform a pull test on the water hose quick connection.

Page 54 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

a.

Pull on the seawater inlet hose near the connection point with an approximate force of 111 N (25 lbf). If the seawater inlet hose does not become separated from the seawater inlet fitting when force is applied, the seawater inlet hose is connected and sealed properly.

a

c b 8515

Shown with engine removed for visual clarity a - Seawater inlet hose c - Seawater inlet fitting b - Quick connect fitting b.

If the seawater inlet hose does become separated from the seawater inlet fitting, reinstall as specified. c.

When all steps have been completed, check for any leaks at this connection.

4. Connect the seawater inlet hose to the engine seawater pump.

NOTE: The seawater inlet hose connects to the engine and the transom.

e

b e a

c

d 8516

Seawater inlet hose assembly a - Seawater inlet hose d - Seawater inlet fitting b - To engine e - Hose clamps c - Quick connect fitting 5. Models Using The Seawater Extension Hose Assembly:

NOTE: The seawater inlet hose connects to the engine and the transom, the seawater extension hose assembly connects to the transom and the seawater inlet hose.

90-899883178 NOVEMBER 2007

Page 55 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

a.

SECTION - 6

When connecting the seawater extension hose assembly to the seawater inlet hose assembly, position the center of the retainer clip away from the engine.

d

b

e a

c

8517

Shown with engine removed for visual clarity a - Retainer clip position (away from d - Quick connect fitting (to seawater inlet engine) fitting) b - Seawater extension hose e - Seawater inlet fitting (to transom) c - Seawater inlet hose (to engine seawater pump) IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly. b.

Perform a pull test and ensure that the requirements for checking the integrity of the connection are met.

NOTE: The seawater extension hose assembly connects to the transom and the seawater inlet hose.

g g

g

e

g

f

d b

c

a a - Seawater inlet hose b - Quick connect fitting to extension hose c - Quick connect male fitting d - Extension hose

8518

e - Quick connect fitting to seawater inlet fitting f - Seawater inlet fitting g - Hose clamp

Coolant Recovery System NOTE: This section applies to Closed Cooled models only.

1. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: • Within limits of clear plastic tubing.

• Level with or above the heat exchanger fill neck.

Page 56 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

• Accessible for observing coolant level and filling.

2. Mount coolant recovery bottle and mounting bracket in desired location using two 19 mm (3/4 in.) long screws and flat washers.

3. Route plastic tubing to recovery bottle. Ensure that tubing is positioned away from any moving parts. Cut plastic tubing as required and connect to bottom connection on recovery bottle and secure with tubing clamp provided.

IMPORTANT: Seal the plastic tubing connections completely to ensure the coolant recovery system operates properly.

4. Fasten plastic tubing to boat, as necessary, with 2 hose clips and13 mm (1/2 in.) long screws (provided).

b

b a

c d 7804

a - Recovery bottle and mounting bracket b - Screws and flat washers

c - Plastic tubing d - Tubing clamp

5. Connect plastic tubing to bayonet fitting on heat exchanger. Secure with tubing clamp provided.

NOTE: Use side cutter pliers or similar to compress ring type clamps. Use standard pliers to install spring‑tension type.

Alpha Shift Cable Installation Alpha Sterndrive Shift Cable Installation IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control.

• If shift cable end guide moves in direction "A" when control lever is placed in FORWARD, remote control is set up for RIGHT‑HAND (RH) propeller rotation.

• If shift cable end guide moves in direction "B" when control lever is placed in FORWARD, remote control is set up for LEFT‑HAND (LH) propeller rotation.

A B

6614

Arrow indicates direction of motion IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.

90-899883178 NOVEMBER 2007

Page 57 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

SHIFT CABLE TRAVEL We recommend the use of a Quicksilver remote control and cable. Refer to Mercury Precision Parts Accessories Guide for selection. However, if a control other than Quicksilver is to be used, control must provide specified shift cable travel (at the shift plate end).

Description

Specification

Shift cable travel1

73 mm (2‑7/8 in.)‑80 mm (3‑1/8 in.)2

1 At the shift plate end 2 With a 6.8‑9 kg (15‑20 lb) load applied to the cable end guide

NOTE: On engines with Alpha drives, the measurement indicated above can be taken by installing the remote control shift cable and using the shift assist assembly (provided) to place the proper load on the shift cable.

1. Place a mark on the tube against the edge of the cable end guide.

d e

a c

b

7809

a a - Shift assist assembly b - Remote control shift cable ‑ in FORWARD gear position c - Edge of cable end guide

d - Remote control shift cable ‑ in REVERSE gear position e - Measurement taken from mark to edge of cable end guide

SEPARATE SHIFT AND THROTTLE CONTROLS IMPORTANT: If boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS, the shift assist assembly that is shipped with the engine should not be used. The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly.

Page 58 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

The Spacer Kit (23‑11284A1) will have to be ordered to connect remote control shift cable when shift assist assembly is not used.

c b a d

a - Clevis pin b - Washer

7810

c - Spacer d - Cotter pin

NOTE: Do not discard shift assist assembly until after it is used below.

IMPORTANT: Shift cable must be connected at the remote control for the appropriate rotation (LH or RH) drive unit, as explained following: RIGHT‑HAND ROTATION ‑ Control cable will have to be installed in remote control so that cable end will move in direction "A" when shift handle is placed in the FORWARD position.

LEFT‑HAND ROTATION ‑ Control cable will have to be installed in remote control so that cable end will move in direction "B" when shift handle is placed in the FORWARD position.

A B

6614

INSTALLATION 1. Remove shift assist assembly.

90-899883178 NOVEMBER 2007

Page 59 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Remove shift cable attaching hardware.

a

b 7812

a - Shift assist

b - Shift plate

3. Install intermediate cable.

7813

4. Secure the brass barrel retainer with the cotter pin.

5. Secure the cable end guide with washers (one on each end of the end guide) and cotter pin.

6. Locate center of remote control and control cable play (backlash).

IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making the following adjustment. a. a. Shift remote control to NEUTRAL. b.

Push in on control cable end with enough pressure to remove play and mark position "a" on tube. c.

Pull out on control cable end with enough pressure to remove play and mark position "b" on tube.

Page 60 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

d.

Measure distance between marks "a" and "b" and mark position "c" half‑way between marks "a" and "b."

c

a

b

7815

7. Temporarily install control cable end guide into shift lever and insert anchor pin.

8. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of control cable end guide.

9. Place remote control and and sterndrive unit in FORWARD gear.

10. Install the remote control shift cable.

11. Place remote control handle in NEUTRAL. 12. Install the shift assist assembly. Ensure that it fits over the clevis pin and barrel stud with no resistance.

13. Install the fastening hardware. If shift assist assembly attaching points will not align, verify controller is in NEUTRAL. Remove the shift cable and reposition the adjustment barrel as required to allow the shift assembly to be installed with no effort.

d

c

a

e b With shift assist assembly a - Remote control shift cable b - Shift assist assembly c - Clevis pin (and cotter pin not shown)

90-899883178 NOVEMBER 2007

7818

d - Large ID washer e - Small ID washer and cotter pin

Page 61 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

d a

f

e

g

c i h b

7841

Without shift assist assembly a - Remote control shift cable f - Washer b - Clevis pin g - Spacer c - Cotter pin (existing) (not shown) h - Washer (existing) d - Spring (existing) (not shown) i - Cotter pin (existing) e - Washer (existing)

Bravo Shift Cable Installation and Adjustment Bravo Models Shift Cable Installation NOTE: Bravo Models Only: Using shift cable adjustment tool (91‑12427), shift cables can be adjusted with or without the sterndrive installed, using the following procedure.

Shift Cable Adjustment Tool

91‑12427

IMPORTANT: Sterndrive propeller rotation is determined by the shift cable installation in the remote control.

• Bravo One/Two ‑ If shift cable end guide moves in direction A when control lever is placed in FORWARD, remote control is set up for RIGHT‑HAND (RH) propeller rotation.

• Bravo One/Two ‑ If shift cable end guide moves in direction B when control lever is placed in FORWARD, remote control is set up for LEFT‑HAND (LH) propeller rotation.

A B

21620

Arrow indicates direction of motion

Page 62 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

•

Bravo Three ‑ Front propeller on sterndrive is always LH Rotation and rear propeller is always RH Rotation. Shift cable end guide must move in direction A, when control lever is placed in FORWARD gear position.

A 21621

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.

Bravo Models Shift Cable Adjustment 1. Remove the adjustment tool.

a

21611

a - Adjustment tool 2. Loosen the adjustable stud and move it to dimension, as shown. Retighten stud.

a

b 21612

a - Adjustable stud

b - 76 mm (3 in.) (center of pivot bolt to center of stud)

3. Install sterndrive shift cable.

4. Install cotter pin.

90-899883178 NOVEMBER 2007

Page 63 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

5. Insert cotter pin from top and spread ends fully.

b

a

c

21616

a - Sterndrive shift cable b - Long cotter pin

c - Short cotter pin

6. Place adjustment tool over sterndrive shift cable, as shown. Hold tool in place using a piece of tape over the barrel retainer.

a

b

21615

a - Adjustment tool

b - Sterndrive shift cable

7. Locate center of remote control and control cable play (backlash).

IMPORTANT: Keep center mark "C" aligned with control cable end guide edge when making the following adjustment. a.

Shift remote control to NEUTRAL. b.

Push in on control cable end with enough pressure to remove play and mark position "a" on tube. c. d.

Pull out on control cable end with enough pressure to remove play and mark position "b" on tube.

Measure distance between marks "a" and "b" and mark position "c" half‑way between marks "a" and "b."

c

b

Page 64 / 98

a

7815

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

8. Temporarily install control cable end guide into shift lever and insert anchor pin.

9. Adjust control cable barrel so that hole in barrel centers with vertical center line of stud. Ensure that backlash center mark is aligned with edge of control cable end guide.

10. Remove control cable end guide from shift lever by removing clevis pin.

c

a

d

c

b

d

e

21613

a - Control cable end guide b - Clevis pin c - Backlash center

d - Control cable barrel e - Stud, washer and cotter pin

11. Install the control cable.

12. Install the washer and cotter pin to secure the barrel.

13. Install the clevis pin.

14. Install the cotter pin into the clevis pin from the top and spread the ends.

15. Remove the adjustment tool.

16. Shift remote control lever into FORWARD position. Place end of adjustment tool in barrel retainer. If slot does not fit over stud, loosen shift lever stud and slide stud up or down until slot in tool fits over stud. When adjustment is correct, retighten stud.

17. Lift the adjustment tool so that the slot is above the stud.

18. Shift the remote control into REVERSE and repeat the adjustment process.

b

21614

a

a - RH rotation Bravo One, Two, Three FORWARD, LH rotation Bravo One and Two REVERSE slot

b - LH rotation Bravo One and Two FORWARD, RH rotation Bravo One, Two and Three REVERSE slot

19. Remove adjustment tool.

20. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180 degrees.

21. Lubricate shift cable pivot points.

Tube Ref No. 80

90-899883178 NOVEMBER 2007

Description SAE Engine Oil 30W

Where Used

Part No.

Shift cable pivot points

Obtain Locally

Page 65 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

DTS System Installation Refer to DTS System Installation section 7 - Electrical System

Shift Cable Installation For DTS System IMPORTANT: Do not move the shift cable stud on the shift arm.

IMPORTANT: The shift cable barrel is preset and CANNOT be adjusted.

1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows: a.

b. c.

The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing.

The cable should then be routed under the starboard rear engine mount and turn toward the transom.

The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine.

NOTE: Following this routing will prevent the engine coupler from damaging the cable.

8995

NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the pre‑delivery inspection.

2. Apply lubricant to the threads of the shift cable stud.

Tube Ref No. 34

Description

Where Used

Part No.

Special Lubricant 101

Shift cable stud

92-802865Q02

3. Install the intermediate shift cable to the shift actuator on the engine.

Page 66 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Tighten locknut until it contacts and then loosen 1/2 turn.

b c

e a

f d

8996

a - Shift actuator b - Shift cable c - Locknut

d - Shift cable stud e - Shift cable barrel f - Washers

5. Insert cotter pin from top and spread ends.

a

8997

a - Cotter pin

Throttle Cable Installation Throttle Cable Installation And Adjustment IMPORTANT: When installing throttle cables, ensure that cables are routed to avoid sharp bends and / or avoid contact with moving parts. Do not fasten any items to throttle cables.

1. Place remote throttle lever in idle position and attach cable to throttle body, following cable manufacturer’s instructions.

90-899883178 NOVEMBER 2007

Page 67 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever.) Adjust barrel on throttle cable to align with hole in anchor plate. Ensure hole in barrel positions cable as shown. Tighten locknut until it contacts washer, and then loosen 1/2 turn.

b

a

c 8217

a - Locknut and flatwasher b - Cable barrel

c - Cable end

Alpha Sterndrive Installation 1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)

a

b

7713

Typical a - Dust cover

Page 68 / 98

b - Trim cylinder support

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Remove gear lube monitor cap. Fill with lubricant.

b

a

5497

a - ‑ Gear lube monitor cap Tube Ref No.

b - "OPERATING RANGE" line

Description High Performance Gear Lubricant

87

Where Used

Part No.

Gear lube monitor

92-858064K01

3. Push dribble valve stem in until gear lube appears.

a

7851

a - Dribble valve stem 4. Once gear lube appears, release dribble valve stem.

5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING RANGE" (full) line with specified fluid. Do not overfill.

Tube Ref No. 87

Description High Performance Gear Lubricant

Where Used

Part No.

Gear lube monitor

92-858064K01

6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap.

IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing drive unit or water may leak into boat.

7. Ensure that rubber gasket and water passage O‑ring are properly positioned in bell housing.

90-899883178 NOVEMBER 2007

Page 69 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

8. Coat bell housing studs with lubricant.

a

c

c b

7852

a - Rubber gasket b - Water passage O‑ring Tube Ref No. 95

c - Studs (6)

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Bell housing studs

92-802859A1

9. Grease sterndrive U‑joint O‑rings, and drive shaft splines. A grease packet for this procedure is provided with the sterndrive packaging.

a a b 7853

a - U‑joint O‑rings

Page 70 / 98

b - Drive shaft splines

Tube Ref No.

Description

Where Used

Part No.

91

Engine Coupler Spline Grease

Ujoint O-rings

92-802869A1

Tube Ref No.

Description

Where Used

Part No.

91

Engine Coupler Spline Grease

Drive shaft splines

92-802869A1

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

10. Ensure U‑joint bellows are clean and free of debris.

a

7854

a - U‑joint bellows 11. Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft. Do this by placing remote control shift lever in: FORWARD gear position for RH drive or REVERSE gear position for LH drive unit.

c a

d b 7855

a - Shift shaft b - Shift shaft coupler

c - Shift slide d - Slot

IMPORTANT: Shift slide assembly is free to rotate on core wire. Ensure that shift slide remains in upright position and is properly engaged with shift shaft lever roller while installing drive unit.

12. Engage shift shaft roller into shift shaft lever.

13. Place gasket on bell housing.

90-899883178 NOVEMBER 2007

Page 71 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

14. Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide.

d

a

b c c a - Shift shaft lever b - Roller

7859

c - Shift Shaft Slide Stabilizer Tool d - Gasket

Shift Slide Stabilizer

91‑865232

15. Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE while simultaneously turning propeller shaft COUNTERCLOCKWISE.

a

7856

a - Drive unit shift shaft IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dual engine installations. The LH rotation drive unit can be identified by the decal on the back side of the upper drive shaft housing, which states: "Alpha One ‑ Counter Rotation" 16. Install sterndrive unit as follows: a.

Position trim cylinder straight back (over top of acceleration plate). Be careful not to scratch acceleration plate or trim cylinders. b.

Guide U‑joint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into drive shaft housing. Ensure that shift slide remains upright and engaged with bell housing shift shaft lever. c.

If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align U‑joint shaft splines with engine coupler splines while sliding sterndrive into bell housing.

Page 72 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

IMPORTANT: If drive unit will not slide into bell housing, ensure that the shift shaft and couplers are positioned properly. Do not force drive unit into position.

a

b 7857

a - Gasket d. e. f.

b - Shift slide

Remove Shift Slide Stabilizer Tool and discard.

Slide sterndrive all the way into bell housing.

Secure sterndrive to bell housings using fasteners as shown. Torque the fasteners.

a b

7858

a - Locknut and flat washers

b - Locknut and continuity circuit washer (no flat washer at this location)

Description

Nm

Sterndrive unit fasteners

68

lb. in.

lb. ft.

50

17. Return remote control shift lever to the NEUTRAL position.

TRIM CYLINDER INSTALLATION 1. Install trim cylinders on aft end of sterndrive unit with hardware as shown.

90-899883178 NOVEMBER 2007

Page 73 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Install the plastic caps by snapping in place.NOTE: Upon installation of hardware apply lubricant to all components except plastic caps.

a b

a

b a - Aft anchor pin b - Bushings c - Flat washers Tube Ref No. 95

c d

e

7849

d - E‑ring clips e - Plastic caps

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Trim cylinder hardware

92-802859A1

3. Position the sterndrive unit serial number decal.

Speedometer Connection ‑ Alpha Models 1. Raise drive to gain access to area between gimbal housing and sterndrive, immediately above the transom end of the anti‑ventilation plate.

2. Align plastic slots on male and female portions and insert.

3. Push down to secure.

b

a

4803

a - Male end of speedometer tube fitting

Page 74 / 98

b - Female end of speedometer tube fitting

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Ensure that the speedometer tube is secured and out of the way of moving parts.

b a

8029

a - Male end of speedometer tube fitting

b - Female end of speedometer tube fitting

Alpha Notice: Increased Trim‑in Range Capability The Alpha trim cylinders provide the capability for an increased trim‑in range. A spacer can be removed from the trim cylinders to increase the trim‑in range by approximately 1‑1/2 degrees. This will improve the acceleration on some boats by forcing the bow down more quickly. If the spacers are to be removed, the boat must be water tested to ensure that the increased trim‑in range does not cause any undesired boat handling characteristics (bow‑steer, chine‑walk, etc.) if the sterndrive is trimmed in while the boat is operated at higher speeds. The boat should be tested under all conceivable load conditions and maneuvers to ensure that the additional trim‑in does not pose a problem. The final decision and responsibility for use of the additional trim‑in range is left up to the boat manufacturer.

! WARNING On some boats, increased trim‑in range can cause handling problems at high speeds, resulting in personal injury or death. We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for handling problems.

Alpha Trim Cylinder Spacer Removal 1. Disconnect "UP" trim hose from "UP" port on trim cylinder.

2. Disconnect "DOWN" trim hose from hydraulic connector on gimbal housing. Plug holes with 22‑38609 plug.

c

d b a a - "UP" hose b - "UP" port on trim cylinder

90-899883178 NOVEMBER 2007

7843

c - "DOWN" hose d - Hydraulic connector

Page 75 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

3. Remove front power trim cylinder mounting hardware.

a

c

e

b d a - Front anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)

4827

d - E‑ring (port and starboard) (2) e - Plastic caps (port and starboard) (2)

4. Remove rear power trim cylinder mounting hardware.

b

a

c

d

a

e b

a - Rear anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)

7844

d - E‑ring (port and starboard) (2) e - Plastic caps (port and starboard) (2)

Alpha Trim Cylinder Disassembly ! WARNING On some boats, increased trim‑in range can cause handling problems at high speeds, resulting in personal injury or death. We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for handling problems.

! CAUTION Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and lint free during reassembly.

IMPORTANT: During service procedures, clamp the trim cylinder on the front mounting flange.

Clamping the center section of the trim cylinder can cause damage.

1. Remove plug previously installed, if applicable.

Page 76 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Remove end cap with spanner wrench and remove piston rod assembly from cylinder.

a

b

7845

a - Piston rod assembly

b - Cylinder

Trim Cylinder End Cap Tool

91‑821709T

3. Remove bolt, washer, and spacer. Be careful not to lose check balls. Discard spacer.

h d

e

f g

a

b

c 7846

a - Trim cylinder shock piston bolt b - Spacer c - Washer d - Springs (3)

e - Spring pins (3) f - Check balls (3) g - Shock piston assembly h - O‑ring

Alpha Trim Cylinder Reassembly ! CAUTION Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and lint free during reassembly.

1. Apply sealant to threads of shock piston bolt.

Tube Ref No. 7

Description Loctite 271 Threadlocker

Where Used

Part No.

Trim cylinder bolt threads

92-809819

2. Install washer and bolt and torque.

Description

Nm

Trim cylinder shock piston bolt

23

90-899883178 NOVEMBER 2007

lb. in.

lb. ft.

17

Page 77 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

IMPORTANT: During service procedures, clamp the trim cylinder on the front mounting flange.

Clamping the center section of the trim cylinder can cause damage.

IMPORTANT: Use only 2‑4‑C with Teflon on the end cap threads. Other substances may act as an insulator and cause poor electrical continuity between the cap and cylinder, which could promote corrosion.

3. Apply lubricant to end cap threads and install piston rod assembly into cylinder.

4. Torque end cap using the spanner wrench.

a b

c

7847

a - End cap b - Piston rod assembly Tube Ref No.

c - Cylinder

Description Special Lubricant 101

34

Where Used

Part No.

Trim cylinder end cap

92-802865Q02

Description

Nm

Trim cylinder end cap

61

lb. in.

lb. ft.

45

5. Position trim cylinder rear connecting ends.

b

a

c

7848

a - Port trim cylinder b - Starboard trim cylinder

c - Connecting ends (offset as shown)

Alpha Trim Cylinder Installation 1. Install trim cylinders forward mounting hardware.

2. Coat area in trim cylinder between bushings with lubricant.

3. Replace anchor pin and install bushings and washers.

Page 78 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Attach E‑rings and plastic caps to end of anchor pin.

a

c

e

b d a - Front anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2) Tube Ref No. 95

5.

6.

7.

8.

4827

d - E‑ring (port and starboard) (2) e - Plastic caps (port and starboard) (2)

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Trim cylinder hardware

92-802859A1

Install trim cylinders rear mounting hardware.

Coat area in trim cylinder between bushings with lubricant.

Replace anchor pin and install bushings and washers.

Attach E‑rings and plastic caps to end of anchor pin.

b

a

c

d

a

e b

a - Rear anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2) Tube Ref No. 95

7844

d - E‑ring (port and starboard) (2) e - Plastic caps (port and starboard) (2)

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Trim cylinder

92-802859A1

9. Reconnect trim hoses after air bleeding power trim cylinders and hoses following procedures outlined in Mercury MerCruiser Service Manual 14.

90-899883178 NOVEMBER 2007

Page 79 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Bravo Sterndrive Installation 1. If applicable, remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)

a

b 8993

Typical a - Dust cover

b - Trim cylinder support

2. Remove gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE".

a

b

5497

Gear lube monitor a - Gear lube monitor cap Tube Ref No. 87

Page 80 / 98

Description High Performance Gear Lubricant

b - "OPERATING RANGE" line Where Used

Part No.

Gear Lube Monitor

92-858064K01

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

3. To purge air from the system, push in on the dribble valve stem until the new gear lube appears.

a

21440

a - Dribble Valve

4. Release the dribble valve.

5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING RANGE" (full) line with specified fluid. Do not overfill.

c b a

19947

Gear lube monitor a - Gear lube level at the "ADD" mark b - Gear lube level at the "OPERATING RANGE" Tube Ref No.

Description High Performance Gear Lubricant

87

c - Cap

Where Used

Part No.

Gear Lube Monitor

92-858064K01

6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap.

a

19962

a - Gear lube monitor cap

90-899883178 NOVEMBER 2007

Page 81 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7. Coat the O‑rings on the sterndrive U‑joint with lubricant

a

a

21441

a - O‑rings 8. Coat the splines on the sterndrive U‑joint with lubricant.

a

21442

a - Splines Tube Ref No.

Description

Where Used

Part No.

91

Engine Coupler Spline Grease

U-joint O-rings

92-802869A1

91

Engine Coupler Spline Grease

Driveshaft splines

92-802869A1

9. Ensure that the U‑joint bellows are clean and free of debris.

a

b

21456

Bell housing of the transom assembly a - U‑joint bellows edge b - U‑joint bellows

Page 82 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

10. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the bell housing studs.

b

a a

a - Bell housing studs (6) Tube Ref No. 95

21457

b - Tube of lubricant

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Bell housing studs

92-802859A1

11. Lubricate the shift linkage O‑ring.

a 21678

a - Shift linkage O‑ring Tube Ref No.

Description 2-4-C with Teflon

95

Where Used

Part No.

O-ring

92-802859A1

12. Lubricate the water passage seal.

a 21679

a - Water passage seal

90-899883178 NOVEMBER 2007

Page 83 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION Tube Ref No. 95

SECTION - 6 Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Water passage seals

92-802859A1

13. Pull out the shift linkage as far as it moves. The jaws will open.

b a

a

c c 5311

21471

a - Shift linkage assembly b - Jaws open

c - Underside of lower lip

IMPORTANT: As the sterndrive is inserted into the entry of the bell housing, the shift cable must be closely checked to ensure that it enters the jaws of the shift linkage assembly of the sterndrive.

14. Place remote control in NEUTRAL position.

NOTE: As the bell housing shift cable enters the shift linkage assembly, it pushes the assembly back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps "A", "B" and "C."

A

B

C

5312

IMPORTANT: If the bell housing shift cable does not line up to properly enter the jaws of the shift linkage assembly, use your hand to guide the cable into place while installing the sterndrive.

15. Place the driveshaft housing in position on bell housing and install the sterndrive, as follows:

Page 84 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

a.

Remove the nuts from the trim cylinders.

a

c

b

d e 21521

a - Socket b - Wrench c - Anchor pin b.

d - Ground wires e - Trim cylinders

Position the sterndrive so that the universal joint shaft aligns with the bell housing bore.

a

b

c

d

a - Universal joint b - Bell housing c.

21518

c - Shift linkage d - Shift cable

Guide the U‑joint shaft through the bearing in the gimbal housing and into the engine coupler. Ensure that the shift linkage jaws engage the bell housing shift cable assembly.

a

a - Shift cable b - Shift linkage jaws open

90-899883178 NOVEMBER 2007

b

c 21519

c - Shift linkage jaws engage the shift cable

Page 85 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

d.

SECTION - 6

If necessary, rotate the propeller shaft COUNTERCLOCKWISE slightly (using a propeller) to align the U‑joint shaft splines with the splines in the engine coupling, then slide the sterndrive all the way into bell housing.

b a

c

21520

a - Bell housing studs b - Dribble valve

c - Shift cable

16. Secure the sterndrive to the bell housing with 4 flat washers and 6 locknuts. Do not use flat washers on the ground plate.

a

25908

Ground plate with serial number and gear ratio a - Washers not used here

Page 86 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

17. Start from the center and torque the nuts.

a b 25909

a - Locknut (6) flat washers (4)

b - Torque wrench

Description

Nm

Sterndrive fasteners

68

lb. in.

lb. ft.

50

TRIM CYLINDER INSTALLATION 1. Install the mounting hardware of the trim cylinder forward as shown 2. Lubricate the anchor pin threads to prevent the threads from galling.

3. Hand thread the locknuts onto the pin. Do not tighten at this time.

NOTE: Upon installation of hardware apply lubricant to all stainless steel components.

a

b

c

d e

e

f

g

h

14326

Front a - Anchor pin b - Retainer clip groove c - Flat washer (large I.D.) d - Retainer clip Tube Ref No. 95

e - Bushing f - Flat washer (small I.D.) g - Locknut h - Plastic cap

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Trim cylinder hardware

92-802859A1

IMPORTANT: On Bravo One, Two, and Three Models the trim‑in limit insert must be properly positioned before installing the trim cylinder anchor pin in the following steps.

90-899883178 NOVEMBER 2007

Page 87 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTE: Ensure that the trim‑in limit insert is reinstalled in the same position as before removal of the sterndrive. If you are not sure of the original position, contact the boat manufacturer for their recommendation. Refer to Special Information at the front of this section before reinstalling the trim‑in limit insert.

a

b

14571

a - Trim‑in limit insert Bravo One and Two (positioned forward)

b - Trim‑in limit insert Bravo Three (positioned aft)

IMPORTANT: The position of the trim‑in limit insert on the Bravo Three sterndrive should only be changed after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a particular boat application.

4. Install the mounting hardware of the trim cylinder aft as shown.

5. Lubricate the anchor pin threads to prevent the threads from galling.

6. Hand‑thread locknuts onto the anchor pin.

NOTE: Upon installation of hardware apply lubricant to all Stainless steel components.

c

b

c

a

d e

f

c

9295

a - Aft anchor pin b - Larger flat washers (2) c - Bushings (4) Tube Ref No. 95

d - Small ID flat washers (2) e - Locknuts (2) f - Plastic caps (2)

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Trim cylinder hardware

92-802859A1

7. Tighten the locknuts until the washer and locknut contact the shoulder on the anchor pin.

Page 88 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

8. Install plastic caps and tighten hand‑tight only.

a b

b

a c

21677

a - Socket and tool b - Wrench tool

c - Plastic cap (4)

Speedometer Connections ‑ Bravo Models 1. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately atop the transom end of the anti‑ventilation plate.

2. Insert speedometer tube fitting into opening on topside of anti‑ventilation plate, in position shown.

a

b 5319

a - Tube fitting

90-899883178 NOVEMBER 2007

b - Opening

Page 89 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.

a

5320

a - Fitting installed (handle pointing forward)

Trim Limit and Trim Position Settings To adjust the trim limit switch and the trim position sender see Section 9—Predelivery Preparation for the appropriate procedure.

Bravo Sterndrive Shift Check (Engine Running) ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

This test requires sufficient water supply to your engine and sterndrive.

1. Check sterndrive for proper gear shift with boat out of water.

2. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/ IN position. Do not allow the sterndrive skeg to contact the ground.

a b

4805

Typical single handle remote control shown a - Drive trim switch b - Drive trailer button 3. Connect a garden water hose between flushing attachment and water source.

Page 90 / 98

Dual Water Pick‑up Flush Gearcase Seal Kit

91‑881150K 1

Flushing Device

91‑44357Q 2

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION Flushing Kit

91‑849996T 1

4. Partially open water source until water continuously leaks out around the flushing device.

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.

IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.

5. Place remote control handle in NEUTRAL, idle speed position and start engine.

NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of each gear FORWARD, NEUTRAL, and REVERSE, at idle speed position.

NOTE: The operator at the remote control handle should feel a slight detent before and after each gear. FORWARD‑detent‑NEUTRAL‑detent‑REVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment.

6. Move the remote control handle to FORWARD, idle speed position.

7. Check that the sterndrive propeller shaft is turning in the FORWARD direction.

8. Shift the remote control handle to NEUTRAL, idle speed position.

9. Check that the sterndrive propeller shaft is not turning.

10. Shift the remote control handle to REVERSE, idle speed position.

11. Check that the sterndrive propeller shaft is turning in the REVERSE direction.

12. If the sterndrive will not shift: a.

Remove the sterndrive and check for proper shift hook ups. b.

Check that the shift cables are connected IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/ or contact with moving parts. DO NOT fasten any items to shift cables.

Troubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear.

1. When installing the control box in the side panel of the boat, ensure that the cables have enough clearance to operate. This is necessary because the cables move up and down when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, the cables will be interfered with; this will cause very hard shifting.

NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.

7873

Proper cable bend

90-899883178 NOVEMBER 2007

Page 91 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7872

Improper cable bend 2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull, it does not have any extremely sharp bends in it as this will cause stiff shifting.

IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends on too‑short cables result in kinks and too‑long cables require unnecessary bends or loops. Both conditions place extra stress on the cables.

IMPORTANT: Shift cable/throttle cable lubrication points use 2‑4‑C with Teflon.

3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.

b c

a

d a - Remote control end b - Engine end Tube Ref No. 95

7874

c - Adjusting barrel d - Lubricating point

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Shift cable end

92-802859A1

NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GEN II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.) thickness.

Cable radius at any one point must not be less than 305 mm (12 in.).

4000 GEN II Series Panel Mount Remote Control Description

Specification

Mounting surface maximum thickness

25 mm (1 in.)

Minimum cable bend radius at any point

305 mm (12 in.)

4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 cm (3 ft) of the control box.

Page 92 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

5. Ensure that the cable is not permanently kinked.

6. Ensure that there is proper clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE. 7. Ensure that the engine was not set down on the intermediate shift cable during installation, as this will crush the inner cable tubing and cause improper and / or stiff shifting.

8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of the shift plate.

9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1.5 m (5 ft) of the shift plate.

10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud.

NOTE: Lubricate attaching points with engine oil.

Description SAE 30W Engine Oil

Where Used

Part Number

Shift cable pivot points

Obtain Locally

11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows:

NOTE: Cable route is the same for through transom and through prop exhaust. a.

The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. b.

The cable should then be routed under the starboard rear engine mount and turn toward the transom. c.

The cable should then go up behind the power steering valve and loop over to the shift plate on the engine, where it is connected to the anchor points on the shift plate.

Following this routing will prevent the engine coupler from damaging the cable.

8995

Through prop exhaust shown

NOTE: NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the pre‑delivery inspection 12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.

Refer to 90‑865523 Instruction Sheet for more information.

90-899883178 NOVEMBER 2007

Page 93 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Paddle Wheel Speed Sensor Installation (If Equipped) PARTS PROVIDED

e a b

d

i

c i

ABCD

h f

29269

j g

a - Spare pin yoke b - Wire retainer c - Connector d - Bracket e - Paddle wheel

f - Flat washer (2) g - #10 ‑ 19 mm (3/4 in.) screw (4) h - Cable cap i - #6 ‑ 12 mm (1/2 in.) screw (4) j - Clamp (2)

SELECTING LOCATION Single engine installation ‑ Mount paddle wheel on the transom where the propeller blade is rotating downward. Usually the right (starboard) side to minimize cavitation. If feasible, mount at least 50 mm (2 in.) beyond the swing radius of the propeller.

Dual engine installation ‑ Mount the paddle wheel between the engines as close to the center line (keel) of the boat as possible. On slower, heavier displacement boats, however, positioning it farther from the keel is acceptable.

NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes or outlets for live wells or any protrusion that may cause turbulence or cavitation.

TRANSOM ANGLE REQUIREMENTS Standard 13° to 20° transoms ‑ No special adjustment required.

a

b

29272

a - 13° transom angle

b - 20° transom angle

Stepped or undercut transom with 3 angles ‑ A small shim of tapered plastic, metal or wood must be fabricated and installed as shown. Mount the paddle wheel on the step for best performance.

a 29276

a - Shim

Page 94 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

INSTALLING BRACKET 1. Cut out the template. At the location selected, tape the template to the transom. Make sure the black dotted line on the template is aligned with the transom bottom edge, as shown.

NOTE: The mounting template provided is located on the last page of this instruction sheet.

2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on the template.

To prevent drilling too deeply, wrap masking tape around the drill bit 22 mm (7/8 in.) from the point end of drill bit.

NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drilling about 1.5 mm (1/16 in.) deep to prevent surface cracks.

3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to the two #10 screws provided. Using the washer provided, attach and tighten the bracket to the hull making sure the bracket is flush with the underside of the hull.

4. Fill any gap between the housing and the transom with a caulking material, as shown. Using a putty knife, smooth the surface to ensure proper water flow.

e

a b

c a - Template b - 50 mm (2 in.) c - #10 screw

d

29282

d - Flat washer (2) e - Caulking

ROUTING THE CABLE

DRILLING HOLE THROUGH TRANSOM (OPTIONAL) 1. Select a transom location for the hole above the water line that does not interfere with other cables and controls.

2. Drill a 15 mm (5/8 in.) diameter hole.

3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or a comparable marine sealer after the cable has been routed through.

NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. The hole for the second clamp should be positioned halfway between the first clamp and the cap covering the transom hole drilled for the cable.

4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm (1/2 in.) deep.

5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads, install the cable clamps and feed the cable through cable cap.

90-899883178 NOVEMBER 2007

Page 95 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL) Route the cable over the transom or through a drain hole that is above the water line.

a b

c e d 29285

a - Splash well drain hole b - Cable cap c - Cable clamp d - Paddle wheel assembly e - Distance between first cable clamp and top of paddle wheel ‑ 25.4 mm (1.0 in.)

INSTALLING AND REMOVING THE PADDLE WHEEL Installation ‑ Slide the pins into the slots in the bracket and snap the tabs into place.

Removal ‑ squeeze open (unlock) the tabs and pull on the paddle wheel.

a

b a - Tabs

29288

b - Pins

WIRING CONNECTIONS IMPORTANT: Before making wire connections, make sure wires are routed through the transom.

Page 96 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs inside the connector. Have the wiring routed through the transom. Push each wire terminal into its respective location in the connector. Push wire in until they snap into place. Secure wires into connector with the wire retainer.

D C BA

DC BA

WHT YEL BL U BL K

29289

b

b

a a - Connector

b - Wire retainer

TEMPLATE - PADDLE WHEEL SPEED SENSOR

a

b

29291

a - Drill holes here b - Align dotted line with the transom bottom edge and fold under

90-899883178 NOVEMBER 2007

Page 97 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTES:

Page 98 / 98

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

SECTION 7 - ELECTRICAL SYSTEM Table of Contents General Information................................................................................................................................................. 3 Boat Harness and Accessories Information......................................................................................................3 Power Trim Electrical Connection.....................................................................................................................3 Batteries.................................................................................................................................................................. 4 Battery...............................................................................................................................................................4 Battery Cables...................................................................................................................................................4 Multiple MPI Engine Battery Information...........................................................................................................5 Boat Harness and Installation Connections............................................................................................................ 5 Engine Harness and Accessory Power Supply.................................................................................................5 Boat Wiring........................................................................................................................................................5 Single Station ............................................................................................................................................. 6 Dual Station ............................................................................................................................................... 6 Boat Harness Installation Guidelines—MPI Sterndrive.....................................................................................6 Boat Harness Deutsch Connector to Engine ............................................................................................. 6 Key Switch Connector ............................................................................................................................... 7 Trim Switch ................................................................................................................................................ 8 Neutral Switch ............................................................................................................................................ 9 Lanyard Stop Switch .................................................................................................................................. 9 Optional E Stop ........................................................................................................................................ 10 Warning Horn ........................................................................................................................................... 10 Accessory Relay Connection ................................................................................................................... 10 Additional Relay Kit .................................................................................................................................. 10 Gauge Connection ................................................................................................................................... 10 CAN P (CAN 1) Connections ................................................................................................................... 12 CAN V (CAN 3) Connection ..................................................................................................................... 12 General Repower Information .................................................................................................................. 12 Transom Harness—MPI .......................................................................................................................... 13 Transom Harness—DTS ......................................................................................................................... 14 Transom Ground Connection .................................................................................................................. 15 Wiring Diagrams.................................................................................................................................................... 16 Transom Harness—MPI .................................................................................................................................16 Transom Harness—DTS.................................................................................................................................17 Boat Harness...................................................................................................................................................18 Drawing .................................................................................................................................................... 18 Diagram ................................................................................................................................................... 19 Analog Gauge Harness...................................................................................................................................20 Drawing .................................................................................................................................................... 20 Diagram ................................................................................................................................................... 20 Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly).................21 Power Trim System ........................................................................................................................................23 Adaptor Harness for Power Trim Pump—DTS................................................................................................ 24 14‑Pin Engine Harness Connector..................................................................................................................24 DTS Information and Installation........................................................................................................................... 24 Special Tools ‑ DTS Installation......................................................................................................................24 Installation Guidelines for DTS System Components.....................................................................................24 Data Harness ........................................................................................................................................... 25 Connectors .............................................................................................................................................. 25 Weather Caps.................................................................................................................................................25 DTS Battery Specifications.............................................................................................................................. 25 Junction Box (if Equipped)..............................................................................................................................26

90-899883178 NOVEMBER 2007

7

Page 1 / 38

ELECTRICAL SYSTEM

SECTION - 7

Data Harness Installation...................................................................................................................................... 27 Data Harness Pulling Procedure.....................................................................................................................27 Connecting 14 Pin Data Harness ‑ Single Engine........................................................................................... 28 Single Helm ............................................................................................................................................. 28 Dual Helm ................................................................................................................................................ 28 Connecting 14 Pin Data Harness ‑ Dual Engine.............................................................................................29 Single Helm ............................................................................................................................................. 29 Dual Helm ................................................................................................................................................ 29 DTS Command Module and Harness Installation................................................................................................. 30 Installing DTS Command Module and Harness ‑ Single Engine.....................................................................30 Harness Installation ................................................................................................................................. 30 Module Installation ................................................................................................................................... 31 Installing DTS Command Module and Harness ‑ Dual Engine.......................................................................32 Harness Installation ................................................................................................................................. 32 Module Installation ................................................................................................................................... 34 Analog Gauge Interface (AGI)............................................................................................................................... 35 Analog Gauge Interface (AGI) Installation....................................................................................................... 35 Configuring Analog/Digital Tachometer Signal through PCM.........................................................................36 PCM Configuration with CDS .................................................................................................................. 36

Page 2 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Special Tools Data Cable Puller

91‑888462A1

4618

Attaches to end of DTS data harness to aid in pulling harness through boat. Prevents damage to DTS data harness.

General Information • • • •

•

Fuel injected MerCruiser engine models are "SmartCraft" ready and may be rigged using the SmartCraft instrumentation, analog instrumentation, or a combination of both.

The SmartCraft data is carried in the 14 pin system without the use of a special data harness.

Adapters have been made to adapt a 14 pin connector engine to a 10 pin connector boat and from a 14 pin boat to a 10 pin engine.

If an adapter is used the accessory current through the boat harness is limited to 15 amps even if the boat has a 10 pin harness that in the past has been capable of handling larger accessory loads.

SmartCraft data is not supported across the adapters so a separate CAN line will be needed on a boat using SmartCraft instrumentation and an adapter harness.

Boat Harness and Accessories Information Refer to the Mercury Precision Parts and Accessories Guide or the OEM Rigging and Accessories Guide for part number information 1. Ensure that the 14‑pin boat harness is the correct length to properly route from the boat dash to the locking 14‑pin electrical connector on the engine.

2. An analog gauge dash harness or a SmartCraft junction box plugs into the 14‑pin boat harness 3. If SmartCraft instruments and analog instruments are desired on the same boat, an analog gauge interface (AGI) adapter to power the analog gauges.

4. A key switch assembly plugs into the 14‑pin boat harness (both 3‑position and 4‑position available) 5. Select a remote control assembly a.

The remote control must be compatible with MerCruiser applications b.

A remote control can have a lanyard stop switch and will connect directly to the boat harness or a separate stop switch can be installed and connected to the boat harness c.

A power trim switch can be part of the remote control or a separate dash mounted power trim switch can be installed.

6. A separate harness is required to connect the control or dash mounted power trim switch to the power trim pump. (Do not use the connector in the 14‑pin boat harness labeled power trim.

This connection is for outboard only) 7. Up to 15 amps of accessory power can be supplied through the 14‑pin wiring harness. An accessory kit is available to provide accessory power up to 40 amps.

Power Trim Electrical Connection NOTE: ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information) ABYC further recommends: if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also specified.

MerCruiser has developed three methods to facilitate compliance with ABYC recommendations.

These come in the form of one standard production and two accessory kits.

90-899883178 NOVEMBER 2007

Page 3 / 38

ELECTRICAL SYSTEM

SECTION - 7

1. Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery.

2. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: The red current conductor (for the trim pump) must be: a.

Connected to the switched side of the battery switch and either: i. provided with circuit protection within 7 inches of the power source or ii. Provided with circuit protection within 40 inches of the point of connection with the power source, sheathed the entire length of wire from the point of connection to the source and the circuit protection device.

This will require the use of an accessory kit.

Part Number

Description

Color

Length

Type

8M2000587

Cable Assembly – Trim Pump

Red

72 inches

Fused

8M2000588

Cable Assembly – Trim Pump

Red

40 inches

Sheathed

Batteries Battery IMPORTANT: Boating industry standards (NMMA, BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations.

IMPORTANT: It is recommended (required in some states) that battery be installed in an enclosed case. Refer to regulations for your area.

IMPORTANT: Engine electrical system is negative (‑) ground.

1. Select a battery that meets all of the following specifications: • 12‑volt marine type cranking battery • Deep cycle batteries are not recommended for cranking applications • Tapered post connectors or side terminal connectors.

IMPORTANT: Do not use a battery with wing nut connectors.

• Battery cables should always be tightened with a wrench.

• Spray terminals with a battery connection sealant to retard corrosion.

• The battery should have a capacity rating of at least: Engine (Cyl./Type)

Minimum Required Cranking Battery Size

V6 and V8 MPI models

750cca, 950 mca or 180 AH

V8 DTS models

800 cca, 1000 mca or 180 AH

Battery Cables Select proper size positive (+) and negative (‑) battery cables. Using the following chart, battery should be located as close to engine as possible.

• Add the positive (+) and negative (‑) battery cable lengths together.

• Divide by 2 to obtain the average cable length.

IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and a subsequent failure.

Page 4 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM Cable Length

Cable Gauge

Less than or equal to 1.1m (3.5 ft.)

25 mm2 (4)

1.1 ‑ 1.8m (3.5 ‑ 6 ft.)

35 mm2 (2)

1.8 ‑ 2.3m (6 ‑ 7.5 ft.)

50mm2 (1)

2.3 ‑ 2.9m (7.5 ‑ 9.5 ft.)

50mm2 (0)

2.9 ‑ 3.7m (9.5 ‑ 12 ft.)

70mm2 (00)

3.7 ‑ 4.6m (12 ‑ 15 ft.)

95mm2 (000)

4.6 ‑ 5.8m (15 ‑ 19 ft.)

120mm2 (0000)

Both positive (+) and negative (-) cables

Multiple MPI Engine Battery Information Batteries: Boats with multi‑engine MPI power packages require each engine be connected to its own battery. This ensures that the engine's Electronic Control Module (ECM) has a stable voltage source.

Battery switches: Battery switches should always be positioned so each engine is operating off its own battery. Do not operate engines with switches in BOTH or ALL position. In an emergency, another engine's battery can be used to start an engine with a dead battery.

Battery isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.

NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.

1. The boat may have 2 engines connected to a single Model 32023A battery isolator.

2. The Model 32023A battery isolator is connected to 2 banks of batteries.

3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.

4. The second battery in each bank is connected in parallel to the cranking battery.

5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2 charging sources, 120 amps (maximum alternator output).

6. When the engines are operating, either engine's alternator could be charging either bank of batteries through the Model 32023A battery isolator.

Any other manufacturer's battery isolator that is the same type as the Sure Power Inc., Model 32023A could also be used.

Generators: The generator's battery should be considered another engine's battery.

Boat Harness and Installation Connections Engine Harness and Accessory Power Supply If the engine harness is used to supply power for boat accessories (lights, blower, pumps, stereo, or any other electrical device using the engine wiring harness for power), the maximum accessory power available on the 14‑pin wiring harness is 15 amps. Relay kits are available to provide additional accessory power at the helm. This maximum is fuse‑protected and must be observed.

If the fuse opens, the engine will stop and will not restart until the fuse is corrected.

Boat Wiring NOTE: Twin engines are treated as two single engines in the same boat. No twin engine disconnect is required.

90-899883178 NOVEMBER 2007

Page 5 / 38

ELECTRICAL SYSTEM

SECTION - 7

SINGLE STATION

25043

DUAL STATION

25041

•

On dual helm installations, use the extension harness from the engine to the lower station.

• • •

Use the Y‑adapter to connect the upper and lower stations.

Use the proper length harness from the Y to the lower station.

Use the proper length harness from the Y to the upper station.

25132

Y‑adapter for dual helm installations

Boat Harness Installation Guidelines—MPI Sterndrive BOAT HARNESS DEUTSCH CONNECTOR TO ENGINE Select the boat harness by length.

Page 6 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM Boat Harness Length of the Boat Harness

Boat Harness and Key Switch Three Position (off/run/start)

Boat Harness (key switch is not included)

61 cm (02 ft.)

84‑896537 K02

84‑896537 A02

4.6 m (15 ft.)

84‑896537 K15

84‑896537 A15

6.0 m (20 ft.)

84‑896537 K20

A84‑896537 20

7.3 m (24 ft.)

84‑896537 K24

84‑896537 A24

8.8 m (29 ft.)

84‑896537 K29

84‑896537 A29

12.2 m (40 ft.)

84‑896537 K40

84‑896537 A40

NOTE: Extension harnesses are available if longer length is needed.

KEY SWITCH CONNECTOR 1. A mounting bezel is not available for the three position key switch.

NOTE: 899203A01 Decal and washer kit is available for the three position key switch if needed.

25046

Typical three position key switch (off/run/start) 2. The four position key switch is available with mounting hardware.

25045

25044

Typical four position key switch (off/accessory/run/start)

NOTE: When installing the ignition verify that the drain hole in the barrel of the switch is positioned downward for proper drainage.

3. For dual helm installation, a key switch is used at the upper and lower station. The key switches must operate independently.

IMPORTANT: For dual helm installation, both key switches used must be modified to operate independently.

IMPORTANT: Cutting the black / yellow stripe wire disconnects the E stop circuit incorporated in the the key switch.

90-899883178 NOVEMBER 2007

Page 7 / 38

ELECTRICAL SYSTEM

SECTION - 7

4. To modify the key switches, cut the black / yellow stripe wire at each key switch and cover both open wire ends with heat shrink tubing.

a

25136

Typical key switch a - Black/yellow stripe wire IMPORTANT: The key switch at the station being used should be the only key switch in the "run" position. If both station key switches are in the "run" position the engine cannot be turned off with the key switch and the lanyard stop switches will not function.

5. If a momentary stop switch is added, the "stop" switch will override the key switch and the engine will shut off when the stop switch is activated.

6. If a stop button is desired on a dual helm installation. the black wire and black/yellow stripe wire can be clipped at the key switch and connected to a normally open momentary button switch. Any marine momentary push button, rocker style or toggle switch could be utilized to create the "stop" switch. Label the switch on the dash after installation.

7. To Install a momentary "stop" switch: a.

Cut the black wire at the key switch and cover the cut wire at the key switch with heat shrink tubing. b.

Install an eye terminal on the black wire from the connector side. Cover cut wire ends with heat shrink tubing. c.

Install an eye terminal on the black/yellow stripe wire from the connector side. Cover cut wire ends with heat shrink tubing. d.

Connect the black wire and the black/yellow stripe wire eye terminals to a momentary switch.

a

d b

c 25137

Typical key switch with momentary "stop" switch for MPI models a - Black wire with eye terminals c - Eye terminals connected to momentary switch b - Black/yellow stripe wire with eye terminals. d - Momentary switch

TRIM SWITCH The trim switch connection is only used on Mercury outboards.

MerCruiser models require a separate trim harness from the trim control to the power the trim pump connection. A Y‑harness is available with adapters to connect the dual helm power trim harnesses together to connect to the power trim pump. DTS models do not need the separate trim harness.

Page 8 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Use the power trim adapter harness for the single helm harness connection the remote control to the power trim pump.

25166

Power trim adapter harness For dual helm installation, use a power trim extention harness from the upper and lower helm to a Y‑harness.

25168

Power trim extention harness An adapter connects the Y‑harness to the power trim pump, (The original hog nose Y‑harness).

25171

Power trim Y‑harness

25172

Power trim adapter harness

NEUTRAL SWITCH The neutral switch connects to the remote control.

On dual‑helm installations, the lower and the upper station controls need a neutral safety switch.

LANYARD STOP SWITCH PPL and PPL/WHT wires are connected together through a normally closed stop switch.

When the lanyard is pulled and the switch is tripped, the circuit is opened and the power to the engine, ECM, or ignition system is interrupted and the engine is shut off.

If a lanyard stop switch is not used, or an E stop switch is used, these two wires must be plugged together for the engine to run.

90-899883178 NOVEMBER 2007

Page 9 / 38

ELECTRICAL SYSTEM

SECTION - 7

OPTIONAL E STOP The E stop lanyard switch connection is used on Mercury outboards and can be used on MerCruiser MPI engines.

The black and black/yellow wires are connected together through a lanyard switch that is normally open. When the lanyard is pulled and the switch is is tripped, the circuit will close and ground the ECM to shut the engine off.

When this connection is not used, the wires should be kept separate and capped.

WARNING HORN The audio warning horn and connections are included with the Mercury harness assemblies.

(Another horn is also supplied with the engine for those using custom wiring systems.)

ACCESSORY RELAY CONNECTION Accessory relay kit connection. The 14-pin wiring system is able to provide up to 15 amps of accessory power to the helm through the purple wire (key controlled) or the red wire (constant on) circuit. This harness is fuse protected on the engine with a 15‑amp fuse on the engine. If the fuse is blown, the engine will not start or continue to run.

An accessory relay kit connected to this location can provide up to 40 amps of accessory power.

The key switch will power‑up the relay in the "accessory" position and "run" position.

25048

Relay With Power Harness

ADDITIONAL RELAY KIT An additional 40‑amp relay kit can be installed and connected to a junction box at the dash gauge connection location. This location will power up with the key in the "run" position only.

The use of both relay kits will result in a maximum of 80 amps of key controlled power at the helm. This multiplies out on dual engine and dual helm applications as long as the power wires to the helm are adequate to carry the total current demand.

25144

Accessory relay harness

GAUGE CONNECTION The gauge connection of the boat harness connects to the analog gauge harness.

If SmartCraft instrumentation is used, connect to a a SmartCraft junction box.

Page 10 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

If a combination of SmartCraft and analog is used, an AGI (analog gauge interface) kit is used to provide analog instrumentation. The AGI harness connects to the junction box along with the SmartCraft connection.

IMPORTANT: The AGI requires setting the tachometer signal to digital with CDS or DDT.

AGI (Analog Gauge Interface) Length of the Harness

Analog Gauge Harness (14 pin)

1.5 m (5 ft.)

84‑892990T01

3.0 m (10 ft.)

84‑892990T10

4.6 m (15 ft.)

84‑892990T15

IMPORTANT: On dual‑helm installations, the oil pressure sender and the cooling temperature sender must be changed to special dual‑helm senders, unless the SmartCraft and an AGI kit are used.

i

h

j f

a

e

d

c b

g

25052

Analog gauge harness a - Connector to boat harness b - Trim c - Tach d - Key on (+) e - Temp

90-899883178 NOVEMBER 2007

f - Oil g - Ground (–) h - Can (+) or spare i - Can (–) or spare j - 12V (+)

Page 11 / 38

ELECTRICAL SYSTEM

SECTION - 7

A system link adapter can be used to connect SmartCraft link gauges without a System Gauge (requires resetting tach signal to digital with CDS or DDT) fuel tank and trim gauge setting will be defaulted. There is no provision with link gauge to calibrate these gauges.

25147

System Link SC 100 adapter

CAN P (CAN 1) CONNECTIONS CAN P (CAN 1) connection with a terminator resistor in place: • If a this is a dual engine and the SmartCraft instrumentation is used, the terminator resistor is removed and a jumper harness connects the CAN P (CAN 1) lines together so that the engines will share SmartCraft data.

• The resistors on the engines are the required terminator resistors for the SmartCraft‑equipped dual engine applications.

• If the boat is dual engine and dual helm, the terminator resistor at the lower helm is removed from the connector. The jumper harness is installed at the upper station.

25149

Two pin link harness—CAN

CAN V (CAN 3) CONNECTION CAN V (CAN 3) connection is not currently used by MerCruiser. Leave the protective cap in place.

GENERAL REPOWER INFORMATION Harness adapters are used for installing 14‑pin engines into boats with 10‑pin wiring harnesses and 10‑pin engines into boats with 14‑pin wiring harnesses.

a

b

25054

14‑pin engine to 10‑pin boat wiring harness 25054 a - 10‑pin boat harness connection b - 14‑pin engine connection

Page 12 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

NOTE: The adapter used with 10‑pin engine to 14‑pin boat wiring harness includes a 15‑amp fuse.

a

c

b

25055

10‑pin engine to 14‑pin boat wiring harness a - 10‑pin engine connection c - 14‑pin boat harness connection b - 15‑amp fuse For repower of the original 10‑pin engines with the 14‑pin engines: • If adapters are used, a separate CAN (blue data cable) harness is required for SmartCraft instrumentation. Remove the terminator resistor on the engine and connect the CAN harness • If a 14‑pin engine (limited to 15 amps of current draw) is installed into a 10‑pin wired boat, boat accessories may need to be rewired to meet the new amperage load limitation.

• Accessory kits are available to provide additional amperage to the helm.

•

The fuel tank, auxiliary tank, and paddle wheel harness has been changed on MerCruiser to match the harness used by Mercury Outboard. The new harness is needed to replace the original harness for any 10‑pin engine installation using SmartCraft fuel level or paddle wheel.

a

b

f c

e

d 25150

Typical MPI engine a - 14‑pin connector b - 16‑pin transom harness connector c - DLC and depth transducer connector

Qty. 1

Description Fuel tank, auxiliary tank, and paddle wheel harness

d - Fuel – paddle wheel connector e - Standard terminator resistor (remove and connect CAN harness if necessory for repower) f - 50‑amp circuit breaker Part Number 84‑859743T03

TRANSOM HARNESS—MPI This transom harness is designed so that connections can be made after the transom is installed in the boat but before the engine is installed. Connections made before the engine is installed are: • Mercathode connection • Trim connections • Ground connection

90-899883178 NOVEMBER 2007

Page 13 / 38

ELECTRICAL SYSTEM

SECTION - 7

• SmartCraft sensor connections Secure the wiring and position the engine connector out of the way until the engine is installed.

After the engine is in place, make the single connection between the transom and the engine.

b c

a h

25155

d

g f

e

Transom harness—MPI a - 16‑pin connector to engine harness b - SmartCraft steering sensor c - SmartCraft petot sensor d - MerCathode

e - Trim gauge sender (orange with white stripe is for analog gauges) f - Trim gauge sender ground (black is common) g - Trim gauge sender (orange with pink stripe is for digital gauges) h - Transom ground (to the transom bonding screw)

TRANSOM HARNESS—DTS DTS engines are shipped with an adapter to connect the transom harness to the power trim pump.

b

c d e f

j g a

h i

Transom Harness—DTS a - 16‑pin connector to engine harness b - Power trim connects to power trim harness (color coded) c - SmartCraft steering sensor d - SmartCraft pitot sensor e - Trim gauge sender for analog gauges

Page 14 / 38

25154

f - MerCathode g - Transom ground (to the transom bonding strap screw) h - Trim gauge sender for digital gauges i - DTS power trim harness connects to power trim pump j - DTS power trim harness connects to transom DTS harness

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

TRANSOM GROUND CONNECTION The ground wire for the transom is incorporated into the transom harness included with the engine.

Connect the ground wire in the transom harness under the bonding strap screw on the transom.

Do not connect any other ground wires here.

Use the ground studs on the flywheel housing for other grounding needs.

NOTE: In some cases, a ground wire to connect to the flywheel housing may be attached to the bonding screw on the transom. This ground wire is not needed with the transom harness,but can be connected to the flywheel housing or removed. In any case the grounding wire in the transom harness must be connected to the bonding strap screw.

a

b

25173

Ground wire from the transom harness to the transom bonding strap screw a - Bonding strap screw b - Ground wire from transom harness

90-899883178 NOVEMBER 2007

Page 15 / 38

ELECTRICAL SYSTEM

SECTION - 7

Wiring Diagrams Transom Harness—MPI BLK-PNK

B

PNK-DK BLU

A

GRA-BLK

R

C

L

a

A C B

b

L

R

BLK-PNK GRA-BLK

WHT-LT BLU

WHT-LT BLU PNK-DK BLU ORN-PNK

ORN

B

BRN

A

d

ORN-WHT ORN BRN BLK

L

R

BLK

1

e

BLK

ORN-PNK

BLK

g a - Steering b - Pitot c - Analog trim d - Mercathode

Page 16 / 38

1

1

h

c

ORN-WHT

GRA-BLK BLK-PNK

1

A B C D E F G H J K L M N P R S

f

23812

e - Analog trim f - Ground g - Digital Trim h - 16 pin connector

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Transom Harness—DTS

BLK-PNK

B

PNK-DK BLU

A

GRA-BLK

C

B

A

BLK-PNK

GRA-BLK

R

C

L

a

ORN-PNK

b

A C B

c

L

R

BLK-PNK GRA-BLK

WHT-LT BLU

d

ORN-WHT

GRA-BLK BLK-PNK

1

WHT-LT BLU

e

PNK-DK BLU ORN-PNK

ORN

B

BRN

A

ORN-WHT ORN BRN BLK

L

R

BLK

BLK

1

f

GRN BLK

PPL DK BLU

1

A B C D E F G H J K L M N P R S

1

1

1

k

g j

i

a - Steering b - Digital trim c - Pitot d - Analog trim e - Mercathode f - Analog trim

90-899883178 NOVEMBER 2007

23810

h g - Ground h - Trim down i - Relay power j - Trim up k - 16 pin connector

Page 17 / 38

ELECTRICAL SYSTEM

SECTION - 7

Boat Harness DRAWING

2 7

11 10

4 3

1

8

6 5 9

12345-

14‑pin Deutsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 - Lanyard (outboard) or E Stop connection

Page 18 / 38

12340

7 - Warning horn 8 - Accessory relay connection (15‑amp) 9 - Gauge connector/CAN connector for SmartCraft 10 - CAN P (CAN 1) with resistor cap 11 - CAN V (CAN 3) with weather cap

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

DIAGRAM

A B

10

9

DKBLU

A B C D E F G H J K

PPL_WHT BLK RED

A B C

RED BLK ORG GRN

8

PPL GRY YEL WHT

1

PPL

6

PPL

BLK

BLK

BLK

1

PPL

YEL_RED

1

4

YEL_RED

14‑pin Deutsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 - Lanyard (outboard) or E Stop connection

3

RED BLK PPL_WHT PPL BLK_YEL YEL_RED

A B C D E F

12345-

BLU_WHT GRN_WHT

A B C

RED RED

1

A B C D E F G H J K L M N P

BLK_YEL

1

1

GRN YEL_RED GRY BRN YEL GRN_WHT BLU_WHT DKBLU WHT ORG BLK_YEL PPL BLK RED

5

1

PPL_WHT

7

1

BRN

1

11 A B

WHT DKBLU

A B

ORG GRN

A B

2 12339

7 - Warning horn 8 - Accessory relay connection (15‑amp) 9 - Gauge connector 10 - CAN P (CAN 1) with resistor cap 11 - CAN V (CAN 3) with weather cap

NOTE: Dual engines are treated as two singles in the same boat and are not connected together.

NOTE: The lanyard stop switch (PPL and PPL/WHT wires) breaks power to the ECM or ignition to stop the engine. The switch is normally closed until activated. Therefore the PPL and PPL/WHT wires must be connected together if Lanyard Stop Switch is not used, or if the E Stop Switch is used.

NOTE: E Stop Switch (BLK and BLK/YEL wires) connects ground to ECM to stop engine. The switch is normally open; the circuit closes when switch is activated. Wires must be separate unless connected through E Stop Switch.

Up to 15 amps total accessory power can be provided; on purple wire (switched) and the red wire (continuous power).

An accessory relay kit can be used for loads up to 40‑amps. Refer to the MerCruiser Parts and Accessory Guide or MerCruiser Rigging Guide

90-899883178 NOVEMBER 2007

Page 19 / 38

ELECTRICAL SYSTEM

SECTION - 7

Analog Gauge Harness DRAWING

8

2

9

3

10

4 5 6

1 7 12312

12345-

Connector to boat harness Trim Tach Key on (+) Temp

6 - Oil 7 - Ground (–) 8 - CAN (+) or spare 9 - CAN (–) or spare 10 - 12V (+)

DIAGRAM BRN_WHT

GRY

A B C D E F G H J K

PPL DK_BLU WHT BRN_WHT GRY PPL

TAN

LTBLU TAN LTBLU BLK RED

BLK

1

WHT

DK_BLU

RED

12345-

Page 20 / 38

Connector to boat harness Trim Tach Key on (+) Temp

2 3 4 5 6 7

8 9 10 12318

6 - Oil 7 - Ground (–) 8 - CAN (+) or spare 9 - CAN (–) or spare 10 - 12V (+)

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly) b

a

c a - Connection to control box b - Connection to trim pump

90-899883178 NOVEMBER 2007

12323

c - Connections to trim limit switch

Page 21 / 38

ELECTRICAL SYSTEM

SECTION - 7

GRN-WHT

3

4

PPL-WHT

RED

1

2

DK BLU-WHT

C1

B

C GRN-WHT

RED

DK BLU-WHT

A

b

C2

1 T1

T2

1

a

c a - Connection to control box b - Connection to trim pump

Page 22 / 38

12322

c - Connections to trim limit switch

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

RED

BLK

Power Trim System

BLU/WHT

BLK GRN/WHT

b

RED/PPL

a

BLK

c

BLK

RED

BLU/WHT

YEL/RED

YEL/RED

e GRN/WHT

RED/PPL GRN/WHT PPL/WHT

d

BLU/WHT

g

BLU/WHT

BLK

BLK

h

f

7866

a - 20 A fuse b - Ground bolt (floor mount) c - UP solenoid d - DOWN solenoid

90-899883178 NOVEMBER 2007

e - 110 A fuse f - Y‑harness (optional) g - Neutral switch to instrument wiring harness h - Trim limit switch

Page 23 / 38

ELECTRICAL SYSTEM

SECTION - 7

Adaptor Harness for Power Trim Pump—DTS a

A

PPL

1

b

B

DK BLU

1

c

C

GRN

d

1

23809

a - To power trim pump b - To transom DTS harness

c - To transom DTS harness d - Not used on DTS

14‑Pin Engine Harness Connector Mechanical 14‑Pin Connector Pin‑Out Pin

Wire Color

Function

A

PINK

+ 12 Volt

B

BLACK

Ground (‑)

C

PURPLE

Wake

D

DK GREEN/YELLOW

E‑Stop

E

DK BLUE

Analog oil pressure

F

WHITE

CAN 1+

G

LT BLUE

CAN 1‑

H

Open

Spare

J

Open

Spare

K

ORANGE/WHITE

Analog trim position

L

BROWN/DK BLUE

Audio warning horn

M

GRAY/WHITE

Tachometer/Link gauge

N

YELLOW/BLACK

Crank

P

TAN

Analog coolant temperature

DTS Information and Installation Special Tools ‑ DTS Installation Data Cable Puller

91‑888462A1

Installation Guidelines for DTS System Components ! WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system.

Page 24 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

DATA HARNESS

! WARNING Prevent serious injury or death from a loss of boat control. Pulling on or flexing connectors can loosen terminals and cause open or intermittent electrical connections, which will interrupt control of throttle and shifting. Do not pull on cable connectors when pulling cables through the boat. Do not allow cables to flex at connection points. Fasten all electrical harnesses within 25.4 cm (10 in.) of any connection.

CONNECTORS IMPORTANT: Connectors should never have to be forced into the receptacle. Ensure that connectors are free of any lubricant or dielectric grease before installation. When the connector is properly aligned, it will only take a small amount of pressure to insert it into the receptacle. Rotate the locking collar to secure the electrical connection.

NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than 12.2 m (40 ft.), contact Mercury Marine for more information.

Weather Caps Weather caps are to be used whenever there are any unused connectors on a harness. Verify all connections are tight to prevent moisture or corrosion occurring inside the connections.

Typical weather caps are as follows:

4958

a a - 10 pin cap b - 5 pin cap

b

d

c

c - 3 pin cap d - 2 pin cap

DTS Battery Specifications IMPORTANT: Do not use deep cycle batteries for the main engine starting battery.

IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations.

IMPORTANT: It is recommended (required in some states) that the battery be installed in an enclosed case. Refer to regulations for your area.

Minimum SAE Starting Battery Requirements ‑ BCI GRP 24 MCA

1000

CCA

800

Ah

180 (International Rating)

NOTE: Due to the wide variety of battery manufacturers throughout the world, ratings and physical battery sizes will vary. Check with the manufacturer for a starting battery with a MCA, CCA, or Ah specification that will be equal to or greater than the SAE Standard J537 specified previously.

90-899883178 NOVEMBER 2007

Page 25 / 38

ELECTRICAL SYSTEM

SECTION - 7

IMPORTANT: For DTS products, each engine must be equipped with its own starting battery. If your boat application requires additional battery loads for boat accessories or marine electronics, it is recommended that an auxiliary battery or batteries be installed.

! WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.

When connecting engine battery, hex nuts must be used to secure battery leads to battery posts.

Torque nuts to specifications.

Description

Nm

lb. in.

Hex nuts

13.5

120

lb. ft.

IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine installation manual for size requirements.

Spray terminals with a battery connection sealant to help retard corrosion.

Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied.

NOTICE - DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating.

13.5Nm (120 lbs. in.)

DO NOT USE WING NUTS.

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.

37-895387 Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.

3486

Junction Box (if Equipped) • • • • •

Page 26 / 38

Although the junction box connections are watertight, it is recommended that the junction box be mounted in an area that stays relatively dry.

Mount in an area where the wiring connection will not get stepped on or disturbed.

Mount in an area that is accessible for troubleshooting and servicing the system.

Ensure the DTS command module harness will reach all the connection points.

Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

•

Seal all unused connections with weather caps.

c

b a

d

e 29220

a - Clamp b - Weather cap (859318T 2) c - Junction box

d - 25.4 cm (10 in.) e - DTS command module harness

Data Harness Installation Data Harness Pulling Procedure IMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads, and spark plugs), high power VHF coax, or radios. An electrical field generated from these components could cause interference with data transmission.

IMPORTANT: Do not route data harness near sharp edges, hot surfaces, or moving parts. Fasten cables away from any sharp edges, fasteners, or objects that could wear into the harness.

IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be 7.6 cm (3 in.) for the final wiring installation.

1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs that could cut the harness.

2. Install cable pulling tool to data harness.

3. Secure pulling tool with two cable ties.

IMPORTANT: The cable ties must be tight to prevent any slipping during installation.

3836

Data Cable Puller

91‑888462A1

IMPORTANT: Carefully inspect data harness pins to ensure all pins are securely fastened to data harness connector end following installation.

NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.

90-899883178 NOVEMBER 2007

Page 27 / 38

ELECTRICAL SYSTEM

SECTION - 7

Connecting 14 Pin Data Harness ‑ Single Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).

b a

3619

a - 14 pin data harness

b - Clamp or cable tie

DUAL HELM

b

a

c d

e a - 14 pin data harness b - Helm 2 (upper helm) ‑ auxilary c - Helm 1 (lower helm) ‑ primary

Page 28 / 38

3682

d - Dual helm adapter (Y harness) e - Clamp or cable tie

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Connecting 14 Pin Data Harness ‑ Dual Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).

a

b

3977

a - 14 pin data harness

b - Clamp or cable tie

DUAL HELM a

c b c

d

e a - Helm 2 (upper helm) b - Helm 1 (lower helm) c - 14 pin data harness

90-899883178 NOVEMBER 2007

3978

d - Dual helm adapter (Y harness) e - Clamp or cable tie

Page 29 / 38

ELECTRICAL SYSTEM

SECTION - 7

DTS Command Module and Harness Installation Installing DTS Command Module and Harness ‑ Single Engine HARNESS INSTALLATION • • •

Locate a routing path for the harness connections so they reach their installation points.

Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.

Fasten and support the harness with clamps or cable ties along the routing path.

•

Make sure all connections are tight and seal all unused connectors with weather caps.

a

b 3622

Single Helm Application a - DTS command module harness

Page 30 / 38

b - Clamp or cable tie

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

NOTE: For dual helm application ‑ Remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm closest to the engine), and seal connectors with weather caps.

a

c

Terminator CAN 2

Terminator CAN 1

f

e

d h g b

c

d 3677

Dual Helm Application a - Helm 2 (upper helm) b - Helm 1 (lower helm) c - DTS command module harness d - Clamp or cable tie

e - CAN P (CAN 1) connector f - CAN X (CAN 2) connector g - Weather caps h - Terminator resistors, blue (CAN P and CAN X)

MODULE INSTALLATION • • • •

Although the Command Module connection is watertight, it is recommended that it be mounted in an area that stays relatively dry.

Mount in an area where the wiring connection will not get stepped on or disturbed.

Mount in an area that is accessible for troubleshooting and servicing the system.

Ensure the wiring harness connected to the command module will reach all the connection points.

90-899883178 NOVEMBER 2007

Page 31 / 38

ELECTRICAL SYSTEM

SECTION - 7

•

Mounting the Command Module with the supplied rubber grommets/bushings to minimize vibration.

a

3939

a - DTS Command Module

Installing DTS Command Module and Harness ‑ Dual Engine HARNESS INSTALLATION • • •

Page 32 / 38

Locate a routing path for the harness connections so they reach their installation points.

Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.

Fasten and support the harness with clamps or cable ties along the routing path.

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

•

Make sure all connections are tight and seal all unused connectors with weather caps.

Terminator CAN 1

c a Terminator CAN 2

b

c

Terminator CAN 1

Terminator CAN 2

d Single Helm Application a - CAN link harness b - CAN X (CAN 2) Terminator resistors ‑ do not remove c - CAN P (CAN 1) connectors

90-899883178 NOVEMBER 2007

e 3689

d - Clamp or cable tie e - DTS command module harness

Page 33 / 38

ELECTRICAL SYSTEM

SECTION - 7

NOTE: For dual helm application ‑ Remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm closest to the engine), and seal connectors with weather caps.

b c

e d

a

2

f

d

1 4079

Dual helm application a - Weather caps b - CAN link harness c - Helm 2

d - DTS Command Module harness e - Termination resistors ‑ do not remove from helm 2 f - Helm 1

MODULE INSTALLATION • • •

Page 34 / 38

Although the Command Module connection is watertight, it is recommended that it be mounted in an area that stays relatively dry.

Mount in an area where the wiring connection will not get stepped on or disturbed.

Mount in an area that is accessible for troubleshooting and servicing the system.

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

•

Ensure the wiring harness connected to the command module will reach all the connection points.

a

4080

a - DTS Command Module

Analog Gauge Interface (AGI) Analog Gauge Interface (AGI) Installation NOTE: This Analog Gauge Interface (AGI) can only be used with the 14 pin Digital Throttle and Shift (DTS) system to drive analog and/or SmartCraft System Link gauges. For analog gauges, use ring terminals on AGI harness to connect to analog sender inputs on gauge backs, and tape back any unused terminals. For SmartCraft System Link gauges, use 3 pin System Link connection on AGI harness. The AGI system can support 10 System Link gauges per helm, 2 helms maximum.

IMPORTANT: Mount AGI module with wires coming out of potting facing downward to prevent moisture from collecting at base of wires and wicking into module. Route and secure all wires and harnesses away from hot or moving parts.

1. With screws and washers supplied in kit, mount the AGI module securely under dash or helm in close proximity to gauges being used.

2. Refer to the following table for AGI harness wire color/analog gauge sender input connections.

Tape back any unused terminals. Secure connections per gauge manufacturers specifications.

Analog Gauge Type

AGI Harness Wire Color

Tachometer

Gray

Oil Pressure/Oil Level

Blue

Water Temperature

Tan

Trim Positions

90-899883178 NOVEMBER 2007

Brown/White

Page 35 / 38

ELECTRICAL SYSTEM

SECTION - 7 Analog Gauge Type

AGI Harness Wire Color

Fuel Level

a

Pink/Black

b

c

GRY PNK/BLK BRN/WHT

d

TAN BLU

f

e a - AGI module b - 14 pin connection c - AGI harness

3688

d - Analog gauge terminal connections e - System Link 3 pin connection f - 10 pin CAN data connection

3. Route and connect wire from key switched 12 volt positive power source to analog gauges.

Secure connections per gauge manufacturers specifications.

4. Route and connect ground wire from analog gauges to a common ground. Secure connections per gauge manufacturers specifications.

5. Connect any SmartCraft System Link gauges to 3 pin System Link connection. The AGI system can support 10 System Link gauges per helm, 2 helms maximum.

6. Plug 14 pin AGI harness connection into AGI module.

7. Connect 10 pin CAN data harness connection on command module harness to AGI harness. a.

If SmartCraft System View is not being used, plug 10 pin CAN data connection on AGI harness directly into 10 pin CAN data connection on command module harness. b.

If SmartCraft System View is being used, a junction box and harness adaptor will be required. Plug 10 pin CAN data connection on command module harness, 10 pin CAN data connection on System View harness, and one end of harness adaptor into junction box. Plug 10 pin CAN data connection on AGI harness into other end of harness adaptor.

Insulate any unused connection ports on junction box with weather caps.

Configuring Analog/Digital Tachometer Signal through PCM IMPORTANT: The engine Propulsion Control Module (PCM) tachometer configuration factory default has been set to an analog. This will allow the operation of one analog tachometer.

Depending on the desired use of analog/digital gauges, the PCM set‑up may have to be configured from analog to a digital.

Following are optional uses of analog and digital gauges and the setting for the tachometer configuration in the PCM necessary to run them.

Gauge Configuration

Analog Digital

Analog Tachometer Only

X

System Link Gauges used with System View, System Monitor, or System Tach

-

-

System Link Gauges used in conjunction with System Link Adaptor Harness and Command Module Harness without the use of System View, System Monitor or System Tach

X

AGI used with or without System View, System Monitor or System Tachometer, to run analog and System Link Gauges

X

The Digital Diagnostic Tool (DDT) or Computer Diagnostic System (CDS) can be used to select analog or digital PCM tachometer configuration.

PCM CONFIGURATION WITH CDS 1. Attach CDS to engine. Refer to on‑line help if needed.

2. From Logon screen, navigate to Engine Select screen.

Page 36 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

3.

4.

5.

6.

From Engine Select screen fill in engine type information and select Tool Box. From Tool Box screen, select Active Diagnostics.

From Active Diagnostics screen, scroll down and select Tach Link Config.

To change PCM configuration from default of analog to digital, select Enable and then select Run. 7. To change PCM configuration from digital to analog, select Disable and then select Run.

90-899883178 NOVEMBER 2007

Page 37 / 38

ELECTRICAL SYSTEM

SECTION - 7

NOTES:

Page 38 / 38

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

SECTION 8 - REMOTE CONTROLS Table of Contents Remote Control Installation..................................................................................................................................... 4 Locating and Drilling Mounting Area.................................................................................................................4 Installing DTS Panel Mount Control..................................................................................................................4 Installing DTS Single Handle Console Control..................................................................................................6 Installing DTS Dual Handle Console Control....................................................................................................9 Installing DTS Zero Effort Control...................................................................................................................12 Steering System Information................................................................................................................................. 14 High Speed Or Twin Engine Applications Steering Recommendation ...........................................................14 Steering Helm and Cable................................................................................................................................15 Steering Cable Specifications.........................................................................................................................16 Hydraulic (Helm) Steering...............................................................................................................................16 Sterndrive Shift Cable Information........................................................................................................................ 17 Propeller Rotation............................................................................................................................................17 Checking Alpha Shift Cable Installation and Adjustment................................................................................17 Bravo Sterndrive Shift Check (Engine Running).............................................................................................21 Troubleshooting Shift Problems......................................................................................................................22 DTS Remote Control ‑ Sterndrive...................................................................................................................25 DTS Calibration..................................................................................................................................................... 25 Special Tools ‑ DTS Calibration......................................................................................................................25 Methods of Calibration....................................................................................................................................25 Setting Trailer and Trim Limit................................................................................................................................ 25 Setting Trailer Limit with CDS.........................................................................................................................25 Setting Trim Limit with CDS............................................................................................................................26 Troubleshooting Procedure................................................................................................................................... 26 Troubleshooting Information............................................................................................................................26 Default Sensor Values ............................................................................................................................. 26 Fault Conditions ....................................................................................................................................... 27 Sticky/Non‑Sticky Faults .......................................................................................................................... 27 Engine Guardian ...................................................................................................................................... 27 Warning Horn Signals .............................................................................................................................. 27 Special Tools ‑ DTS Troubleshooting.............................................................................................................. 27

90-899883178 NOVEMBER 2007

8

Page 1 / 28

REMOTE CONTROLS

SECTION - 8

Lubricant, Sealant, Adhesives Tube Ref No. 95

Description 2-4-C Marine Lubricant with Teflon

Where Used

Part No.

Shift cable end

92-802859A1

Special Tools Dual Water Pick‑up Flush Gearcase Seal Kit

91‑881150K 1

Blocks off the front water inlet holes on the dual water inlet gearcases.

9194

Flushing Device

91‑44357Q 2

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

9192

Flushing Kit

91‑849996T 1

Use for flushing gearcases with low water inlets.

9195

Male to Male 10 Pin Adapter

84‑892452A01 Allows connection between CAN 1 communications cable and Computer Diagnostic System in applications where a junction box is not used.

4621

Can 1 Diagnostic Cable

84‑892663

Connects into a junction box or male to male adapter cable for Command Module configuration. Not for use with DDT. 4680

Adapter Harness

84‑822560A13 Data link harness between engine and Computer Diagnostic System (CDS) or Digital Diagnostic Terminal (DDT).

5826

Page 2 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS Computer Diagnostic System (CDS)

4520

Breakout Box

Order through SPX Monitors all electrical systems for proper function, diagnostics. and calibration purposes. For additional information, pricing, or to order the Computer Diagnostic System contact: SPX Corporation 28635 Mound Rd. Warren, MI 48092 or call: USA ‑ 1‑800‑345‑2233 Canada ‑ 800‑345‑2233 Europe ‑ 49 6182 959 149 Australia ‑ (03) 9544‑6222 SPX P/N MM‑46225

Connects to Propulsion Control Module (PCM) to test engine circuits and components without probing wires. May be used with Computer Diagnostic System (CDS).

5974

Terminal Test Probe Kit

SPX P/N MM‑46523

Test probes adapt test meter leads to harness connections without damaging harness terminals. May be used with Computer Diagnostic System (CDS).

7915

12 Volt Shunt Connector

889675A01 Connects to data harness allowing operation of the DTS system with the Digital Diagnostic Terminal.

8036

Adapter Harness

84‑822560A5 Data link harness between engine and Digital Diagnostic Terminal (DDT).

4009

2 to 4 Pin Harness Adapter

84‑822560A12 Adapts the 2 pin Digital Diagnostic Terminal harness to the 4 pin connector on the engine.

4679

90-899883178 NOVEMBER 2007

Page 3 / 28

REMOTE CONTROLS

SECTION - 8 DMT 2004 Digital Multimeter

Measures RPM, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately reads in high RFI environments.

H z TEMP mA A

V Hz mV

IG

OFF

IP TEMP

A

mA

COM

V

91‑892647A01

Hz

4516

Remote Control Installation Locating and Drilling Mounting Area 1. Locate area of boat where the remote control is to be mounted. Allow sufficient clearance for handle movement and clearance for the wiring.

2. Select the correct template for mounting application.

3. Place template over mounting area; cut and drill as instructed on template.

IMPORTANT: After cutting mounting area, make sure opening is free of sharp edges.

a

3600

a - Template

Installing DTS Panel Mount Control 1. Ensure opening is free of sharp edges.

2. Route wiring for the remote control into opening.

26744

3. Connect trim harness and lever harness.

Page 4 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

4. Insert the bayonet end into bracket hole. This will prevent connector from pulling out.

IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle movement.

b

a 5086

a - Trim harness

b - Lever harness

5. Place the remote control into the opening.

3250

6. Fasten the remote control with three #12 x 1.25 in. long screws.

a a 3251

a - Mounting screw (3) 7. Control Handle Tension Adjustment – This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–" to decrease tension.

90-899883178 NOVEMBER 2007

Page 5 / 28

REMOTE CONTROLS

SECTION - 8

8. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "–" to decrease tension.

b

a

3252

a - Control handle tension adjustment screw b - Detent tension adjustment screw 9. Install front and back bezel covers with attaching screws.

b

a

c

3254

a - Front cover b - Back cover

c - Screw ‑ (2) M4 x 12

Installing DTS Single Handle Console Control 1. Ensure opening is free of sharp edges.

2. Route wiring for the remote control into opening.

3509

3. Connect trim, lever and trackpad harnesses.

4. Insert the bayonet end of the lever harness into bracket hole. This will prevent connector from pulling out.

Page 6 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle movement.

b c a 5098

a - Trim harness b - Lever harness

c - Trackpad harness

5. Place the remote control into the opening.

3296

90-899883178 NOVEMBER 2007

Page 7 / 28

REMOTE CONTROLS

SECTION - 8

6. Fasten the remote control with four M6 x 40 long screws.

a

b c a - Mounting screw (4) M6 x 40 b - Washer

3297

c - Nut ‑ nylon insert

! CAUTION Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket.

7. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–" to decrease tension.

8. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "–" to decrease tension.

a

b 5102

a - Detent tension adjustment

Page 8 / 28

b - Control handle tension adjustment

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

9. Install the side cover with attaching screws.

b a 3298

a - Attaching screws (4) M4 x 20

b - Side cover (2)

Installing DTS Dual Handle Console Control 1. Make sure opening is free of sharp edges.

2. Route wiring for the remote control into opening.

3606

3. Insert the bayonet ends into bracket holes. This will prevent connectors from pulling out.

90-899883178 NOVEMBER 2007

Page 9 / 28

REMOTE CONTROLS

SECTION - 8

IMPORTANT: Allow slack in the trim button harness going to the control handle. This harness will flex and move during control handle movement.

b c

d

e

f

a a - Bayonet ends b - Trim button harness c - Blue paint dot

3305

d - Yellow paint dot e - Starboard engine f - Port engine

4. Place the remote control into the opening.

3306

Page 10 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

5. Fasten the remote control with four M6 x 40 screws.

a

b c a - Mounting Screw (4) M6 x 40 b - Washer

3307

c - Nut ‑ nylon insert

! CAUTION Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket.

! CAUTION Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket.

6. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–" to decrease tension.

7. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "–" to decrease tension.

a

b 5102

a - Detent tension adjustment

90-899883178 NOVEMBER 2007

b - Control handle tension adjustment

Page 11 / 28

REMOTE CONTROLS

SECTION - 8

8. Install the side cover with attaching screws.

a b

3308

a - Side cover (2)

b - Attaching screws (4) M4 x 20

Installing DTS Zero Effort Control

B LU/W HT B LU/W HT

e

d R ED

a

R ED

c

G RN/W HT

b

G RN/WHT

1. Ensure opening is free of sharp edges.

2. Route wiring for the remote control into opening.

3. Connect trim, lever and adaptor harnesses.

LEVER 1

f 5181

a - Throttle adaptor harness b - Remote control c - Trim harness

Page 12 / 28

d - Trackpad ‑ not used e - Lever 1 harness (blue) f - Trim adaptor harness

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

4. Ensure the control is positioned so the forward‑neutral‑reverse (F‑N‑R) decal is in the correct orientation.

a

b c d

5184

a

c

b

b c

a d

d

5182

Forward Cant Models a - Reverse b - Neutral

Aft Cant Models c - Forward d - F‑N‑R decal location

5. Ensure the control is position so the forward‑neutral‑reverse ("F‑N‑R") decal is in the correct orientation.

d

d

c

c

a

b

b a - Throttle lever b - Trim switch

c - Shift lever d - "F‑N‑R" label

a 4749

NOTICE Chipped paint can lead to rapid corrosion. Always install a nylon washer between each screw and the control plate.

90-899883178 NOVEMBER 2007

Page 13 / 28

REMOTE CONTROLS

SECTION - 8

6. Secure control to the console using the 8 X 1‑1/4 in. self tapping screws and nylon washers.

a b c d 5192

a - 8 X 1‑1/4 in. self tapping screw (4) b - Nylon washer (4)

c - Control quadrant assembly d - Console

Steering System Information High Speed Or Twin Engine Applications Steering Recommendation Mercury MerCruiser power packages come standard with Mercury MerCruiser's internal power steering. This durable system provides precise effortless steering control and is recommended for most sport boat applications. On certain applications, however, Mercury MerCruiser recommends the use of an external power steering system where the power steering cylinders connect directly to the sterndrive unit on the outside of the boat. This arrangement gives additional support for even tighter, more firm steering control, and is recommended for the following applications: • High speed single or twin engine applications and/or boats with unusual handling characteristics.

NOTE: It is virtually impossible to give a specific recommendation as to when external power steering should be used, as this varies from boat design to boat design. Mercury MerCruiser recommends using external power steering on boats which operate in excess of 70 mph. There are boats which operate at 60 mph that would benefit from the use of external power steering.

Because of the many variables involved, the final decision as to whether or not external power steering is required rests with the boat manufacturer and must be made after a thorough test and evaluation of each specific boat. If there is any question whether or not external power steering is necessary, Mercury MerCruiser recommends that it be installed.

• Any Hi‑Performance sport boat powered by three or more engines.

• Offshore boats or other applications where the boat and sterndrive units may come out of the water occasionally.

External power steering systems are generally either mechanical cable actuated or hydraulic actuated.

External power steering and hydraulic helm systems can be obtained from the following after market suppliers: Latham Marine, Inc. 280 S.W. 32nd Court Ft. Lauderdale, FL 33315 Phone: (305) 462-3055 Fax: (305) 462-3081, Mayfair Marine Machine 12890 N. W. 30th Avenue Opalocka, FL 33054 Phone: (305) 681-1815,

Page 14 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

Steering Helm and Cable Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook.

The steering cable coupler nut must also have a means of locking it to the guide tube, as specified in ABYC requirements.

! WARNING Failure to use a steering cable locking device can cause serious injury or death due to loss of boat control. Use a locking device, such as a self‑locking coupler or external locking device when installing steering controls.

NOTE: All current production Quicksilver RideGuide steering cables have a self‑locking coupler nut and do not require an external locking device. (Other cable manufacturers also make cables with self‑locking coupler nuts.)

a

7255

a - Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove) IMPORTANT: If using a steering cable that does not have a self‑locking coupler nut, an external locking device such as a locking sleeve must be used.

! WARNING Failure to use the correct cables or other steering system components can cause serious injury or death due to loss of boat control. Use only approved or required components when installing steering systems.

1. Steering cable must be the correct length, particularly when installed in larger boats.

2. Avoid sharp bends, kinks, or loops in cable.

3. Refer to Steering Cable Specifications for fully extended steering cable and dimensions.

90-899883178 NOVEMBER 2007

Page 15 / 28

REMOTE CONTROLS

SECTION - 8

Steering Cable Specifications IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.

c

a b

d

e

g

f

C L

j

k l

h i 7254

a - Coupler nut ‑ 7/8 ‑ 14 UNF ‑ 28 thread b - 29.8 cm (11‑3/4 in.) minimum c - Interface point d - 12.7 mm (1/2 in.) maximum e - 10.7 mm (27/64 in.) minimum flat f - 3.1 mm (7/64 in.) minimum radius

g - 15.9 mm (5/8 in.) maximum diameter end fitting h - 9.5 mm (3/8 in.) i - 9.8 mm (3/8 in.) diameter through hole (chamfered each side) j - 34.9 mm (1‑3/8 in.) maximum k - 15.9 mm (5/8 in.) diameter tube l - Cable travel: mid‑travel position ‑ 42.9 cm (16‑7/8 in.) total travel to be20.3 cm (8 in.) minimum to 22.8 cm (9 in.) maximum travel each side of mid‑travel position ‑ 1.02 cm (4 in.) minimum to 114 mm (4‑1/2 in.) maximum

Hydraulic (Helm) Steering If your power package is equipped with Compact Hydraulic Steering, refer to the Compact Hydraulic (Helm) Steering Installation Instructions .

Page 16 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

Sterndrive Shift Cable Information Propeller Rotation Propeller rotation for sterndrive can be clockwise or counterclockwise, as viewed from the aft (rear) end of the propeller.

4802

Clockwise rotation

4747

Counterclockwise rotation

Checking Alpha Shift Cable Installation and Adjustment IMPORTANT: Do not use excessive force when holding pressure on the drive unit shift cable.

Gasoline Alpha Models Only: Excessive force would be indicated by movement of the V‑notch of the actuator lever assembly.

1. Right-hand (RH) rotation drive unit ‑ Verify remote control travel for FORWARD gear. a.

Place the remote control in FORWARD gear, past detent, into WOT position.

7807

90-899883178 NOVEMBER 2007

Page 17 / 28

REMOTE CONTROLS

SECTION - 8

2. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).

7817

3. Left-hand (LH) rotation drive unit ‑ Verify remote control travel for FORWARD gear. a.

a. Place the remote control in FORWARD gear, past detent, into WOT position.

7807

4. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotating propeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).

7870

5. Right-hand (RH) rotation drive unit ‑ Verify remote control travel for REVERSE gear.

Page 18 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

a.

Place the remote control in REVERSE gear, past detent, into WOT position.

7869

6. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotating propeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).

7870

7. Left-hand (LH) rotation drive unit ‑ Verify remote control travel for REVERSE gear. a.

Place the remote control in REVERSE gear, past detent, into WOT position.

7869

90-899883178 NOVEMBER 2007

Page 19 / 28

REMOTE CONTROLS

SECTION - 8

8. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).

7817

IMPORTANT: It may be necessary to make additional adjustments if using extra long remote control shift cable, if there are a lot of bends in the cable, or if the remote control has inadequate output travel.

9. If drive unit is installed and the package is equipped with a single lever shift/throttle control: a.

Right-hand (RH) propeller rotation drive unit ‑ Shift remote control into REVERSE gear, WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutch should engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with REVERSE gear. Retighten stud. Shift remote control several times and stop in REVERSE to recheck shift cutout switch position. Pin must be centered. b.

Left-hand (LH) propeller rotation drive unit - Shift remote control into FORWARD gear, WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutch should engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear. Retighten stud. Shift remote control several times and stop in FORWARD to recheck shift cutout switch position. Pin must be centered.

10. If drive unit is installed and the package is equipped with a two lever remote control with separate shift and throttle levers: a.

Page 20 / 28

Right-hand (RH) propeller rotation drive unit - While turning propeller shaft CLOCKWISE, move remote control shift handle into full REVERSE position. Clutch should engage before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with REVERSE gear. Retighten stud. Shift remote control several times and stop in REVERSE to recheck shift cutout switch position. Pin must be centered.

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

b.

Left-hand (LH) propeller rotation drive unit - While turning propeller shaft CLOCKWISE, move remote control shift handle into full FORWARD position. Clutch should engage before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear. Retighten stud. Shift remote control several times and stop in FORWARD to recheck shift cutout switch position. Pin must be centered.

a b 7871

a - Adjustable stud

b - Shift interrupt switch plunger

Bravo Sterndrive Shift Check (Engine Running) ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

This test requires sufficient water supply to your engine and sterndrive.

1. Check sterndrive for proper gear shift with boat out of water.

2. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/ IN position. Do not allow the sterndrive skeg to contact the ground.

a b

4805

Typical single handle remote control shown a - Drive trim switch b - Drive trailer button 3. Connect a garden water hose between flushing attachment and water source.

Dual Water Pick‑up Flush Gearcase Seal Kit

90-899883178 NOVEMBER 2007

91‑881150K 1

Page 21 / 28

REMOTE CONTROLS

SECTION - 8 Flushing Device

91‑44357Q 2

Flushing Kit

91‑849996T 1

4. Partially open water source until water continuously leaks out around the flushing device.

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.

IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.

5. Place remote control handle in NEUTRAL, idle speed position and start engine.

NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of each gear FORWARD, NEUTRAL, and REVERSE, at idle speed position.

NOTE: The operator at the remote control handle should feel a slight detent before and after each gear. FORWARD‑detent‑NEUTRAL‑detent‑REVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment.

6. Move the remote control handle to FORWARD, idle speed position.

7. Check that the sterndrive propeller shaft is turning in the FORWARD direction.

8. Shift the remote control handle to NEUTRAL, idle speed position.

9. Check that the sterndrive propeller shaft is not turning.

10. Shift the remote control handle to REVERSE, idle speed position.

11. Check that the sterndrive propeller shaft is turning in the REVERSE direction.

12. If the sterndrive will not shift: a.

Remove the sterndrive and check for proper shift hook ups. b.

Check that the shift cables are connected IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/ or contact with moving parts. DO NOT fasten any items to shift cables.

Troubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear.

1. When installing the control box in the side panel of the boat, ensure that the cables have enough clearance to operate. This is necessary because the cables move up and down when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, the cables will be interfered with; this will cause very hard shifting.

NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.

7873

Proper cable bend

Page 22 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

7872

Improper cable bend 2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull, it does not have any extremely sharp bends in it as this will cause stiff shifting.

IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends on too‑short cables result in kinks and too‑long cables require unnecessary bends or loops. Both conditions place extra stress on the cables.

IMPORTANT: Shift cable/throttle cable lubrication points use 2‑4‑C with Teflon.

3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.

b c

a

d a - Remote control end b - Engine end Tube Ref No. 95

7874

c - Adjusting barrel d - Lubricating point

Description

Where Used

Part No.

2-4-C Marine Lubricant with Teflon

Shift cable end

92-802859A1

NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GEN II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.) thickness.

Cable radius at any one point must not be less than 305 mm (12 in.).

4000 GEN II Series Panel Mount Remote Control Description

Specification

Mounting surface maximum thickness

25 mm (1 in.)

Minimum cable bend radius at any point

305 mm (12 in.)

4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 cm (3 ft) of the control box.

90-899883178 NOVEMBER 2007

Page 23 / 28

REMOTE CONTROLS

SECTION - 8

5. Ensure that the cable is not permanently kinked.

6. Ensure that there is proper clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE. 7. Ensure that the engine was not set down on the intermediate shift cable during installation, as this will crush the inner cable tubing and cause improper and / or stiff shifting.

8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of the shift plate.

9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1.5 m (5 ft) of the shift plate.

10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud.

NOTE: Lubricate attaching points with engine oil.

Description SAE 30W Engine Oil

Where Used

Part Number

Shift cable pivot points

Obtain Locally

11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows:

NOTE: Cable route is the same for through transom and through prop exhaust. a.

The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. b.

The cable should then be routed under the starboard rear engine mount and turn toward the transom. c.

The cable should then go up behind the power steering valve and loop over to the shift plate on the engine, where it is connected to the anchor points on the shift plate.

Following this routing will prevent the engine coupler from damaging the cable.

8995

Through prop exhaust shown

NOTE: NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the pre‑delivery inspection 12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.

Refer to 90‑865523 Instruction Sheet for more information.

Page 24 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

DTS Remote Control ‑ Sterndrive IMPORTANT: Boat must be equipped with Mercury electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in FORWARD or REVERSE.

T R IM SC R O L L SEL EC T F

R

RUN 8994

The Digital Throttle and Shift System (DTS) required to operate this engine package provides start, stop, throttle, shift control, start in gear protection and emergency lanyard stop function. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

The Digital Throttle and Shift system (DTS) works with specialized helm component, command module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

DTS Calibration Special Tools ‑ DTS Calibration Male to Male 10 Pin Adapter Can 1 Diagnostic Cable Adapter Harness Computer Diagnostic System (CDS)

84‑892452A01 84‑892663 84‑822560A13 Order through SPX

Methods of Calibration NOTE: DTS system calibration must be performed following complete system installation. It must also be completed after an accessory or replacement part is added to the system that requires new configuration codes. A DTS system reset must be performed prior to calibration, or if an error is made during the calibration setup.

• Mercury Marine Computer Diagnostic System (CDS) ‑ Connect the CDS to the CAN bus circuit and follow the helm configuration setup on the computer diagnostic screen.

Setting Trailer and Trim Limit Setting Trailer Limit with CDS IMPORTANT: Incorrectly configuring the trim limit using a DDT or CDS can create a programming error in the engine's PCM. Always set the trailer limit before setting the trim limit. If you configure the limit incorrectly, contact the Mercury Marine Technical Service Department for further instructions.

90-899883178 NOVEMBER 2007

Page 25 / 28

REMOTE CONTROLS

SECTION - 8

The function of the trailer limit: • Outboard - To limit the maximum tilt up position, preventing damage to the cowl.

•

MerCruiser - To limit the maximum trailer up position, preventing damage to swim platforms etc.

1. Connect the CDS to the engine data link harness.

2. Turn the ignition key to the "RUN" position.

3. Select the correct engine location.

4. Open the Tool Box icon in the CDS. 5. Open the Active Diagnostics Icon.

6. Scroll down the Active Diagnostics window and highlight "Trailer Limit".

7. Run the trim system completely in (down) and hold the trim button in for 3‑4 seconds. This will configure the PCM to recognize the maximum trim in position according to the trim position sensor.

8. Run the test.

9. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to store the current position in the ECU." 10. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.

Setting Trim Limit with CDS IMPORTANT: Incorrectly configuring the trim limit using a DDT or CDS can create a programming error in the engine's PCM. Always set the trailer limit before setting the trim limit. If you configure the limit incorrectly, contact the Mercury Marine Technical Service Department for further instructions.

IMPORTANT: The engine must be running above 2000 RPM in gear to initiate the trim limit.

The trim limit configures the PCM to control the maximum up trim limit. The trim limit function is only supported if the PCM has input for the three wire trim sensor.

1. Connect the CDS to the engine data link harness.

2. Turn the ignition key to the "RUN" position.

3. Open the Tool Box icon in the CDS. 4. Open the Active Diagnostics Icon.

5. Scroll down the Active Diagnostics window and highlight "Trim Limit".

6. Run the test.

7. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to store the current position in the ECU." 8. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.

Troubleshooting Procedure Troubleshooting Information NOTE: All of the following are determined by the calibration of the PCM. Upgrading the calibration can result in changes to these settings.

DEFAULT SENSOR VALUES Default sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignition values, when the sensor in question has exceeded its preprogrammed diagnostic limits. Default sensor values typically are used when the sensor has a circuit high or circuit low fault.

Most temperature sensors default to 0 °C (32 °F). This can be verified by unplugging the sensor in question and watching the data stream value with the CDS. Most pressure sensors default to a preprogrammed number also. MAP sensors usually default to 100 kPa (29.5 in. Hg). This can be verified by unplugging the sensor in question and watching the data stream value. Other pressure sensors will have their own default values which may be determined as described previously.

Page 26 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

FAULT CONDITIONS Most faults can be detected with the engine running, or key‑on, engine off. However, some faults require the presence of engine RPM, and cannot be detected key‑on, engine off. Examples of this type of fault are EST (cylinders 1 through 8) shorted circuit and all injector faults (fuel and direct).

Some faults are only detected in the key‑on, engine off mode. Examples of the type of fault would be EST (cylinders 1 through 8) open circuit.

In addition, some faults are programmed to ignore certain engine speeds. For example, the low block pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled until enough RPM has been achieved to develop a reasonable amount of water pressure. Therefore, this fault will not be set at idle.

Faults also take a certain time to set. The time it takes to set a fault varies greatly and can also vary with engine RPM. Faults generally set faster at higher engine speed.

STICKY/NON-STICKY FAULTS All faults are classified as either sticky or non‑sticky. Sticky means that the fault, once set, will continue to show up as active, even if the circuit or problem has corrected itself. A key switch cycle is required to reset a sticky fault.

A non‑sticky fault is a fault that will change it's status from active to inactive without requiring a key switch cycle.

TheCDS will continue to display a sticky fault as active, even though the cause of the fault has been corrected. Cycle the key to reset all faults if there is difficulty correcting a fault.

ENGINE GUARDIAN Almost every fault will cause the guardian program (within the PCM) to become active. The amount of guardian protection is expressed as a percentage. The higher the percentage, the more power the engine is allowed to produce. If available power is showing 100%, then guardian is not currently active and the engine is capable of producing full power. On a DTS engine, guardian closes the ETC to reduce engine power. Non‑DTS engine reduce engine power by changing injector and ignition operation.

Guardian is always accompanied by another fault or faults that actually caused the guardian to become active. The more severe the fault, the more the guardian reduces available power. A small problem, such as a non‑critical sensor going circuit high or circuit low, will result in available power of 90% depending on product line. A severe problem such as low oil pressure, or a DTS shift or throttle actuator failing, will result in forced idle which is usually displayed as 5‑6% available power.

Several minor faults occurring at the same time will cause the PCM to treat the faults as a more severe situation.

WARNING HORN SIGNALS Most faults will cause the warning horn circuit to activate. How the warning horn activates depends on how serious the problem is. There are four warning horn states: • Caution ‑ horn signal varies with product line and calibration. Minimal guardian.

• Warning ‑ horn signal varies with product line and calibration.

• Severe ‑ horn is beeping constantly.

• Critical ‑ horn is beeping constantly and guardian will be at forced idle.

In addition, depending on the gauge package, there will be warning icons and fault messages on the dash mounted gauges.

Special Tools ‑ DTS Troubleshooting Computer Diagnostic System (CDS)

Order through SPX

Breakout Box

SPX P/N MM‑46225

Terminal Test Probe Kit

SPX P/N MM‑46523

90-899883178 NOVEMBER 2007

Page 27 / 28

REMOTE CONTROLS

Page 28 / 28

SECTION - 8 12 Volt Shunt Connector

889675A01

Adapter Harness

84‑822560A5

2 to 4 Pin Harness Adapter

84‑822560A12

Adapter Harness

84‑822560A13

Male to Male 10 Pin Adapter

84‑892452A01

DMT 2004 Digital Multimeter

91‑892647A01

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

SECTION 9 - PREDELIVERY PREPARATION AND STORAGE Table of Contents Predelivery Preparation........................................................................................................................................... 4 Engine Oil..........................................................................................................................................................4 Checking .................................................................................................................................................... 4 Adding Engine Oil ...................................................................................................................................... 4 Power Steering Fluid.........................................................................................................................................5 Power Trim Pump.............................................................................................................................................. 5 Drive unit gear lube monitor..............................................................................................................................6 Filling Coolant Recovery Bottle ........................................................................................................................7 Alpha Trim Limit Switch Adjustment..................................................................................................................7 Analog Guages .......................................................................................................................................... 7 Bravo Trim Limit Switch Adjustment ‑ Analog Gauges ..................................................................................... 8 Trim Position Sender Adjustment ‑ Analog Gauges........................................................................................10 Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method...................................................11 Trim Position Sender Adjustment ‑ SmartCraft Gauges Multimeter Method...................................................12 Propeller Selection..........................................................................................................................................12 Alpha Sterndrive Propeller Installation ...........................................................................................................13 Alpha Models ........................................................................................................................................... 14 Bravo Sterndrive Propeller Installation............................................................................................................14 Bravo One Models ................................................................................................................................... 15 Bravo Two Models ................................................................................................................................... 16 Bravo Three ............................................................................................................................................. 17 Battery Connection..........................................................................................................................................18 Priming the Fuel System.................................................................................................................................18 Test Running Engine ......................................................................................................................................19 Boat Out Of the Water ............................................................................................................................. 19 Boat In the Water ..................................................................................................................................... 19 Testing Preparation ................................................................................................................................. 20 Testing .................................................................................................................................................... 21 Boat In The Water Tests.................................................................................................................................21 Engine Idle Speed ................................................................................................................................... 21 Wide Open Throttle Test .......................................................................................................................... 21 Checking Shift Operation ......................................................................................................................... 22 Flushing the Power Package................................................................................................................................. 22 Flushing Attachments .............................................................................................................................. 22 Sterndrive Water Pickups ........................................................................................................................ 23 Alternative Water Pickups ........................................................................................................................ 24 SeaCore Power Package Flushing Procedure................................................................................................25 Models Using The Sterndrive Water Pickup ............................................................................................ 25 Cold Weather or Extended Storage...................................................................................................................... 29 Preparing Power Package for Storage............................................................................................................29 Engine and Fuel System Preparation ...................................................................................................... 30 Draining the Seawater System.............................................................................................................................. 31 Drain System Identification.............................................................................................................................. 32 Air Actuated Single Point Drain System .................................................................................................. 32 Manual Single Point Drain System .......................................................................................................... 32 Three Point Manual Drain System ........................................................................................................... 33 Multi‑Point Drain (MPD) System .............................................................................................................. 33 Air‑Actuated Single‑Point Drain System.......................................................................................................... 34 Boat in the Water ..................................................................................................................................... 34

90-899883178 NOVEMBER 2007

9

Page 1 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Boat out of the Water ............................................................................................................................... 36 Manual Single‑Point Drain System.................................................................................................................. 38 Boat in the Water ..................................................................................................................................... 38 Boat out of the Water ............................................................................................................................... 39 Three Point Manual Drain System..................................................................................................................40 Boat in the Water ..................................................................................................................................... 40 Boat out of the Water ............................................................................................................................... 41 Multi‑Point Drain (MPD) System.....................................................................................................................42 Boat out of the Water ............................................................................................................................... 42 Boat in the Water ..................................................................................................................................... 44 Battery Storage...................................................................................................................................................... 46 Power Package Recommissioning........................................................................................................................ 46

Page 2 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

Lubricant, Sealant, Adhesives Tube Ref No.

Description

Where Used

Part No.

34

Special Lubricant 101

Propeller shaft splines

92-802865Q02

80

SAE Engine Oil 30W

Power trim pump

Obtain Locally

87

High Performance Gear Lubricant

Gear Lube Monitor

92-858064K01

94

Anti-Corrosion Grease

Propeller shaft splines

92-802867Q 1

95

2-4-C Marine Lubricant with Teflon

Propeller shaft splines

92-802859A1

114

Power Trim and Steering Fluid

Power steering pump Power trim pump

92-858074K01

115

Premium Plus 2-cycle TC-W3 Outboard Oil

Fuel system

92-858026K01

124

Fuel System Treatment & Stabilizer

Fuel system

858071K01

Special Tools Propeller Nut Tool

91‑805457T 1

Aids in the removal and installation of the front propeller nut.

10677

Flushing Device

91‑44357Q 2

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

9192

Flushing Kit

91‑849996T 1

Use for flushing gearcases with low water inlets.

9195

Dual Water Pick‑up Flush Gearcase Seal Kit

91‑881150K 1

Blocks off the front water inlet holes on the dual water inlet gearcases.

9194

90-899883178 NOVEMBER 2007

Page 3 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Predelivery Preparation Once the power package installation is complete, the following final steps should be taken to prepare power package for delivery to the customer. It is the boat manufacturer's responsibility to perform these procedures or to make arrangement with the dealer to have these procedures completed.

Engine Oil

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.

CHECKING 1. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water.

2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.

NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end).

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and add. Fill as necessary with specified fluid.

NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the ADD mark to the top of the OK range.

ADDING ENGINE OIL IMPORTANT: Do not overfill the engine with oil.

1. Remove oil fill cap.

a

6077

a - Oil fill cap IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

Page 4 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

3. Replace the fill cap.

Power Steering Fluid IMPORTANT: Use only specified lubricant.

IMPORTANT: Running the pump dry will damage the pump. Always check steering fluid levels before operating the boat.

1. Position sterndrive unit so that it is straight back.

2. Remove fill cap from power steering pump and check fluid level using dipstick. Add fluid as required.

NOTE: Be prepared to add fluid to pump when first starting engine.

a

b 9356

a - Fill cap

b - Dipstick

Tube Ref No.

Description

Where Used

Part No.

114

Power Trim and Steering Fluid

Power steering pump

92-858074K01

Description Dexron III ‑ Automatic Transmission Fluid

Where used

Part Number

Power steering pump

Obtain locally

Power Trim Pump 1. Check oil level with sterndrive unit in the full DOWN/IN position.

IMPORTANT: Use only specified lubricant.

90-899883178 NOVEMBER 2007

Page 5 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

2. Raise and lower sterndrive unit (to the full UP/OUT position) 6 to 10 times to purge air from system. Check oil level visually, (with drive unit in the full DOWN/IN position). Oil level should be maintained within the "MIN" and "MAX" lines on the reservoir.

a

b

c 8539

a - Fill cap (top and underneath side views) b - Reservoir fill neck

c - "MIN" and "MAX" lines

Tube Ref No.

Description

Where Used

Part No.

114

Power Trim and Steering Fluid

Power trim pump

92-858074K01

Tube Ref No.

Description

Where Used

Part No.

Power trim pump

Obtain Locally

SAE Engine Oil 30W

80

3. Check the power trim pump hose fittings for leaks. If fluid is visible at the fittings, check connections.

Drive unit gear lube monitor IMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always check oil level when drive is cool and engine is shut down.

1. Remove the gear lube monitor cap.

2. Fill the gear lube monitor to the Operating Range (full) line.

a

b

7884

Typical a - Gear lube monitor cap Tube Ref No. 87

Page 6 / 46

Description High Performance Gear Lubricant

b - Operating Range (full) line Where Used

Part No.

Gear Lube Monitor

92-858064K01

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

3. Ensure that the rubber gasket is inside the gear lube monitor cap.

4. Install the gear lube monitor cap. Do not overtighten.

5. Recheck gear lube level after first use.

Filling Coolant Recovery Bottle NOTE: This section applies to Closed Cooled models only.

1. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution.

Reinstall cap.

2. Recheck coolant level after first WOT boat test and add coolant, if necessary.

3. Maintain coolant level in coolant recovery reservoir between ADD and FULL marks with engine at normal operating temperature.

Alpha Trim Limit Switch Adjustment ANALOG GUAGES

! CAUTION Trimming the sterndrive creates pinch points, which can cause personal injury. Stay clear from the sterndrive when trimming or tilting.

IMPORTANT: Follow these procedures exactly as outlined below. Incorrect switch adjustment can cause the drive unit to move beyond the gimbal ring support flanges, causing product damage.

1. Alpha sterndrive, adjust trim limit switch as follows:

NOTE: Trim limit switch is located on the port side of gimbal ring. a.

Loosen screws and turn trim limit switch clockwise to end of slots.

a

b

b 7879

Trim limit switch a - Screws b. c.

b - Slots

Ensure drive unit is in the full DOWN/IN position.

Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON.

90-899883178 NOVEMBER 2007

Page 7 / 46

PREDELIVERY PREPARATION AND STORAGE

d.

SECTION - 9

Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.

a

7880

Trim limit switch a - Rotate Counterclockwise To Adjust

a 7881

Alpha trim cylinder extended a - Maximum520 mm (20‑3/4 in.) e.

Retighten screws when adjustment is correct.

Bravo Trim Limit Switch Adjustment ‑ Analog Gauges ! CAUTION Trimming the sterndrive creates pinch points, which can cause personal injury. Stay clear from the sterndrive when trimming or tilting.

IMPORTANT: Follow these procedures exactly as outlined below. Incorrect switch adjustment can cause the drive unit to move beyond the gimbal ring support flanges, causing product damage.

IMPORTANT: All Bravo models must have the trim‑in‑limit insert positioned properly before performing the trim position sender adjustment.

Page 8 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

1. Ensure that the trim‑in‑limit insert is positioned as shown for the appropriate Bravo model.

a

a

8548

8557

Bravo One and Two (positioned forward) a - Trim‑in‑limit insert

Bravo Three (positioned aft)

2. Bravo sterndrive, adjust trim limit switch as follows: a.

Loosen screws and turn trim limit switch clockwise to end of slots.

a

Trim limit switch

16524

a - Screws b. c.

Ensure drive unit is in the full DOWN/IN position.

Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON.

90-899883178 NOVEMBER 2007

Page 9 / 46

PREDELIVERY PREPARATION AND STORAGE

d.

SECTION - 9

Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.

a

21675

Trim limit switch a - Rotate Counterclockwise To Adjust

a 8558

Bravo trim cylinder extended a - Trim Limit Dimension 21‑3/4 in. (552 mm) e.

Retighten screws when adjustment is correct.

Trim Position Sender Adjustment ‑ Analog Gauges 1. Loosen both trim position sender retaining screws.

b

a

a - Retaining screws

21676

b - Trim position sender

IMPORTANT: Do not start the engine during this procedure.

2. Turn ignition key to RUN position.

3. Trim sterndrive unit to the full DOWN/IN position.

Page 10 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

4. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown.

a 7883

a - Trim gauge needle 5. Tighten retaining screws and turn ignition key to the OFF position.

b

a

21674

a - Retaining screws

b - Trim position sender

Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method

a

b

a - Trim position sender

21076

b - Retaining screws

1. Trim the sterndrive unit to the full DOWN/IN position.

2. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool.

90-899883178 NOVEMBER 2007

Page 11 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3.

4.

5.

6.

Turn ignition key switch to the RUN position.

Set the scan tool to display TRIM POS counts and note the value displayed.

TRIM POS counts must be between 20 and 24 counts.

If TRIM POS counts are within specified range, proceed to step 6. Otherwise: a.

Loosen both trim position sender retaining screws. b.

Rotate the trim position sender until TRIM POS counts are within the specified range, preferably near the middle of the range. c.

Tighten the trim position sender retaining screws. d.

Verify TRIM POS counts are still within the specified range. Repeat steps "a" through "c" if necessary.

7. Turn the ignition key switch to the OFF position, disconnect the scan tool from the Diagnostic Link connector, and install the weather cap in the Diagnostic Link connector.

Trim Position Sender Adjustment ‑ SmartCraft Gauges Multimeter Method

a

b

a - Trim position sender

21076

b - Retaining screws

1. Trim the sterndrive unit to the full DOWN/IN position.

2. Disconnect trim position sender wires from engine wiring harness connections.

3. Connect Multimeter leads to trim position sender wires and set Multimeter to display resistance (Ohms).

4. Note resistance reading. Resistance must be between 16 and 20 Ohms.

5. If resistance reading is within specified range, proceed to step 6. Otherwise: a.

Loosen both trim position sender retaining screws. b.

Rotate the trim position sender until resistance reading is within the specified range, preferably near the middle of the range. c.

Tighten the trim position sender retaining screws. d.

Verify resistance reading is still within the specified range. Repeat steps "a" through "c" if necessary.

6. Disconnect the trim position sender wires from the multimeter leads and reconnect trim position sender wires to engine wiring harness connections.

7. Refer to Mercury SmartCraft Operator's Manual for final Trim Calibration procedure.

Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum WOT rpm.

Use an accurate service tachometer to verify engine operating rpm.

Page 12 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. Specified engine WOT and operating rpm range are listed in the Mercury MerCruiser Operation, Maintenance and Warranty Manual attached to the engine.

Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating rpm range with a normal load.

If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch.

• Warmer weather and greater humidity cause a loss of rpm.

• Operating in a higher elevation causes a loss of rpm.

• Operating with increased load (additional passengers, pulling skiers) causes a loss of rpm.

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle when using the lower pitch propeller but not pulling skiers.

Because of the many variables of boat design, only testing will determine the best propeller for a particular application. Available propellers are listed in the Mercury Precision Parts Accessories Guide.

See BOAT IN THE WATER TESTS, Maximum RPM Test at the back of this manual.

Alpha Sterndrive Propeller Installation ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

7885

1. To aid in future removal of the propeller, liberally coat propeller shaft splines with lubricant.

Tube Ref No. 34

90-899883178 NOVEMBER 2007

Description Special Lubricant 101

Where Used

Part No.

Propeller shaft splines

92-802865Q02

Page 13 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed through propeller nut after torquing it.

ALPHA MODELS 1. Install propeller with attaching hardware as shown.

2. Torque the nut, then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer.

3. Bend the 3 tabs down into grooves.

d e a

b

f

c g

a - Propeller shaft splines b - Forward thrust hub c - Flo‑torque II drive hub d - Propeller

5301

e - Drive sleeve adapter f - Locking tab washer g - Propeller nut

Description

Nm

lb. in.

75

Alpha propeller nutAlpha propeller nut1.

lb. ft.

55

Then align tabs with grooves.

Bravo Sterndrive Propeller Installation ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

a b c 4826

a - Wood block b - Propeller

c - Propeller nut under socket

1. The propeller torque stated is the minimum torque value.

Page 14 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

BRAVO ONE MODELS IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller shaft.

1. Coat the propeller shaft spline with one of the following Quicksilver lubricants.

Tube Ref No.

Description

Where Used

Part No.

34

Special Lubricant 101

Propeller shaft splines

92-802865Q02

95

2-4-C Marine Lubricant with Teflon

Propeller shaft splines

92-802859A1

94

Anti-Corrosion Grease

Propeller shaft splines

92-802867Q 1

NOTE: Anti‑corrosion grease is for salt water applications only.

2. Install the propeller with the attaching hardware as shown.

3. Torque the propeller nut.

d e a

b

f

c g

5301

Typical Bravo One models a - Propeller shaft splines e - Drive sleeve adapter b - Forward thrust hub f - Tab washer c - Flo‑Torque II drive hub g - Propeller nut d - Propeller

a b

c d e f g

19816

Bravo One XR models a - Propeller shaft b - Propeller hub insert with snubbers c - Propeller d - Thick washer

e - Washer f - Washer g - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.

90-899883178 NOVEMBER 2007

Page 15 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Description

Nm

lb. in.

lb. ft.

Bravo One propeller nut

75

–

55

NOTE: Bravo One XR models do not use the tab washer.

4. Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.

5. Bend the three tabs down into the grooves.

a

b

c d e

4750

a - Prop b - Tab washer c - Drive sleeve adapter

d - Tab bent down e - Propeller nut

BRAVO TWO MODELS IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller shaft.

1. Coat the propeller shaft spline with one of the following Quicksilver lubricants.

Tube Ref No.

Description

Where Used

Part No.

34

Special Lubricant 101

Propeller shaft splines

92-802865Q02

95

2-4-C Marine Lubricant with Teflon

Propeller shaft splines

92-802859A1

94

Anti-Corrosion Grease

Propeller shaft splines

92-802867Q 1

NOTE: Anti‑corrosion grease is for salt water applications only.

2. Install the propeller with the attaching hardware as shown.

Page 16 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

3. Torque the propeller nut.

c d f a b e

8566

Bravo Two a - Propeller shaft splines b - Forward thrust hub c - Propeller

d - Spline washer e - Tab washer f - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.

Description

Nm

lb. in.

lb. ft.

Bravo Two propeller nut

81

–

60

4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.

5. Bend the three tabs down into the grooves.

a

b

c d e

4750

a - Prop b - Tab washer c - Drive sleeve adapter

d - Tab bent down e - Propeller nut

BRAVO THREE 1. Coat the propeller shaft spline with one of the following Quicksilver lubricants.

Tube Ref No.

Description

Where Used

Part No.

34

Special Lubricant 101

Propeller shaft splines

92-802865Q02

95

2-4-C Marine Lubricant with Teflon

Propeller shaft splines

92-802859A1

95

2-4-C Marine Lubricant with Teflon

Propeller shaft splines

92-802859A1

NOTE: Anti‑corrosion grease is for salt water applications only.

90-899883178 NOVEMBER 2007

Page 17 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

2. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.

3. Align splines and place front propeller on propeller shaft.

4. Install front propeller locknut and torque using the Propeller Nut tool.

Propeller Nut Tool

91‑805457T 1

Description

Nm

lb. in.

lb. ft.

Bravo Three front propeller nut

136

–

100

5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 6. Align splines and install aft propeller.

7. Install propeller nut and torque.

Description

Nm

lb. in.

lb. ft.

Bravo Three rear propeller nut

81

–

60

8. Install propeller shaft anode and screw and torque.

e f b

i g h

c

d

a j 5304

Bravo Three a - Rear propeller nut b - Rear propeller c - Rear propeller thrust hub d - Front propeller nut e - Front propeller

f - Front propeller thrust hub g - Propeller shaft anode screw h - Flat washer i - Star washer j - Propeller shaft anode

Description

Nm

lb. in.

lb. ft.

Propeller shaft anode screw

19

168

–

Battery Connection IMPORTANT: Engine electrical system is negative (‑) ground.

1. Ensure that all battery terminal connections are tight.

Priming the Fuel System IMPORTANT: Use a portable fuel tank with a primer bulb fuel line.

! WARNING Fuel is flammable and explosive. Ensure 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.

Page 18 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

1. Disconnect the fuel line from the fuel tank to the fuel inlet fitting and plug the line, if attached to the engine.

2. Attach portable fuel tank to the fitting and secure tightly.

3. Squeeze the primer bulb until the bulb becomes firm.

4. Turn the ignition switch to the "RUN" position for 3 seconds and then turn OFF.

NOTE: Do not turn the key switch to the "START" position during the priming.

5. Repeat Step 3. and Step 4. three more times.

IMPORTANT: Before disconnecting the fuel line primer bulb, ensure that the bulb is soft and does not still have fuel in it to prevent spilling fuel.

6. Disconnect the primer bulb fuel line from the fuel inlet fitting.

7. Remove the plug from the fuel tank fuel line.

8. Attach the fuel line from the fuel tank to the fuel inlet and tighten securely.

Test Running Engine ! WARNING Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury.

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.

BOAT OUT OF THE WATER For engine operation tests with the boat out of the water: IMPORTANT: If using a flushing attachment over the water inlet holes with a water hose, do not use full water source pressure.

1. Install a flushing attachment over the sterndrive water inlet holes.

2. Connect a hose between the flushing attachment and a water source.

3. Open the water source about 1/2 maximum. Do not use full water pressure.

IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet, need a supply of cooling water available to both the sterndrive unit and to the engine during operation.

4. On Engines With Through The Hull Water Inlet, supply sufficient cooling water to the engine.

5. Proceed to Testing Preparation.

BOAT IN THE WATER For engine operation tests with the boat in the water: IMPORTANT: If using a test tank the water level must be above the water inlet holes on the sterndrive unit or the through the hull pickup.

1. Ensure that the water level is above the water inlet holes on the sterndrive or the through the hull pickup.

2. Proceed to Testing Preparation.

90-899883178 NOVEMBER 2007

Page 19 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

TESTING PREPARATION

! WARNING Leaving the helm unattended while performing tests with the boat in the water may result in loss of boat control causing serious injury or death. Ensure someone is at the helm at all times, unless the boat is secured to a dock.

1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight.

NOTE: Refer to appropriate Mercury MerCruiser Operation, Maintenance and Warranty Manual for operating specifications. Refer to appropriate Mercury MerCruiser Service Manual for fluid capacity information.

2. Check crankcase oil level.

IMPORTANT: Oil level in monitor will rise and lower during sterndrive operation. Always check oil level when sterndrive is cool and engine is shut down.

3. Check sterndrive unit oil level in the monitor.

4. Check drive belt tension.

5. Test Audio Warning system in accordance with instructions on instrumentation panel decal.

6. Supply water to the engine either by putting boat in the water or by using the correct flush device.

IMPORTANT: If using a test tank, ensure water level is above water intake holes.

IMPORTANT: If using a flush test device, do not use full water tap pressure. During operation, do not operate the engine above 1500 RPM to ensure the engine seawater pump suction does not collapse the hose to the water source causing the engine water supply to stop.

! WARNING Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury.

5752

Low water pickup

5773

Side pickup

IMPORTANT: Engines may also use a through the hull or through the transom inlet. If so, water must be provided to these inlets or air flow must be blocked. If a block‑off plate is used, the through the transom or through the hull fitting is the only water inlet to the engine.

Page 20 / 46

Flushing Device

91‑44357Q 2

Flushing Kit

91‑849996T 1

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

TESTING 1.

2.

3.

4.

Place sterndrive in neutral , idle speed and start engine.

Slowly advance throttle until engine reaches 1300 rpm (+/‑100 rpm).

Watch all gauges for normal readings.

Turn steering wheel RIGHT/STARBOARD, then LEFT/PORT, and ensure drive unit turns the correct way.

5. Inspect engine compartment for water, oil, fuel, and exhaust leaks.

6. Turn steering wheel PORT until it stops and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes): a.

Check for an obstruction between gimbal ring and gimbal housing and all moving steering components b.

Ensure that steering lever is not contacting cutout in transom. If contact is being made, modify cutout c.

Check steering cable end dimension with cable FULLY EXTENDED. 7. Turn steering wheel STARBOARD until it stops and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes): a.

Turn off engine. b.

Remove cap/dipstick from power steering pump. Check fluid level and add if necessary.

7890

a a - Dipstick (full when hot line)

Boat In The Water Tests ENGINE IDLE SPEED Engine should idle at RPM as specified in appropriate Mercury MerCruiser Operation, Maintenance, and Warranty Manual with boat in the water, drive unit in FORWARD gear and engine at normal operating temperature. If idle speed is incorrect, proceed as follows: 1. Ensure that throttle cable has been adjusted properly.

WIDE OPEN THROTTLE TEST IMPORTANT: To operate engine at full throttle before the break‑in period is complete, follow this procedure.

1. Place remote control in neutral , idle speed and start engine.

2. Slowly advance throttle until engine reaches 1300 rpm (+/‑100 rpm).

3. Watch all gauges for normal readings.

4. When engines reaches mornal operating temperature, run the boat up on plane.

5. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM. 6. To test if the correct propeller has been installed, operate boat (with normal load on board) at WOT and check RPM with an accurate tachometer. Engine RPM should be near top of the specified range so that, under a heavy load, engine speed will not fall below specifications. If engine speed is too high, replace propeller with a higher pitch propeller. Normally a 25 mm (1 in.) propeller pitch change causes an RPM change of 150 RPM.

90-899883178 NOVEMBER 2007

Page 21 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

7. Return to idle speed.

8. Shut off engine.

9. Check coolant level and add coolant if necessary.

CHECKING SHIFT OPERATION With sterndrive unit installed and engine operating, ensure that drive unit shifts properly, as explained following: 1. Shift into FORWARD and REVERSE gear, ensuring that clutch engages before engine begins to accelerate.

2. Accelerate engine while in FORWARD and REVERSE gear to ensure that engine does not stop.

3. If the proper results are not achieved in the previous steps, shift cables must be readjusted.

4. Shifting from FORWARD and REVERSE to NEUTRAL: ensure drive unit is in NEUTRAL before remote control shift lever comes to the NEUTRAL detent position. Perform this check using various shifting rates to ensure that the drive unit shifts the same whether shifting fast or slow.

Flushing the Power Package The boat can be equipped with a combination of any of three different types of water pickups: through the hull, through the transom, and through the sterndrive. The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups.

IMPORTANT: Engines that require dual water pickups require a through‑the‑hull or through‑the‑transom pickup in addition to the sterndrive water inlets.

IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through‑the‑hull or through‑the‑transom pickup need a supply of cooling water available to both the sterndrive and to the engine during operation.

FLUSHING ATTACHMENTS

a

a

b

b

c 21514

Flushing attachments for dual water pickup a - Flushing device b - Hose attachment

Page 22 / 46

21515

Flushing attachments for side water pickup c - Dual water pickup flush gearcase seal kit

Flushing Device

91‑44357Q 2

Dual Water Pick‑up Flush Gearcase Seal Kit

91‑881150K 1

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).

5752

5773

Dual water pickup

Side water pickup

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications.

Flushing is recommended after each outing for best results.

NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine. Keep the seacock closed until starting the engine.

1. On seawater cooled models: Proceed to Step 4. or Step 5.

2. On models with the sterndrive seawater inlet blocked, supply water to the sterndrive and to the engine. See Alternative Water Pickups.

3. On models using the sterndrive seawater inlet and a through‑hull or through‑transom alternative water pickup, supply water to only the sterndrive by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet Y‑fitting. a.

If equipped with a seacock, close the seacock in the hose from the alternative water pickup. b.

If not equipped with a seacock, disconnect the hose from the alternative water pickup and plug both ends. c.

If there is not a hose running to the transom, refer to Alternative Water Pickups.

4. If flushing the cooling system with the boat in the water: a.

Raise sterndrive to trailer position. b.

Install the appropriate flushing attachment over the water inlet holes in the gear housing. c.

Lower sterndrive to full down (in) position.

5. If flushing the cooling system with the boat out of the water: a.

Lower sterndrive to full down (in) position.

! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

90-899883178 NOVEMBER 2007

Page 23 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

b.

Remove propeller. c.

Install the appropriate flushing attachment over the water inlet holes in the gear housing.

6. Connect hose between flushing attachment and water source.

7. With sterndrive in normal operating position, open the water source fully.

8. Place the remote control in the neutral idle speed position and start engine.

NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.

9. Depress the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).

10. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear.

12. Slowly return throttle to idle speed position.

13. Stop engine.

14. Shut off water and remove flushing attachment.

15. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine.

16. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.

ALTERNATIVE WATER PICKUPS IMPORTANT: Two water sources are needed for this procedure.

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications.

Flushing is recommended after each outing for best results.

IMPORTANT: Models with the sterndrive water inlet blocked off at the gimbal housing and using a through‑hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.

1. If flushing the cooling system with the boat in the water: a.

Raise sterndrive to trailer position. b.

Install the appropriate flushing attachment over the water inlet holes in the gear housing. c.

Lower sterndrive unit to full down (in) position.

2. If flushing the cooling system with the boat out of the water: a.

Lower sterndrive to full down (in) position.

! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. b.

Remove propeller. c.

Install the appropriate flushing attachment over the water inlet holes in the gear housing.

3. Connect hose between flushing attachment and water source.

4. Close the seacock, if equipped, to prevent water from siphoning into the engine or boat.

Page 24 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine or boat.

6147

6. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.

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.

7. With sterndrive in normal operating position, open the water source fully.

8. Place the remote control in neutral idle speed position and start engine.

NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.

9. Slowly advance throttle until engine reaches 1300 RPM (+/‑100 RPM).

10. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear.

12. Slowly return throttle to idle speed position.

13. Stop engine.

14. Shut off the water and remove flushing attachments.

15. If the boat is out of the water: Install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp securely.

16. If the boat is in the water: Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.

SeaCore Power Package Flushing Procedure NOTE: Flushing is needed only for salt, brackish, mineral laden or polluted water applications.

Flushing is recommended after each outing for best results.

IMPORTANT: Flushing the SeaCore power package with the boat and sterndrive in the water is less effective. Flushing the SeaCore power package is most effective when performed with the boat and sterndrive out of the water, such as on a boat lift or trailer.

MODELS USING THE STERNDRIVE WATER PICKUP IMPORTANT: The system is designed to flush the Bravo sterndrive and the engine with one water source. Do not block or remove the inlet water hose from the sterndrive to the engine.

NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: Refer to Alternative Water Pickups.

90-899883178 NOVEMBER 2007

Page 25 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends.

1. Remove the boat from the water.

2. Close the seacock, if equipped.

c a

b

d

18510

For visual clarity, the secock shown is not installed a - Hose fitting to engine c - Handle (closed position) b - Seacock d - To water source pickup attachment 3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive.

4. Ensure that the inlet water hose from the sterndrive to the engine is connected.

5. Remove the quick‑connect fitting from the parts bag supplied with the engine.

6. Attach the quick‑connect fitting to a water hose.

a

b

18487

a - Quick connect fitting (water hose end)

Page 26 / 46

b - Water hose

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine.

a b

c

18489

a - Water hose b - Quick‑connect fitting (water hose end)

c - Flush socket

8. Open the water source of the water hose to a full flow.

9. Allow the water to flush the sterndrive for 30 seconds.

10. Place the remote control in neutral idle speed position and start engine.

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.

11. Operate the engine at idle speed in neutral gear. Do not exceed 1200 RPM. 12. Monitor the engine temperature while operating the engine.

13. Flush the engine for 5 to 10 minutes or until discharge water is clear.

14. Shut off the engine.

15. Allow the water to flush the sterndrive for 10 seconds.

16. Turn off the water source.

90-899883178 NOVEMBER 2007

Page 27 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

17. Disconnect the quick‑connect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket.

a b

18488

a - Quick‑connect fitting (water hose end)

b - Flush socket release button

18. Remove the quick‑connect fitting from the water hose.

a

b

18487

a - Quick‑connect fitting (water hose end)

b - Water hose

19. Retain the quick‑connect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access.

IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty.

a

25900

Quick‑connect fitting stored in the boat a - Quick‑connect fitting (water hose end)

Page 28 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

20. Insert the dust cover in the flush socket on the engine.

a b

18490

Dust cover installed in the flush socket a - Dust cover b - Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock.

21. Open the seacock, if equipped, or reconnect the alternative water inlet source prior to operating the engine.

Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty.

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 cold weather. 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.

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.

IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

Preparing Power Package for Storage 1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline. Follow instructions on the container.

2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Mercury/ Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank.

Refer to Fuel Requirements for additional information.

90-899883178 NOVEMBER 2007

Page 29 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. Flush the cooling system. Refer to the Maintenance section.

IMPORTANT: In order to run the engine as required in the remainder of the storage preparation procedure, water must be supplied to the engine as described in the flushing procedure.

4. Provide cooling water to the engine as done in the previous step.

5. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel with Mercury/Quicksilver Gasoline Stabilizer to circulate through the fuel system. Shut off the engine.

6. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System Preparation. Perform this operation.

7. Drain the engine seawater cooling system. Refer to Draining the Seawater System.

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 cold weather. 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.

8. Ensure that the sterndrive vent holes and water drain holes and passages are unobstructed and open (refer to Draining Instructions).

9. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.

NOTICE The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.

10. Store boat with drive unit in full down/in position.

11. Store the battery according to the manufacturer's instructions.

ENGINE AND FUEL SYSTEM PREPARATION

! WARNING Fuel is flammable and explosive. Ensure 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.

! WARNING Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package.

1. In a 23 liter (6 U.S.gal.) remote fuel tank mix: a.

19 liter (5 U.S. gal) regular unleaded 87 octane (90 RON) gasoline b.

1.89 liter (2 U.S. qts.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil c.

150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System Treatment and Stabilizer Concentrate

Page 30 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE Tube Ref No.

Description

Where Used

Part No.

115

Premium Plus 2-cycle TC-W3 Outboard Oil

Fuel system

92-858026K01

124

Fuel System Treatment & Stabilizer

Fuel system

858071K01

2. Allow the engine to cool down.

IMPORTANT: Immediately wipe up any fuel spills or sprays.

3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off valve.

4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting.

IMPORTANT: Supply cooling water to the engine.

5. Start and operate the engine at 1300 rpm for 5 minutes.

6. After specified operating time is complete, slowly return throttle to idle rpm and shut engine off.

IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the engines fuel system to become completely dry.

7. Replace the water separating fuel filter element. Refer to Section 5 for proper procedure.

Draining the Seawater System ! CAUTION Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining. Do not operate the engine with the drain system open.

IMPORTANT: Only drain the seawater section of the closed‑cooling system.

IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system.

Your power package is equipped with a drain system. Refer to Drain System Identification to determine which instructions apply to your power package.

IMPORTANT: The engine must not be operating at any point during the draining procedure.

IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

90-899883178 NOVEMBER 2007

Page 31 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Drain System Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM

c a

c

b

a b d

d 6125

6124

Closed Cooled Models a - Blue drain plug location b - Blue air pump

Seawater Cooled Models c - Air manifold d - Green indicators

a b c

d d

21125

Scorpion Models a - Blue air pump b - Air manifold

c - Green indicators d - Blue drain plug locations

MANUAL SINGLE POINT DRAIN SYSTEM

b

a b 6128

a - Blue handle

Page 32 / 46

b - Blue drain plug location

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

THREE POINT MANUAL DRAIN SYSTEM

a

a

6126

a - Blue drain plug

MULTI-POINT DRAIN (MPD) SYSTEM

b

b a

M110050

93235672

10226

a

6129

a - Side of cylinder block

b - Bottom of exhaust manifolds

b a 6130

a - Water circulating pump hose

90-899883178 NOVEMBER 2007

b - Fuel cooler to thermostat housing

Page 33 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

a

6131

a - Check valve (if equipped)

Air‑Actuated Single‑Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.

1. Close the seacock (if equipped) or remove and plug the water inlet hose.

2. Remove the air pump from the engine.

3. Ensure that the lever on top of the pump is flush with the handle (horizontal).

4. Install the air pump on the actuator fitting.

5. Pull lever on air pump (vertical) to lock pump on the fitting.

c

e

a

b a - Actuator fitting b - Green indicators c - Manual release valve

d

8293

d - Air pump e - Lever (locking)

6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.

Page 34 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system.

c a

c

b

a b d

d 6125

6124

Closed Cooled Models a - Blue drain plug location b - Blue air pump

Seawater Cooled Models c - Air manifold d - Green indicators

a b c

d d

21125

Scorpion Models a - Blue air pump b - Air manifold

c - Green indicators d - Blue drain plug locations

8. Verify that water is draining from each opening. If not, use the Three Point Manual Drain System instructions.

a

b a - Port side drain location

90-899883178 NOVEMBER 2007

6133

b - Starboard side drain location

Page 35 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.

10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow engine to start.

11. Reinstall the blue drain plug in the thermostat housing or heat exchanger.

12. Remove the air pump from the air manifold and return it to the mounting bracket.

13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a 6135

a - Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.

BOAT OUT OF THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.

1. Place the boat on a lever surface to ensure complete draining of system.

2. Remove the air pump from the engine.

3. Ensure that the lever on top of the pump is flush with the handle (horizontal).

4. Install the air pump on the actuator fitting.

5. Pull lever on air pump (vertical) to lock pump on the fitting.

c

e

a

b a - Actuator fitting b - Green indicators c - Manual release valve

Page 36 / 46

d

8293

d - Air pump e - Lever (locking)

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.

c a

c

b

a b d

d 6125

6124

Closed Cooled Models a - Blue drain plug location b - Blue air pump

Seawater Cooled Models c - Air manifold d - Green indicators

a b c

d d

21125

Scorpion Models a - Blue air pump b - Air manifold

c - Green indicators d - Blue drain plug locations

7. Verify that water is draining from each opening. If not, use the Three Point Manual Drain System instructions.

a

b a - Port side drain location

90-899883178 NOVEMBER 2007

6133

b - Starboard side drain location

Page 37 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.

9. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump. Do not allow engine to start.

10. Remove the air pump from the air manifold and return it to the mounting bracket.

11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a 6135

a - Green indicators

Manual Single‑Point Drain System BOAT IN THE WATER 1. Close the seacock (if equipped) or remove and plug the water inlet hose.

2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not force the handle as this will create new threads.

3. Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system.

b a

6136

a - Blue handle

Page 38 / 46

b - Blue drain plug location

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.

b 6137

a a - Drain location ‑ orange or red

b - Blue drain plug

5. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance.

6. Reinstall the blue drain plug in the thermostat housing.

7. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads.

8. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine.

BOAT OUT OF THE WATER 1. Place the boat on a level surface to ensure complete draining of system.

2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not overtighten the handle, as this action will create new threads.

a

6141

a - Blue handle

90-899883178 NOVEMBER 2007

Page 39 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.

b a a - Drain location ‑ orange or red

6137

b - Blue drain plug

4. Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained.

5. Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug. The handle is fully seated when no red is visible. Do not overtighten handle, as this action will create new threads.

Three Point Manual Drain System BOAT IN THE WATER NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the air actuated single point drain system fails.

1. Close the seacock (if equipped) or remove and plug the water inlet hose.

2. Remove the blue drain plug from the distribution housing (lower front, port side).

a

6138

a - Blue drain plug

Page 40 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

3. To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds.

a

6139

a - Blue drain plug location 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

a

6140

a - Blue drain plugs 5. Verify that water is draining from each opening.

6. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.

7. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start.

8. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain plugs.

9. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.

BOAT OUT OF THE WATER NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails.

1. Place the boat on a level surface to ensure complete draining of the system.

90-899883178 NOVEMBER 2007

Page 41 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side).

a

a

6142

a - Blue drain plug 3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.

5. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start.

6. Prior to launching the boat or starting the engine, close the drain system by installing the three blue drain plugs.

Multi‑Point Drain (MPD) System BOAT OUT OF THE WATER 1. Place the boat on a level surface to ensure complete draining of the system.

2. Remove the blue drain plugs from the following locations. If necessary, clean out the drain holes using a stiff piece of wire. Do so until the entire system is drained. a.

Port and starboard side of cylinder block b.

Bottom of exhaust manifolds

b

b a

M110050

93235672

10226

a

6129

a - Cylinder block drain plug

Page 42 / 46

b - Exhaust manifold drain plug

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

c.

Water‑circulating pump hose

a 6143

a - Drain plug d.

Fuel‑cooler‑to‑thermostat‑housing hose

a

6144

a - Drain plug e.

Check valve

a

6131

a - Drain plug (if equipped)

90-899883178 NOVEMBER 2007

Page 43 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses.

a 6145

b a - Hose clamps

b - Blue drain plugs

4. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start.

5. After the cooling system has been drained completely, install the drain plugs, reconnect the hoses, and tighten all hose clamps securely.

BOAT IN THE WATER 1. Close the seacock (if equipped) or remove and plug the water inlet hose.

2. Remove the blue drain plugs from the following locations. If necessary, clean out the drain holes using a stiff piece of wire. Do so until the entire system is drained. a.

Port and starboard side of cylinder block b.

Bottom of exhaust manifolds

b

b a

M110050

93235672

10226

a

6129

a - Cylinder block drain plug

Page 44 / 46

b - Exhaust manifold drain plug

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

c.

Water‑circulating pump hose

a 6143

a - Drain plug d.

Fuel‑cooler‑to‑thermostat‑housing hose

a

6144

a - Drain plug e.

Check valve

a

6131

a - Drain plug (if equipped)

90-899883178 NOVEMBER 2007

Page 45 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses.

a 6145

b a - Hose clamps

b - Blue drain plugs

4. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start.

5. Before launching the boat or starting the engine, close the drain system by installing the blue drain plugs.

6. Open the seacock, if equipped, or unplug and reconnect the water inlet hose before operating the engine.

Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for storage.

Power Package Recommissioning 1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.

! 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.

2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect cables. Tighten each cable clamp securely when connecting.

3. Coat the terminal connections with a battery terminal anti‑corrosion agent.

4. Perform all the checks in the before starting column of the Operation Chart.

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.

5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly.

6. Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks.

7. Inspect the steering system, shift and throttle control for proper operation.

Page 46 / 46

90-899883178 NOVEMBER 2007