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Mercury Alpha Installation Manual

Gasoline engine sterndrive models
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See also: Owner's Manual
GASOLINE ENGINE STERNDRIVE MODELS
INSTALLATION MANUAL
Models Covered
Alpha
3.0L
4.3L
5.0L
5.7L
Bravo
4.3L
5.0L
5.7L
Notice
After completing installation, these instructions should be placed with the
product for the owner's future use.
Predelivery preparation instructions must be performed before delivering boat
to the product owner.
Page 1 of 137
Model
Model
Printed in U.S.A. -  2001, Mercury Marine
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
Mercury MerCruiser, Mercury, Mercury
Marine, Quicksilver, Ride-Guide, Thruster
and Mercury Precision Parts.
Serial Number or Year
0M093621 and Above
Serial Number or Year
0M093633 and Above
NOTICE
NOTICE
90-860172011 NOVEMBER 2001
INDEX

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  • Page 1 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. Printed in U.S.A. -  2001, Mercury Marine Page 1 of 137 90-860172011 NOVEMBER 2001...

  • Page 2: Table Of Contents

    Special Tools ......Alpha Models - Drive Unit Not Alpha Notice: Increased Trim-In Range Installed .

  • Page 3: General Information

    NOTE: Refer to the Mercury MerCruiser Product Applications Manual - Gasoline Sterndrive Models for application recommendations. This installation manual has been written and published by Mercury Marine to aid the boat manufacturer (OEM) in the installation of the products described herein.

  • Page 4: Torque Specifications

    Speedometer Pickup Barb Fitting Exhaust Pipe or Block-off Plate Power Steering Hydraulic Hose Fittings Power Trim Pump Hose Fittings Propeller Nut Alpha One, Bravo One and Bravo Two Front Propeller Nut Bravo Three Rear Propeller Nut Bravo Three Rear Engine Mounts...

  • Page 5: Lubricants / Sealants / Adhesives

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Lubricants / Sealants / Adhesives Description Where Used Part Number Coupler Splines Drive Unit Pilot Engine Coupler Spline Grease 92-816391A4 U-Joint O-rings Drive Shaft Splines Anchor Pins Trim Cylinder Hardware 2-4-C Marine Lubricant With O-ring Seals 92-825407A3 Teflon Shift Cable End...

  • Page 6: Special Tools

    91-809815A1 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.

  • Page 7: Bravo Three Notice: Trim-In Limit Insert

    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 / Quicksilver Accessories Guide for a complete listing. This Guide is available from:...

  • Page 8: Serial Number Decal Placement

    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 / Quicksilver Accessories Guide for part number.)

  • Page 9: Anti-Fouling Paint

    • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40 mm) UNPAINTED area on transom of the boat around these items.

  • Page 10: Boat Construction

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Boat Construction Transom Thickness and Surface IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts. Transom Specifications Thickness Between 2 - 2-1/4 in. (51 - 57 mm) for 8 in. (203 mm) to either side of the vertical centerline Parallelism Inner and outer surfaces must be parallel within 1/8 in.

  • Page 11: Engine Bed

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Engine Bed Difference Between Starboard and Port Engine Mount 22-1/2 in. (572 mm) Mount Adjustment Up and Down (minimum) 1/4 in. (6 mm) 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.

  • Page 12: Crankshaft Horizontal Centerline

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Crankshaft Horizontal Centerline (X-Dimension) X-Dimension can be measured by the 90 degree Tool Method or by the Tape Measure Method. 90 DEGREE TOOL METHOD 1. Construct 90 degree tool. 90° 71621 13-9/16 in. (345 mm) Measurement: 4 ft.
  • Page 13 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL TAPE MEASURE METHOD 1. Determine X-Dimension from the following chart. Transom Angle This dimension should only be raised or lowered after proper (degrees) testing. 14-5/16 in. (364 mm) 14-1/4 in. (362 mm) 14-3/16 in. (360 mm) 14-1/8 in.

  • Page 14: Transom Cutout

    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 15 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately). 90-79135--3 22056 50017 Transom Cutout Template Transom Drilling Fixture Kit 6. Follow instructions indicated on template or provided with drilling fixture. 7.

  • Page 16: Seawater Connections - General Information

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Seawater Connections - General Information This section covers through the hull and through the transom water inlets only. For informa- tion on sterndrive water inlet connections, refer to the appropriate section after engine instal- lation. IMPORTANT: Seal the inside edges of any hole made through the hull with a suitable sealant to prevent water absorption and deterioration.
  • Page 17 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL TRANSOM MOUNTED 1. Seal the inside edges of the 1-1/2 in. (38 mm) hole hose fitting. 2. Ensure that the hose fitting and plastic plug are in place and threads have been sealed prior to tightening each securely. Description Where Used Part Number...

  • Page 18: Preliminary Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL NOTE: Some installations may have 7/32 in. (5 mm) holes drilled in transom using four 5/16 in. diameter stainless steel lag bolts in place of round head screws. In any case, flat washers and O-rings are required as outlined. 72641 Water Pickup Installed on Transom Diagonal Mount - Leading Edge Of Pickup 1/8 in.

  • Page 19: Fuel Inlet Fitting

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Fuel Inlet Fitting IMPORTANT: The following information is provided to ensure proper installation of brass fittings or plugs installed into fuel pump or fuel filter base: • Use #592 Loctite Pipe Sealant with Teflon on threads of fuel inlet fittings or plugs. DO NOT USE TEFLON TAPE.

  • Page 20: Transom Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS CAUTION The electric fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together. Do not install additional fuel filters and/or water separating fuel filters between fuel tank and engine. The installation of additional filters may cause: •...

  • Page 21: Installing Inner Transom Plate

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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. IMPORTANT: Tighten the transom assembly fasteners using an X-pattern torque sequence, starting from the middle fasteners.

  • Page 22: Connecting Speedometer Pickup

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. Install the water inlet fitting and j-clip for the gear lube and the speedometer hose. 77916 Water Inlet Fitting J-clip 6. Torque J-clip fasteners. Description lb-in. lb-ft J-Clip Fasteners Connecting Speedometer Pickup CAUTION Excess water in bilge can damage engine or cause boat to sink. Do not remove plug from speedometer pickup tube fitting unless connection is to be utilized.

  • Page 23: Fluid Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 2. Apply sealant to threads of barb fitting. Install and torque the barb fitting. 70015 Barb Fitting Description Where Used Part Number Loctite 592 Speedometer Barb Fitting Obtain Locally Description lb-in. lb-ft Barb Fitting 3. Connect a 5/32 in. (4 mm) speedometer hose (not provided) hose from speedometer to barb fitting.
  • Page 24 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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. NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.

  • Page 25: Installing Steering System

    NOTE: For dual installations, power steering unit can be mounted on port or starboard transom assembly. Measure exact distance between power package centerlines. Select a tie bar from Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar installation instructions before proceeding.
  • Page 26 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. Install steering assembly as follows: a. Position steering assembly so that pivot bolts will enter bushings in pivot block or power steering control valve. b. Install upper and lower pivot bolts along with tab washers. Ensure that tab washer tangs straddle the ridge on inner transom plate.
  • Page 27 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL CAUTION MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid from the control valve ports. Wear eye protection. 7. The control valve ram may be stiff and difficult to move when you attempt to pull it out or push it in for installation.
  • Page 28 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Quicksilver Ride Guide steering cable has a self-locking coupler nut and does not require an external locking sleeve or locking plate. 22060 Self-Locking Coupler Nut CAUTION Steering cable outer casing must be free to move back and forth for steering system to function properly.
  • Page 29 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Slight feedback in the steering system could be encountered if the cable guide tube flat surfaces are not positioned vertically. 11. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical posi- tion.
  • Page 30 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL MANUAL STEERING 1. Inspect bushings for debris. Lubricate bushings with Special Lubricant 101. 22946 Manual Steering Bushings Special Lubricant 101 2. Remove shipping hardware. 3. Remove upper and lower pivot bolts and ensure threads are well lubricated with Special Lubricant 101.
  • Page 31 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL CAUTION MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid from the ports. Wear eye protection. 6. The cylinder ram may be stiff and difficult to move when you attempt to pull it out or push it in for installation.
  • Page 32 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL CAUTION Steering cable outer casing must be free to move back and forth for steering system to function properly. Do not fasten any items to steering cable. 7. Connect steering cable as follows: a. Remove shipping cap from both ends of steering cable guide tube or control valve spool.
  • Page 33 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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.
  • Page 34 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 21435 Coupler Nut - 7/8 - 14 UNF - 28 Thread 11-3/4 in. (298 mm) Minimum Interface Point 1/2 in. (12.7 mm) Maximum 27/64 in. (10.7 mm) Minimum Flat 7/64 in. (3.1 mm) Minimum Radius 5/8 in.

  • Page 35: Transom Preparation

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Transom Preparation IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches and O-ring must be properly seated in groove or water and exhaust may leak into boat. 22059 Gimbal Housing Mating Surface O-ring...
  • Page 36 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 3. Through the Prop Exhaust Models: Install exhaust pipe assembly as shown, using four bolts and lockwashers. Torque bolts. 50684 Exhaust Pipe Bolts And Lockwashers (4) Description lb-in. lb-ft Bolts 4. Through the Transom Exhaust Models: Install block-off plate as shown, using four bolts and lockwashers.
  • Page 37 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. Position rear engine mount attaching hardware on inner transom plate mounts as shown. 50634 22054 3.0L Models Exhaust Pipe Bolts and Lockwashers (4) 50628 Fiber Washers Double-Wound Lockwashers Locknuts 90-860172011 Page 37 of 137...
  • Page 38 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL BRAVO MODELS 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.

  • Page 39: Driveshaft Extension Models

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Driveshaft Extension Models If your power package is equipped with a driveshaft extension, refer to the Driveshaft Extension Installation Instructions included with your engine package. Engine Preparation 1. Remove and read all tags attached to engine. 2.

  • Page 40: Engine Installation

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Engine Installation NOTE: An engine mount drilling fixture (91-806794A1) can be used to align and adjust engine mounts. Refer to instructions with fixture for proper use. 1. Remove the engine cover. 2. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended.
  • Page 41 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. Line up the intermediate elbows with the exhaust tubes. 6. Spray lubricant into the exhaust tubes to assist with intermediate elbow installation into exhaust tubes. 50635 50682 3.0L Models Typical V6 And V8 Models Bullhorn Intermediate Elbow Exhaust Tube...
  • Page 42 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL e. Push oil drain hose through flange into boat hull. Install bilge drain plug in hull. 8. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tube with intermediate elbows. 9. Install both rear engine mounting bolts and hardware and torque. Do not relieve hoist tension.

  • Page 43: Exhaust System

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Exhaust System CAUTION It is the responsibility of the boat manufacturer or installing dealer to properly lo- cate the engine and install the exhaust system. Improper installation may allow wa- ter to enter the exhaust manifolds and combustion chambers and severely damage the engine.
  • Page 44 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. On applications with through the propeller exhaust: Proceed to Step 7. 6. On applications with through the hull or through the transom exhaust: a. Move load weight to bow to simulate greatest bow-down attitude the boat will encounter in normal operation.
  • Page 45 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 9. If measurements are less than specified, exhaust elbow risers must be installed to achieve proper dimension. 77991 Typical Riser Installation Exhaust Elbow Restrictor Gasket Riser Open Gasket (4 Slots) Exhaust Manifold NOTE: Up to a maximum of 9 in. (229 mm) of riser height can be added. 90-860172011 Page 45 of 137...

  • Page 46: Methods For Measuring Exhaust Elbow Height

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Methods for Measuring Exhaust Elbow Height STRAIGHT EDGE METHOD 1. Place a straight edge across boat. 2. With the straight edge above the engine as shown, measure the distance between the straight edge and the top of the exhaust elbow. 3.
  • Page 47 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL CLEAR HOSE METHOD 1. Obtain a 5/16 - 3/8 in. (8-10 mm) long hose approximately 15 ft. (4.5 m) long. Put a metal fitting or a weight on one end of the hose to keep that end of the hose below the water line.

  • Page 48: Exhaust System Hose / Tube Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Exhaust System Hose / Tube Connections CAUTION Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots which could eventually result in burned-through exhaust hoses. Exhaust hoses and/or tubes must be cor- rectly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow.

  • Page 49: Engine Alignment

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Engine Alignment 1. Ensure that the dust cover is removed or folded back out of the way. 22027 Dust Cover CAUTION DO NOT use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Alignment Tool may cause improper alignment and damage to gimbal bearing and/or engine coupler.
  • Page 50 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 4. Repeat step 3. until the alignment tool installs easily (SLIDES FREELY WITH TWO FINGERS) all the way into and out of engine coupler splines. Do not check by turning the alignment tool. 22029 Alignment Tool (Use Only Recommended Alignment Tool) Insert This End Of Alignment Tool Through Gimbal Housing Assembly 27647 Alignment Tool...
  • Page 51 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Finished boat stringer must position engine so that a minimum mount adjustment exists after front mount is adjusted down to stringer. This allows for future adjustments. 5. 3.0L Center Mount Model: a. Set the engine on the stringer. b.
  • Page 52 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required to align engine. 6. All Other Models: a. Adjust front engine mounts until they rest on boat stringers. b. Relieve hoist tension entirely and fasten both front mounts to boat stringer using ap- propriate hardware.

  • Page 53: Hot Water Heater Installation

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 7. Recheck alignment with alignment tool. Tool must enter coupling splines freely. If not, readjust front mounts. 8. When alignment is correct, tighten locknut securely. Recheck alignment. 9. Bend tab down on adjusting nut. 10. Remove alignment tool. If not installing drive, fold bell housing dust cover flap back into place and tape shut for boat shipment.
  • Page 54 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 74973 75473 Seawater Cooling - If Location Is Available Location For Hot Water Supply 71758 Seawater Cooling - Alternate Location Location For Hot Water Supply 74639 Closed Cooling Models - If Location Is Available Location for Hot Water Supply (Bayonet Fitting Replaces Brass Plug) Thermostat Housing Page 54 of 137 90-860172011...

  • Page 55: Electrical Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL RETURN HOSE CONNECTION 73572 Typical 3.0L Location For Hot Water Return (T-Fitting Installed in Water Circulating Pump Hose) 75480 Seawater or Closed Cooling System Location For Hot Water Return Electrical Connections IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts.

  • Page 56: Instrumentation Connections

    We recommend the use of Quicksilver Instrumentation and Wiring Harnesses. On dual sta- tion applications, oil pressure and water temperature senders (on engine) must be changed. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for selection. The 4 basic gauges that must be used with the engine are: •...

  • Page 57: Trim Position Sender Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Trim Position Sender Connections 1. Connect trim position sender wires (from transom assembly) to engine harness. ORG/WHT 74029 Engine Harness Bullet Connector Transom Assembly Bullet Connector MerCathode Connections (If Equipped) 1. Connect wires to MerCathode controller assembly as shown. Apply a thin coat of Liquid Neoprene to all connections.

  • Page 58: Audio Warning System Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Audio Warning System Connections WARNING Alarm is not external ignition-proof, therefore, DO NOT mount alarm in engine or fuel tank compartments. 1. Select a location for audio warning alarm which meets all of the following: •...

  • Page 59: Power Trim Pump Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Power Trim Pump Connections IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking out of system. Be careful not to cross-thread or overtighten hose fittings. 1. Connect hydraulic hoses to trim pump. Torque fittings. Description lb-in.
  • Page 60 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 4. Unscrew fill cap and remove cap plug from fill neck and discard. Install fill cap. 50630 Caplug Fill Cap 5. Connect power trim pump wires to battery. 76631 Positive Battery Lead Negative Battery Lead Page 60 of 137 90-860172011...

  • Page 61: Fluid Connections

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Fluid Connections Gear Lube Monitor Hose IMPORTANT: Avoid using excessive hose when routing it to gear lube monitor. Hose should be routed directly to oil reservoir in as straight a line as possible to avoid low spots (traps) in the system.

  • Page 62: Power Steering Hoses

    3. Use extra hose clips to secure hose to transom. NOTE: Power Steering Fluid can be added at this point, if desired. Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups 1. Connect water hose to water inlet fitting.

  • Page 63: Alpha Or Bravo Models Using Alternative Water Pickups

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Alpha or Bravo Models Using 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.
  • Page 64 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 3. Install the block-off plate with new gasket. Secure with screws and lockwashers. Torque the screws. 75314 75313 Block-Off Plate Gasket Screw Lockwasher Description lb-in. lb-ft Screw, Water Fitting 4. 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.
  • Page 65 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL WARNING Avoid water leakage into boat. Damage to U-joint bellows could result in water entering the boat. Do not damage the U-joint bellows when removing a section of the water hose attached between the gimbal housing and bell housing. NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose.

  • Page 66: Coolant Recovery System

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Coolant Recovery System CAUTION Avoid engine overheating and subsequent damage to engine. The coolant recovery system will not operate properly without proper sealing. Plastic tubing MUST seal completely at connections. 1. Connect plastic tubing to bayonet fitting on heat exchanger. Secure with tubing clamp provided.

  • Page 67: Shift Cable Installation

    2-7/8 in. (73 mm) to 3-1/8 in. (80 mm) with a 15-20 lb. (6.8-9 kg) 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.
  • Page 68 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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 69 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Use the following procedure to temporarily install shift cables if boat will be shipped without drive unit installed. Refer to Shift Cable Installation for shift cable adjustment procedure once drive unit is installed. 1. Remove shift cable attaching hardware. 50308 Cotter Pin Clevis Pin And Cotter Pin...
  • Page 70 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 4. Remove remote control shift cable and shift assist assembly. IMPORTANT: Install the cotter pin through the top of the barrel retainer. 5. Install drive unit shift cable as shown. Secure brass barrel in barrel retainer with cotter pin and spread both prongs.
  • Page 71 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 6. Install remote control shift cable (with or without shift assist assembly as applicable) and secure with hardware as shown. Tighten locknut finger tight only and do not spread cotter pin completely. (Remote control shift cable fasteners will have to be removed again to properly adjust shift cables under Shift Cable Installation section of this manual.) 50308...

  • Page 72: Bravo Models

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Bravo Models NOTE: Using Adjustment Tool (91-12427), shift cables can be adjusted without or with the sterndrive installed, using the following procedure. IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control. •...
  • Page 73 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 4. Install sterndrive unit shift cable. 5. Tighten locknut until it contacts and then loosen 1/2 turn. 6. Insert cotter pin from top and spread ends. 71658 Washers (2) Locknut Cotter Pin 7. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place, using a piece of tape over the barrel retainer.
  • Page 74 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 9. Temporarily install control cable end guide into shift lever and insert anchor pin. 10. 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. CAUTION DO NOT attempt to install or remove control cable barrel from stud without first re- moving end guide anchor pin from shift lever and removing cable.
  • Page 75 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 16. Remove adjustment tool. 17. Shift remote control lever into full FORWARD position. Place end of adjustment tool in barrel retainer. RH rotation Bravo One, Two and Three Models: Rear slot in tool should fit over shift lever stud.

  • Page 76: Throttle Cable Installation And Adjustment

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Throttle Cable Installation and Adjustment 1. Place remote control handle(s) in neutral/idle position. IMPORTANT: Be sure that cable is routed to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.

  • Page 77: Sterndrive Unit Installation

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Sterndrive Unit Installation 1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.) 2. Remove gear lube monitor cap. Fill with lubricant. 77108 Gear Lube Monitor Description Where Used Part Number...
  • Page 78 GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing drive unit or water may leak into boat. 7. Alpha Models: Ensure that rubber gasket and water passage O-ring are properly positioned in bell housing. 75531...

  • Page 79: Alpha Models

    9. Ensure drive shaft bellows are clean and free of debris. 72472 Drive Shaft Bellows Alpha Models 1. 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.
  • Page 80 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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. 2. Engage shift shaft roller into shift shaft lever. Snap the Shift Shaft Slide Stabilizer Tool onto stud directly below shift slide and position as shown.
  • Page 81 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” 4. Place gasket on bell housing. 70010 Gasket 5.

  • Page 82: Bravo Models

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL e. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align U-joint shaft splines with engine coupler splines. Then slide drive unit all the way into bell housing. Secure drive unit to bell housings using fasteners as shown. Torque the fasteners.
  • Page 83 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 2. Pull out shift linkage as far as it moves. Jaws will open. 72460 Shift Linkage IMPORTANT: As sterndrive is inserted into sterndrive unit, entry of the bell housing shift cable must be closely checked to make sure cable enters the jaws of shift linkage assembly in the sterndrive.
  • Page 84 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: If Bell Housing Shift Cable does not line up to properly enter jaws of shift linkage assembly, cable will have to be aligned manually. 72457 Shift Linkage Assembly Shift Cable 4. Place drive shaft housing in position on bell housing and install sterndrive unit, as follows: a.
  • Page 85 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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. 6. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model.

  • Page 86: All Models

    1. Install trim cylinders on aft end of sterndrive unit with hardware as shown. 2. Install plastic caps and tighten hand tight only. NOTE: Upon installation of hardware apply lubricant to all components except plastic caps. b c d 70026 70027 Alpha Models Aft Anchor Pin Bushings Flat Washers E-ring Clips Plastic Caps...

  • Page 87: Speedometer Connection

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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.

  • Page 88: Bravo Models

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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.

  • Page 89: Shift Cable Installation

    GASOLINE STERNDRIVE INSTALLATION MANUAL Shift Cable Installation Alpha Models - Drive Unit Installed IMPORTANT: Shift cable adjustment for a right hand (RH) rotation drive unit is different than the procedure for adjusting a left hand (LH) rotation drive unit. Be sure to refer to the appropriate procedure when performing the following steps.
  • Page 90 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 3. Shift remote control as stated in a. or b. following: a. Right Hand (RH) Rotation Drive Unit - FORWARD gear, past detent, into WOT position. b. Left Hand (LH) Rotation Drive Unit - REVERSE gear, past detent, into WOT position.
  • Page 91 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 5. Lightly pull on remote control shift cable end guide (to remove slack from remote control and cable) and adjust brass barrel as necessary to align attaching points with shift lever clevis pin hole and stud. Be sure to maintain light pressure on drive unit shift cable. 50309 End Guide Brass Barrel...
  • Page 92 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 8. To ensure full clutch engagement, simultaneously rotate propeller shaft CLOCKWISE until shaft stops. 22267 Propeller Shaft - Rotate CLOCKWISE 9. Check shift cutout switch plunger position. Pin must be centered. 75435 Shift Cutout Switch Plunger Pin 10.
  • Page 93 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 11. After remote control shift cable has been properly adjusted, reinstall cable and shift assist assembly (if applicable) and secure with hardware as shown. If shift assist assembly attaching points will not align, push in or pull out on end of shift assist assembly to install.
  • Page 94 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: If an extra long remote control shift cable is used, there are a large number of bends in remote control shift cable or remote control has inadequate output travel, an additional adjustment may be necessary. Refer to step 12. or 13. as applicable.

  • Page 95: Troubleshooting Shift Problems

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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, make sure that the cables have enough clearance to operate.
  • Page 96 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and grease it with 2-4-C Marine Lubricant with Teflon. Move it back and forth to allow even distribution of the grease. 22005 Description Where Used...
  • Page 97 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows: 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.

  • Page 98: Predelivery Preparation

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 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.

  • Page 99: Filling Coolant Recovery Bottle

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Filling Coolant Recovery Bottle 1. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution. Reinstall cap. 2. Recheck coolant level after first open-throttle boat test and add coolant, if necessary. 3.

  • Page 100: Trim Position Sender Adjustment

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Trim Position Sender Adjustment ANALOG GAUGES 1. Loosen both trim position sender retaining screws. 71220 Retaining Screws Trim Position Sender CAUTION DO NOT start engine in the following step or damage to sterndrive unit and engine could result from lack of cooling water.

  • Page 101: Propeller Selection

    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 / Quicksilver Accessories Guide. See BOAT IN THE WATER TESTS, Maximum RPM Test at the back of this manual.

  • Page 102: Propeller Installation

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL ENGINE REV-LIMITER IMPORTANT: The engines listed in the following chart are equipped with a rpm rev-limiter that is set to an upper (or limited) rpm amount. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine rpm.
  • Page 103 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. Torque the nut, then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer. Bend the 3 tabs down into grooves.
  • Page 104 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL BRAVO ONE AND TWO IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. 1. Install propeller with attaching hardware as shown. 2. Apply lubricant on splines of propeller shaft. 3. Torque the nut, then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer.
  • Page 105 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL BRAVO THREE IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. 1. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub. 2. Align splines and place front propeller on propeller shaft. 3.

  • Page 106: Battery

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Battery IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations.

  • Page 107: Test Running Engine

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL BATTERY 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.
  • Page 108 Do not leave helm unattended when making test with boat in the water. 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.
  • Page 109 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL WARNING If engine is to be tested with boat out of water, the propeller must be removed to avoid injury. IMPORTANT: If using a test tank, ensure water level is above water intake holes. 70082 Minimum Water Level Water Intake Holes CAUTION...
  • Page 110 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 7. Start engine and run at idle rpm until water temperature is normal. 8. Watch all gauges for normal readings. 9. Turn steering wheel RIGHT/STARBOARD, then LEFT/PORT, and ensure drive unit turns the correct way. 10.

  • Page 111: Boat In The Water Tests

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Boat In The Water Tests ENGINE IDLE SPEED - 3.0L MODELS WARNING DO NOT leave helm unattended while performing idle speed adjustment. Boat MUST BE moving forward (not tied to the dock) when setting idle speed. 1.
  • Page 112 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL WIDE-OPEN-THROTTLE TEST IMPORTANT: To run engine at full throttle before the break-in period is complete, follow this procedure. 1. Start engine and run at idle rpm until normal operating temperature is reached. 2. Run boat up on plane. 3.
  • Page 113 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL CHECKING SHIFT OPERATION With sterndrive unit installed and engine running, ensure that drive unit shifts properly, as explained following: 1. Shift into FORWARD and REVERSE gear, making sure that clutch engages before engine begins to accelerate. 2.

  • Page 114: Cold Weather And Extended Storage

    “set” if unit is stored in raised position and may fail when unit is returned to service. IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage.

  • Page 115: 3.0L Single Point Drain

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 3.0L Single Point Drain CAUTION Ensure bilge pump is operating before beginning procedures. Excess water in bilge can damage engine or cause boat to sink. CAUTION Allow engine to cool down before disconnecting blue drain hoses. Engine water temperature can exceed 160°...
  • Page 116 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 4. Push down on T-handle to force the blue drain hoses below their connection points to the block. 76244 Connection Points 5. Ensure water is draining from both blue drain hoses. If water is not draining from one or both blue drain hoses, go to “Clearing Clogged Blue Drain Hoses.”...
  • Page 117 Steps 7 - 9 in “3.0L Single Point Drain.” The unit will need to be serviced by an authorized Mercury MerCruiser dealer. If water is draining, return to Step 4 of “3.0L Single Point Drain.”...
  • Page 118 Steps 7 - 9 in “3.0L Single Point Drain.” The unit will need to be serviced by an authorized Mercury MerCruiser dealer. If water is draining, return to Step 3 of “3.0L Single Point Drain.”...

  • Page 119: V6 And V8 Seawater (Raw-Water) Cooled Models

    Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. 1. Ensure engine is as level as possible to ensure complete draining of cooling system.
  • Page 120 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. 4.
  • Page 121 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 122: V6 And V8 Closed Cooled Models

    Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. IMPORTANT: Closed cooling section must be kept filled year-round with recom- mended coolant.
  • Page 123 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. 1. Ensure engine is as level as possible to ensure complete draining of cooling system. 2. Remove drain plug(s) from bottom of exhaust manifold(s). 3.

  • Page 124: All Models

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL 7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. DO NOT allow engine to start. 8. Make sure gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed.
  • Page 125 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL THIS PAGE IS INTENTIONALLY BLANK 90-860172011 Page 125 of 137...

  • Page 126: Wiring Diagrams

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Wiring Diagrams Instrumentation SINGLE STATION INSTALLATIONS - TYPICAL BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW...
  • Page 127 INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Refer to gauge manufacturer’s instructions for specific connections. NOTE: Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection. NOTE: Power for a Fused Accessory Panel May Be Taken from This Connection. Load Must Not Exceed 40 Amps.

  • Page 128: Power Trim System

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Power Trim System BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN 73962 WHT = WHITE YEL = YELLOW LT OR LIT = LIGHT 20 Amp Fuse...

  • Page 129: Mercathode System Wiring Diagram

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL MerCathode System Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LT OR LIT = LIGHT DRK = DARK...

  • Page 130: Mcm Gasoline Engine Wiring Diagrams

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL MCM Gasoline Engine Wiring Diagrams 3.0L Engines BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT...

  • Page 131: Mcm 4.3L, 5.0L And 5.7L Alpha Engines

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL MCM 4.3L, 5.0L And 5.7L Alpha Engines BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN...

  • Page 132: Mcm 4.3L Bravo Engines

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL MCM 4.3L Bravo Engines BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT DRK = DARK...

  • Page 133: Mcm 5.0L And 5.7L Bravo Engines

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL MCM 5.0L and 5.7L Bravo Engines BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT...

  • Page 134: Water Flow Diagrams

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Water Flow Diagrams 181 cid / 3.0L Engines Engine Circulating Pump Thermostat Housing Intake and Exhaust Manifold Exhaust Elbow Power Steering Cooler (If Equipped) Seawater Intake (From Sterndrive) Engine Block and Cylinder Head Assembly “A” Water Flow With Thermostat Closed “B”...

  • Page 135: V8 Engines - Seawater Cooled

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL V8 Engines - Seawater Cooled 262 CID, 305 CID AND 350 CID ENGINES NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water flow paths remain similar on all engines. 77992 Seawater Intake (From Sterndrive) Seawater Pump (Bravo Models)

  • Page 136: V6 And V8 Engines - Closed Cooled

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL V6 and V8 Engines - Closed Cooled NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water and coolant flow paths remain similar on all engines. 75005 Seawater Intake (From Sterndrive) Power Steering Cooler...

  • Page 137: Predelivery Inspection

    INDEX GASOLINE STERNDRIVE INSTALLATION MANUAL Predelivery Inspection Check/ Check/ Applicable Adjust Applicable Adjust CHECK BEFORE RUNNING ON THE WATER TEST Drain plug in and petcocks Engine alignment (Inboards only) closed Seawater inlet valve open Starter neutral safety switch operation Engine mounts tight Water pump operation Engine alignment Instruments(s) operation...

This manual is also suitable for:

BravoMercruiser alpha 3.0lMercruiser bravo 4.3lMercruiser bravo 5.0lMercruiser bravo 5.7l

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