GASOLINE ENGINES SKI MODELS

Transcription

1 The following re registered trdemrks of Brunswick Corportion: Merc, MerCthode, MerCruiser, Mercury, Mercury Mrine, Quicksilver, nd Ride-Guide. NOTICE to INSTALLER After Completing Instlltion, These Instructions Should Be Plced With The Product For The Owner s Future Use. NOTICE to COMMISSIONING DEALER Predelivery Preprtion Instructions Must Be Performed Before Delivering Bot To The Product Owner. Tble of Contents Generl Informtion Notice to Bot Mnufcturer/Instller Quicksilver Products Instlltion Products Torque Specifictions Seril Number Decl Plcement Fuel Octne Requirements Sticker Engine Rottion Trnsmission Instlltion Requirements Bot Construction Exhust System Fuel Delivery System Bttery Bttery Cbles EFI Electricl System Precutions Instrumenttion Propeller Selection Throttle/Shift Remote Control nd Cbles Sewter Connections - Generl Informtion Hot Wter Heter Instlltion Informtion.. 18 Engine Instlltion Bttery Cble Connection Engine Mount Pre-Adjustment Initil Engine Alignment Finl Engine Alignment Sewter Pickup Pump Connection Throttle/Shift Cble Fuel Supply Connection Audio Wrning System Electricl Connections Exhust System Hoses/Tubes Connection Predelivery Preprtion Bttery Connection Test Running Engine Bot-In-The-Wter Tests Cold Wether or Extended Storge Drining Instructions Quicksilver Instrumenttion Wiring Digrms MIE Gsoline Engine Wiring Digrms MIE Wter Flow Digrm Predelivery Inspection APRIL 2000 Printed in U.S.A , Mercury Mrine Pge 1 of 48

2 THIS PAGE IS INTENTIONALLY BLANK Pge 2 of 48

3 Generl Informtion Notice to Bot Mnufcturer/Instller Throughout this publiction, Wrnings nd Cutions (ccompnied by the Interntionl Hzrd Symbol! ) re used to lert the mnufcturer / instller to specil instructions concerning prticulr service or opertion tht my be hzrdous if performed incorrectly or crelessly Observe Them Crefully! These Sfety Alerts, lone, cnnot eliminte the hzrds tht they signl. Strict complince to these specil instructions when performing the service, plus common sense opertion, re mjor ccident prevention mesures. WARNING Hzrds or unsfe prctices which COULD result in severe personl injury or deth. CAUTION Hzrds or unsfe prctices which could result in minor personl injury or product or property dmge. IMPORTANT: Indictes informtion or instructions tht re necessry for proper instlltion nd/or opertion. This instlltion requirements mnul hs been written nd published by Mercury Mrine to id the bot mnufcturer involved in the ppliction nd instlltion of the products described herein. It is ssumed tht these personnel re fmilir with mrine product ppliction nd the instlltion procedures of these products, or like or similr products mnufctured nd mrketed by Mercury Mrine. Furthermore, it is ssumed tht they re fmilir with, if not trined in, the recommended instlltion procedures of these products. It is the responsibility of the OEM to select the pproprite engine/trnsom/drive pckge (including the correct ger rtio nd propeller) for given bot. Mking n pproprite selection requires knowledge of the bot (weight, length, hull design, intended use nd duty cycle, desired speed, etc.) tht is uniquely in the possession of the OEM. While Mercury employs people cpble of ssisting the OEM on such issues, the finl decision rests with the OEM. Mercury recommends tht ny new or unique hull/power pckge combintion be thoroughly wter tested prior to sle, to verify (mong other things) tht the bot performs s desired, nd tht the engine runs in the pproprite rpm rnge. We could not possibly know of nd dvise the mrine trde of ll conceivble pplictions nd instlltions which might be chieved, nd of the possible hzrds nd/or results of ech conceivble ppliction or instlltion. We hve not undertken ny such wide evlution. Therefore, ny mnufcturer which, or person who, pplies or instlls the product in mnner which does not fulfil the requirements listed herein, first must completely stisfy themselves tht neither their sfety nor the product will be endngered by the ppliction or instlltion procedure selected. It is recommended tht Mercury Mrine Field Product Engineer be contcted for ssistnce if specific ppliction or instlltion problems re encountered. All informtion, illustrtions, nd specifictions contined in this mnul re bsed on the ltest product informtion vilble t time of publiction. As required, revisions to this mnul will be sent to ll OEM bot compnies. Pge 3 of 48

4 Quicksilver Products Instlltion Products Torque Specifictions Quicksilver guges, remote controls, steering systems, propeller shft couplers, etc. re vilble for this product. Refer to Quicksilver Accessories Guide for complete listing. This Guide is vilble from: Attn: Prts Deprtment Mercury Mrine W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Quicksilver 2-4-C Mrine Lubricnt with Teflon A3 Quicksilver Liquid Neoprene Quicksilver Perfect Sel DESCRIPTION lb. in. lb. ft. N m Engine Mount Brcket Screw Trunnion Clmping Screw nd Nut Propeller Shft Coupling Screw nd Nut Exhust Mnifold Screw Fuel Line Inlet Fitting See Note. Note: Refer to Fuel Delivery System - Specil Informtion For All Gsoline Engines. Seril Number Decl Plcement Engine Rottion There re three engine seril number decl strips provided with ech power pckge. One should be used for ech of the following: Engine Specifiction Decl Wrrnty Registrtion Crd Opertion, Mintennce nd Wrrnty Mnul identifiction pge. Engine rottion is described when observed from the rer of the engine (trnsmission end) looking forwrd (wter pump end). Engine rottion is indicted on engine specifictions nd seril number decl. Pge 4 of 48

5 Trnsmission IDENTIFICATION Velvet Drive Trnsmissions On Velvet Drive In-Line Trnsmissions the ger rtio (in forwrd ger) is mrked on trnsmission identifiction plte. Trnsmission output shft rottion nd propeller rottion required (in forwrd ger) is indicted on decl on trnsmission cse. Trnsmission rottion is described when viewed from the rer of trnsmission. c b Propeller Rottion -Trnsmission Identifiction Plte b-ger Rtio (in Forwrd Ger) c -Output Flnge Rottion Decl (in Forwrd Ger) Propeller rottion is not necessrily the sme s engine rottion. Refer to the pproprite following informtion nd drwings for specific informtion. IMPORTANT: Use of proper rottion propeller (specified on trnsmission output flnge rottion decl) is criticl since the trnsmission must be operted in forwrd ger selector position only to drive bot forwrd. If the wrong rottion propeller is instlled nd trnsmission is operted in reverse to propel the bot forwrd, trnsmission filure WILL occur. On engines which re equipped with Velvet Drive in-line, LH propeller is required. Pge 5 of 48

6 ENGINE/PROPELLER SHAFT INSTALLATION ANGLE COUPLING PROPELLER SHAFT DIAMETER The trnsmission nd engine should be mounted so tht the ngle reltive to horizontl is s shown in the instlltion drwings. Refer to individul instlltion drwings for ech specific engine nd trnsmission. Reltive to horizontl, never instll the engine with the front (pulley end) down. IMPORTANT: On ll engines, high ngle of instlltion [front (pulley end) of engine up] long with low trnsmission oil levels cn permit trnsmission pump cvittion on some models when operting in rough wter. The coupling is flnge type coupler (vilble through Quicksilver Accessories). All coupler bolts must be SAE Grde 8 (Metric Grde 10.9) or better, with shoulder (grip length) long enough to pss through the fce mting plne of couplers. All coupler bolts must be torqued to 50 lb. ft. (68 N m). Propeller shft dimeter should be of sufficient size for the type of ppliction. Instlltion Requirements Bot Construction ENGINE BED ENGINE COMPARTMENT Distnce between strbord nd port engine mount is 22-1/2 in. (572 mm). Engine bed must position engine so tht minimum of 1/4 in. (6 mm) up nd down djustment still exists on ll 4 mounts fter performing finl engine lignment. This is necessry to llow for religning engine in the future. NOTE: Although the engine mounts llow some djustment, it is good prctice to ensure tht the front nd rer mount loctions in the vessel re in prllel plnes. This my be checked by tying string from the left front mount loction to the right rer mount loction nd nother from right front to left rer. The strings should touch where they cross. WARNING Boting stndrds (NMMA, ABYC, etc.) nd Cost Gurd regultions must be dhered to when constructing the engine comprtment. Cre must be exercised in the design nd construction of the engine comprtment. Sems must be locted so tht ny rin wter tht my lek through the sems is directed wy from the ir intke system. Wter tht runs onto the ir intke my enter the engine nd cuse serious dmge to internl engine prts. Pge 6 of 48

7 Over the lst severl yers, engine comprtments hve been designed to be quieter. The most common mteril used to deden the engine sound is some type of insultion mteril. Normlly, the quieter the engine comprtment is, the more insultion mteril used, which results in less ir spce inside. The less ir spce inside the engine comprtment, the hotter the inside ir temperture. Attention must be given to the ir temperture tht is inside this engine comprtment while the engine is running or fter period of time fter the engine is shut off (het sok). Refer to the following informtion on Engine Comprtment Ventiltion. ENGINE COMPARTMENT VENTILATION Generl Informtion According to Boting stndrds (NMMA, ABYC, etc.) nd Cost Gurd regultions the engine comprtment ventiltion system hs multiple tsks. Included re the following: 1. To supply the engine with combustion ir. 2. To mintin low temperture in the engine comprtment. Fresh ir should enter the engine comprtment s low s possible nd the heted ir should be dischrged from the highest point. When sufficient ventiltion is not provided, too much het cn build-up inside of engine comprtment nd cuse vpor locking. The engine will not wnt to restrt fter it hs been shut off for short period of time. If it does restrt, the engine will quit when given the throttle to get the bot up on plne or to pull up wter skier. For engines utilizing fuels contining lcohol nd the newer reformulted gsolines (See OEM Service Bulletin 95-2), proper ventiltion is more criticl to prevent vpor locking. If seprte ir shft (or similr) is used to provide engine comprtment ventiltion or dditionl ventiltion, cre must be tken to prevent sewter nd spry from entering it. Combustion Air Requirements Engine comprtments with nturl drft ventiltion must hve vent openings of sufficient size nd loction to ccomplish the tsks previously outlined. IMPORTANT: The size of ventiltion openings must be incresed if ny uxiliry equipment is locted in the engine comprtment. The combustion ir requirement (per engine) for the specified engines t Wide Open Throttle re given in the chrt below: Engine Air Flow Requirements (Per Engine) Model Engine Air Requirements t Wide Open Throttle 5.7L 486 ft. 3 /Min. (0.229 m 3 /sec.) 350 Mg MPI 506 ft. 3 /Min. (0.239 m 3 /sec.) MX 6.2L MPI 568 ft 3/ Min. (0.268 m 3 /sec.) Blck Scorpion 527 ft. 3 /Min. (0.249 m 3 /sec.) Physicl Volume 5.3 ft. 3 (150 L) 5.3 ft. 3 (150 L) 5.3 ft. 3 (150 L) 5.3 ft. 3 (150 L) In ddition, the pressure differentil (outside engine comprtment versus inside engine comprtment) should not exceed 2 in. (51mm) of wter (mesured with mnometer) t Wide Open Throttle. Pge 7 of 48

8 Comprtment Temperture - Specifictions Air tempertures inside of engine comprtments hve been mesured in excess of 200 F (82 C). The long term effect to fuel system components running t these excessive tempertures is not known t this time. According to specifiction SAE J1223 for Mrine Crburetors: The crburetor shll be cpble of opertion throughout n mbient (ir temperture) rnge from +20 to +176 F ( 7 to +80 C) without filure. Crburetors, throttle body injection (TBI) units nd components for multi-port EFI systems used by MerCruiser meet this specifiction. Under the hottest outside ir temperture condition t which the bot will be operted, the ir temperture inside the engine comprtment, mesured t the flme rrestor, shll not exceed 176 F (80 C). Also, the temperture of the fuel being supplied to the engine shll not exceed 110 F (43 C) t ny loction between the fuel tnk nd the engine s fuel pump. Since mny fctors influence engine comprtment temperture, temperture mesurements should lwys be crried out s follows. Comprtment Temperture - Testing Test s follows: 1. The bot being tested shll be stndrd production bot fitted s it would be for delivery to deler. 2. Temperture test meter used shll be of the type tht cn be red without opening the engine cover. 3. During the test, in Step 4, engine comprtments re to remin closed. No outside ir is to be forced into the engine comprtment during the test nd the bilge blower should not be running. 4. Engine Running nd Het Sok Test:. Use 1 meter nd 2 therml couples. Plce one therml couple t the flme rrestor to mesure the inlet ir temperture. Plce the second therml couple t the fuel pump to mesure the inlet fuel temperture. A third therml couple is needed if the fuel supply line between the tnk nd the fuel pump is higher thn the fuel pump. Plce the third therml couple t the highest point of the supply line to mesure the temperture of the fuel t tht point. b. Strt engine to wrm it up. After engine is t its norml operting temperture, run engine t 1500 rpm (in neutrl ger) for 15 minutes. Record both temperture redings t 5 minute intervls. c. After 15 minutes running t 1500 rpm, shut engine off nd continue to record both temperture redings t 5 minute intervls for the next 45 minutes. d. After the 45 minute het sok test, strt engine nd idle (in neutrl ger) for 20 minutes. Continue to record both temperture redings t 5 minute intervls. IMPORTANT: If the temperture t either loction exceeds specifictions, the engine comprtment will need dditionl ventiltion until both tempertures remin below these specifictions. Pge 8 of 48

9 Exhust System IMPORTANT: It is the responsibility of the bot mnufcturer, or instlling deler, to properly locte the engine nd instll the exhust system. Improper instlltion my llow wter to enter the exhust mnifolds nd combustion chmbers nd severely dmge the engine. Dmge cused by wter in the engine will not be covered by MerCruiser Wrrnty unless this dmge is the result of defective prt(s). Determine if exhust elbow risers re required by tking mesurements nd b with bot t rest in the wter nd mximum lod bord. Subtrct (b) from () to find (c). If (c) is less thn specified in chrt, select pproprite size exhust elbow riser kit, nd exhust extension kit if pplicble, tht will correctly position exhust elbow. Model All Models (c) = () Minus (b) (c) Must Be 13 in. (330 mm) or More d b c Typicl Instlltion Shown -From Wterline To Top Of Trnsom b-from Highest Point On Exhust Elbow To Top Of Trnsom c -Equls () Minus (b) d-wterline At (c) Rest System must not cuse excessive bck pressure when mesured t exhust elbow outlets. Bck pressure MUST NOT exceed 2 psi (14 kp). Minimum exhust hose sizes re given in chrt: Minimum Exhust Outlet Hose Size 3-1/2 in. (88.9 mm) Exhust hoses must be secured t ech connection with two (2) hose clmps. Exhust hoses must be connected to exhust elbows so tht they do not restrict the flow of dischrge wter from the elbow. If hoses re connected incorrectly, hot spot in the hose cn occur nd cn eventully burn through. NOTE: A kit is vilble, when pplicble, to reduce from the 4 in. (102 mm) to 3 in. (76 mm). Refer to the Quicksilver Accessories Guide for kit prt number. Pge 9 of 48

10 Fuel Delivery System GENERAL WARNING Boting stndrds (NMMA, ABYC, etc.) nd Cost Gurd regultions must be dhered to when instlling fuel delivery system. The min concern of bot s fuel system is sfety; this must be chieved through techniclly sound instlltion nd constnt inspection. The fuel system, from the filler pipe to the fuel pump, is the sme in principle for ll bots. The fuel tnk is n integrted component of the bot. Refer to the specil informtion on service nd mintennce tht you hve received from the tnk mnufcturer. NOTE: On Ski Bot Applictions: If during testing for prticulr ppliction, you experience fuel strvtion in shrp high speed turns, bffles or fuel sump my be needed in the tnk to help correct this condition. Only few points relted to function nd sfety re listed here. Refer to boting stndrds (NMMA, ABYC, etc.) nd Cost Gurd regultions for complete guidelines: All connections should be on the upper side of the tnk. The drin plug t the lowest point on the tnk serves to permit the removl of wter nd sediment. The filler pipe outer dimeter should be t lest 2 in. (51 mm). The tnk brether pipe must hve n inner dimeter of t lest 1/2 in. (13 mm) nd must be fitted with swn neck to prevent wter from entering the tnk. It is recommended tht the exct route nd length of the fuel lines be estblished t the first instlltion of the engine to prevent problems lter in connecting them to the engine. All fuel lines must be well secured. The holes where the lines run through the bulkheds should be crefully rounded off or protected with rubber grommets. This prevents dmge to the lines from brsion. Pge 10 of 48

11 The following, but not limited to the following, dditionl fuel connection relted points, pplying to ll engines unless otherwise stted, must be considered [Refer to boting stndrds (NMMA, ABYC, etc.) nd Cost Gurd regultions for complete guidelines]: 1. Fuel tnk should be mounted below crburetor level (if possible) or grvity feed my cuse crburetor fuel inlet needle to unset nd flooding my result. 2. On Gsoline Engines: The mximum mesured vcuum t the engine s fuel inlet must not exceed 2 in. Hg (6.9 kp) t idle rpm, 3000, full throttle rpm, nd bck t idle rpm. IMPORTANT: Vcuum reding higher thn specified cn cuse vpor locking with some of tody s fuels. It cn lso cuse poor engine performnce becuse of fuel strvtion. 3. Fuel pickup should be t lest 1 in. (25mm) from the bottom of fuel tnk to prevent picking up impurities. 4. Fuel lines used must be Cost Gurd pproved (USCG Type A1). Dimeter of fittings nd lines must not be smller thn 5/16 in. (8 mm) I.D. on 350 cid / 5.7L nd Blck Scorpion engines. Dimeter of fittings nd lines must not be smller thn 3/8 in. (10 mm) I.D. on 377 cid / 6.2L engines. 5. Lrger dimeter (thn previously specified) lines nd fittings must be used on instlltions requiring long lines or numerous fittings. 6. Fuel line(s) should be instlled free of stress nd firmly secured to prevent vibrtion nd/ or chfing. 7. Shrp bends in fuel lines should be voided. 8. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to bsorb deflection when engine is running. SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS CAUTION The electric fuel pump nd fctory instlled wter seprting fuel filter hve been crefully designed to function properly together. Do not instll dditionl fuel filters nd/or wter seprting fuel filters between fuel tnk nd engine. The instlltion of dditionl filters my cuse: Fuel Vpor Locking Difficult Wrm-Strting Piston Detontion Due to Len Fuel Mixture Poor Drivebility Pge 11 of 48

12 SPECIAL INFORMATION FOR ALL GASOLINE ENGINES WARNING Avoid gsoline fire or explosion. Improper instlltion of brss fittings or plugs into fuel pump or fuel filter bse cn crck csting nd/or cuse fuel lek. IMPORTANT: The following informtion is provided to ensure proper instlltion of brss fittings or plugs instlled into fuel pump or fuel filter bse: Use #592 Loctite Pipe Selnt with Teflon on threds of brss fittings or plugs. DO NOT USE TEFLON TAPE. Brss fittings or plugs should first be threded into fuel pump or fuel filter bse until finger tight. Fittings or plugs should then be tightened n dditionl 1-3/4 to 2-1/4 turns using wrench. DO NOT OVERTIGHTEN. To prevent overtightening when instlling fuel line, the brss fittings should be held with suitble wrench s fuel line connectors re tightened securely. Pge 12 of 48

13 Bttery IMPORTANT: Boting industry stndrds (BIA, ABYC, etc.), federl stndrds nd Cost Gurd regultions must be dhered to when instlling bttery. Be sure bttery cble instlltion meets the pull test requirements nd tht positive bttery terminl is properly insulted in ccordnce with regultions. IMPORTANT: Engine electricl system is negtive ( ) ground. It is recommended (required in some sttes) tht bttery be instlled in n enclosed cse. Refer to regultions for your re. Select bttery tht meets ll of the following specifictions: volt mrine type. 2. Tpered post connector or side terminl connectors. Do not use bttery with wing nut connectors. 3. Reserve bttery cpcity rting of t lest: Engine (cyl./type) cid (L) Minimum Required Crnking Bttery Size V8 Crb 350 (5.7) 375 cc/475 mc/90 Ah V8 MPI 350 (5.7) nd 377 (6.2) 550 cc/700 mc/120 Ah Bttery Cbles Select proper size positive (+) nd negtive ( ) bttery cbles using chrt. Bttery should be locted s close to engine s possible. IMPORTANT: Terminls must be soldered to cble ends to ensure good electricl contct. Use electricl grde (resin flux) solder only. Do not use cid flux solder s it my cuse corrosion nd subsequent filure. GASOLINE ENGINES Cble Length Cble Guge Up to 3-1/2 ft (1.1m) 4 (25mm 2 ) 3-1/2-6 ft ( m) 2 (35mm 2 ) 6-7-1/2 ft ( m) 1 (50mm 2 ) 7-1/2-9-1/2 ft ( m) 0 (50mm 2 ) 9-1/2-12 ft ( m) 00 (70mm 2 ) ft ( m) 000 (95mm 2 ) ft ( m) 0000 (120mm 2 ) Pge 13 of 48

14 EFI Electricl System Precutions Instrumenttion NOTE: All references to EFI models pply to ll EFI nd MPI engines. CAUTION Avoid dmge to the EFI electricl system nd components. Refer to the following precutions when working on or round the EFI electricl hrness or when dding other electricl ccessories: DO NOT tp ccessories into engine hrness. DO NOT puncture wires for testing (Probing). DO NOT reverse bttery leds. DO NOT splice wires into hrness. DO NOT ttempt dignostics without proper, pproved Service Tools. CAUTION If Quicksilver wiring hrness is used nd fused ccessory pnel is to be instlled (40-mp current drw mximum), be sure to connect it s shown in wiring digrm. Do not connect ccessory pnel t ny other loction s wires in wiring hrness my not be of sufficient size to hndle current lod. We recommend the use of Quicksilver Instrumenttion nd Wiring hrness(es). On dul sttion pplictions, oil pressure nd wter temperture senders (on engine) must be chnged. Refer to Quicksilver Accessories Guide for selection. The 4 bsic guges tht must be used with the engine re: Tchometer Oil Pressure Wter Temperture Voltmeter Route instrumenttion wiring hrness bck to engine, mking sure tht hrness does not rub or get pinched. If n extension hrness is required, be sure to secure connection properly. Fsten hrness(es) to bot t lest every 18 in. (460mm), using pproprite fsteners. Pge 14 of 48

15 Propeller Selection GENERAL INFORMATION IMPORTANT: Instlled propeller must llow engine to run t its specified mximum wide-open-throttle revolutions per minute (rpm). Use n ccurte service tchometer to verify engine operting rpm. It is the responsibility of the bot mnufcturer nd/or the selling deler to equip the power pckge with the correct propeller(s). Specified engine wide-open-throttle (WOT) nd operting rpm rnge re listed in the Opertion, Mintennce nd Wrrnty Mnul ttched to the engine. Select propeller tht will llow the engine power pckge to operte t or ner the top end of the recommended wide-open-throttle operting rpm rnge with norml lod. There is chnge in rpm between propeller dimeter or pitches tht is generlized in the following chrt: MIE Models Dimeter or Pitch Chnge RPM Chnge Gsoline 1 Inch 150 If full throttle opertion is below the recommended rnge, the propeller must be chnged to prevent loss of performnce nd possible engine dmge. On the other hnd, operting n engine bove the recommended operting rpm rnge will cuse higher thn norml wer nd/or dmge. After initil propeller selection, the following common problems my require tht the propeller be chnged to lower pitch: Wrmer wether nd greter humidity cuse n rpm loss. Operting in higher elevtion cuses n rpm loss. Operting with incresed lod (dditionl pssengers, pulling skiers, etc.). For better ccelertion, such s is needed for wter skiing, use the next lower pitch propeller. However, do not operte t full throttle when using the lower pitch propeller but not pulling skiers. Becuse of the mny vribles of bot design, only testing will determine the best propeller for prticulr ppliction. Avilble propellers re listed in the Quicksilver Accessories Guide. See BOAT-IN-THE-WATER TESTS, Mximum RPM Test in the power pckge Instlltion Mnul. Pge 15 of 48

16 SPECIAL INFORMATION FOR GASOLINE ENGINES IMPORTANT: When selecting propeller consider this dditionl informtion, if pplicble: The engines listed in the following chrt re equipped with n rpm rev-limiter tht is set to n upper (or limited) rpm mount. This limit is slightly bove the norml operting rnge of the engine nd is designed to help prevent dmge from excessive engine rpm. Once the rpm drop into the recommended operting rpm rnge, norml engine opertion resumes. Model Engine Rev-Limiter Engine Recommended Operting RPM Rnge Rev-Limit RPM Setting 5.7L Mg MPI MX 6.2L Blck Scorpion Throttle/Shift Remote Control nd Cbles Shift control nd shift cble MUST position trnsmission shift lever EXACTLY s stted in the specific power pckge Instlltion Mnul or trnsmission filure my occur. Dmge cused to trnsmission s result of improper shift lever positioning will not be covered by wrrnty. To ensure proper shift nd throttle opertion, we recommend the use of Quicksilver remote control nd cbles. Refer to Quicksilver Accessories Guide for selection. However, if control other thn Quicksilver is to be used, control must provide shift cble trvel of 2-3/4 in. (70 mm). Pge 16 of 48

17 Sewter Connections - Generl Informtion SEAWATER PICKUP AND HOSE IMPORTANT: DO NOT instll wter pickup directly in line with propeller s pickup my crete turbulence nd llow ir to flow into the propeller slipstrem. This will cuse propeller ventiltion nd will dversely ffect bot performnce. Wter pickup must be lrge enough to permit sufficient wter flow to engine sewter pickup pump for dequte engine cooling. Pickup lso must supply positive hed while underwy. Wter pickup should be locted s close to sewter pickup pump inlet s possible nd in n re where n uninterrupted, solid strem of wter will flow pst when bot is underwy. Wter inlet hose connections must be mde with wire reinforced hose of dequte wll thickness to prevent it from collpsing from pump suction. Be sure to secure hose connections with hose clmps. Secure hose to prevent contct with ny moving prts of the engine. Select the proper hose from the following chrt: Gsoline Engines Sewter Pickup Hose Inner Dimeter 1-1/4 in. (32 mm) SEACOCK SIZE Secock used must hve n internl cross-sectionl re equl to or greter thn sewter hose to prevent restricting wter flow. A brss bll or gte vlve is required. Select proper secock bsed on the following chrt: Secock Size (Internl Cross-Sectionl Are Equl to or Greter Thn Size Shown) Gsoline Engines 1-1/4 in. (32 mm) Instll the secock in n re where it will be esily ccessible nd supported dequtely to prevent hose ftigue. SEA STRAINER Striner used must be of sufficient size to ensure tht n dequte supply of wter will be mintined for cooling engine. Select properly rted sewter striner bsed on the following chrt: Sewter Striner Minimum Flow Rte 1 Gsoline Engines 30 (114) 1 Amounts listed re in gllons per minute nd (liters per minute). The sewter striner should be instlled in n re where it will be esily ccessible for inspection nd clening. The striner should be instlled in wter inlet hose fter the secock (wter inlet vlve) to llow opertor to shut off wter when clening striner. Pge 17 of 48

18 Hot Wter Heter Instlltion Informtion SUPPLY HOSE CONNECTION IMPORTANT: When connecting cbin heter or hot wter heter, certin requirements must be met, including, but not limited to the following: Supply hose (from engine to heter) nd return hose (from heter to engine) MUST NOT EXCEED 5/8 in. (16 mm) I.D. (inside dimeter). Mke heter connections ONLY t loctions indicted in the following informtion. Refer to mnufcturers instructions for complete instlltion informtion nd procedures. IMPORTANT: Do not reposition engine temperture switch; it must remin where instlled by fctory. CAUTION On closed cooling models, heter must be mounted lower thn the fill cp on the het exchnger. If the heter is higher thn the fill cp on the het exchnger nd some coolnt is lost from system, n ir pocket my form in the closed cooling system. This cn cuse the engine to overhet. All Engines - If Avilble -Loction For Hot Wter Supply (Instll Byonet Fitting Here) All Engines - Alternte Loction -Loction For Hot Wter Supply (Instll Byonet Fitting Here) Pge 18 of 48

19 RETURN HOSE CONNECTION Loction for Hot Wter Return (Instll Byonet Fitting Here) Engine Instlltion Bttery Cble Connection NOTICE to INSTALLER Before Strting Instlltion, Red Generl Informtion nd Instlltion Requirements completely. IMPORTANT: Engine electricl system is negtive ( ) ground. IMPORTANT: Before connecting bttery cbles, mke sure tht grounding stud nd strter solenoid terminl re free of pint or ny other mteril tht could cuse poor electricl connection. 1. Connect negtive ( ) bttery cble to grounding stud on flywheel housing. Tighten nut securely. -Negtive ( ) Bttery Cble Plce rubber boot (shipped with engine) over end of positive (+) bttery cble nd connect to 3/8 in. (10 mm) terminl on strter. Tighten nut securely. Pge 19 of 48

20 3. Cot negtive nd positive bttery connections with Liquid Neoprene. After Liquid Neoprene hs dried, slide rubber boot over positive bttery cble connection. b c -Negtive ( ) Bttery Cble b-positive (+) Bttery Cble c -90 Amp System Fuse DO NOT Remove (EFI nd MPI Models) Engine Mount Pre-Adjustment 1. Remove hrdwre holding engine to shipping pllet. Attch suitble sling to lifting eyes on engine. Lift engine from pllet with n overhed hoist. 2. Remove L shped shipping brcket from both rer (trnsmission) mounts. Retorque mount brcket ttching screw to 48 lb. ft. (65 N m). IMPORTANT: Engine mounts must be djusted, s explined in Steps 3 nd 4, to center mount djustment nd estblish uniform height on ll mounts. 3. Ensure tht distnce from bottom of ll 4 engine mounts (2 front, 2 rer) mount to bottom of trunnion equls 2-5/8 in. + 1/16 in. (10 mm + 2 mm). If not, loosen mount locking nut nd turn djusting nut in direction required to obtin proper dimension, then retighten locking nut. Be sure to leve mount positioned so tht slot is forwrd (d). Pge 20 of 48

21 4. Loosen clmping screws nd nuts on ll 4 engine mount brckets to ensure the following: Lrge dimeter of mount trunnion extended s shown. Mount bse slotted mounting hole forwrd, if so designed. Ech mount bse is downwrd. Tighten clmping screws nd nuts slightly to prevent moving in or out. Mounts must be free to pivot when instlling engine. e d g c f b Front Mount e c g f b Rer Mount -Locking Nut b-adjusting Nut c -Trunnion Clmp Screw(s) And Nut(s), With Lockwsher(s) d-slot Forwrd e -3/8 in. + 1/16 in. (10 mm + 2 mm) f -2-5/8 in. + 1/16 in. (67 mm + 2 mm) g-mount Trunnion Pge 21 of 48

22 Initil Engine Alignment 1. Lift engine into bot nd position on engine bed so tht trnsmission output flnge nd propeller shft coupler re visibly ligned (no gp cn be seen between coupling fces when butted together). Adjust engine bed height, if necessry, to obtin proper lignment. DO NOT use mount djustments to djust engine position t this time. IMPORTANT: Engine bed must position engine so tht minimum of 1/4 in. (6 mm) up nd down djustment still exists on ll 4 mounts fter performing finl lignment. This is necessry to llow for finl engine lignment. 2. Ensure tht ll 4 mounts re still positioned properly, then fsten mounts to engine bed with 3/8 in. (10 mm) dimeter lg screws (of sufficient length) nd flt wshers. Tighten lg screws securely. 3. Disconnect overhed hoist nd remove sling. Finl Engine Alignment IMPORTANT: Engine lignment MUST BE RECHECKED with bot in the wter, fuel tnks filled nd with norml lod onbord. Engine must be ligned so tht trnsmission nd propeller shft coupling centerlines re ligned nd coupling fces re prllel within.003 in. (0.07 mm). This pplies to instlltions with solid couplings s well s flexible couplings. 1. Check mting fces on trnsmission output flnge nd propeller shft coupler to mke sure they re clen nd flt. 2. Check tht coupling centerlines lign by butting propeller shft coupler ginst trnsmission output flnge. Shoulder on propeller shft coupler fce should engge recess on trnsmission output flnge fce with no resistnce. NOTE: Some propeller shft couplers my not hve shoulder on mting fce. On these instlltions, use stright edge to check centerline lignment. 3. Check for ngulr mislignment by hnd holding coupling fces tightly together nd checking for gp between coupling fces with.003 in. (0.07 mm) feeler guge t 90 intervls. INCORRECT INCORRECT CORRECT Pge 22 of 48

23 4. If coupling centerlines re not ligned or if coupling fces re more thn.003 in. out of prllel, djust engine mounts.. TO ADJUST ENGINE UP OR DOWN: Loosen locking nut () on mounts requiring djustment nd turn djusting nuts in desired direction to rise or lower. IMPORTANT: Both front mount (or rer mount) djusting nuts must be turned eqully to keep engine level from side to side. c b -Locking Nut b-adjusting Nut c -Clmping Screw(s) nd Nut(s), with Lockwsher(s) b. TO MOVE ENGINE TO THE LEFT OR RIGHT: Loosen clmping screws nd nuts on ll 4 mount brckets nd move engine to the left or right s necessry to obtin proper lignment. A smll mount of djustment cn be obtined with slot on front end of some mounts. Loosen lg screws (which fsten mounts to engine bed) nd move engine s required. Retighten lg screw securely. NOTE: Some rer mounts hve one (1) clmping screw nd nut on ech side. IMPORTANT: Lrge dimeter of mount trunnion MUST NOT extend over 1-3/4 in. (45 mm) from mount brckets on ny of the mounts. 5. After engine hs been properly ligned, secure engine mounts s shown. 6. Torque clmping screws nd nuts on ll 4 mount brckets to 50 lb-ft (68 Nm). 7. Tighten locknuts on ll 4 mounts securely. Pge 23 of 48

24 8. Bend one of the tbs on tb wsher down onto flt of djusting nut. d b c Clmping Screws nd Nuts b-locknut c -Tb On Tb Wsher d-1-3/4 in. (45 mm) 9. Connect propeller shft coupler to trnsmission output flnge. Secure coupling together with bolts, lockwshers nd nuts. Torque to 50 lb-ft (68 Nm). Sewter Pickup Pump Connection 1. Remove shipping cp. Connect sewter inlet hose to inlet fitting (bottom hose) on sewter pump Sewter Inlet Hose Pge 24 of 48

25 Throttle/Shift Cble Lubricte cble ends nd brrels nd then ttch to engine nd trnsmission. IMPORTANT: When instlling throttle cble, be sure tht cbles re routed in such wy s to void shrp bends nd/or contct with moving prts. DO NOT fsten ny items to throttle cble. ATTACHING/ADJUSTING THROTTLE CABLE - CARBURETED MODELS 1. Lubricte cble ends nd brrels. 2. Plce remote control throttle lever in idle position nd ttch cble end guide to crburetor throttle lever s shown. 3. Grsp cble behind brrel nd push lightly s shown. Adjust cble brrel to lign hole with nchor stud, then slide brrel onto stud. d c b e g d h f -Cble End Guide b-throttle Lever Stud c -Elstic Stop Nut nd Wsher d-spcer e -Cble Brrel f -Anchor Stud g-wsher h-elstic Stop Nut Pge 25 of 48

26 ATTACHING/ADJUSTING THROTTLE CABLE - EFI MODELS 1. Plce remote control hndle in neutrl idle position. 2. Remove flme rrestor. 3. Attch cble to the lowest hole on the throttle body unit following cble mnufcturer s instructions. 4. Instll cble end guide on throttle lever, then push cble brrel end lightly towrd throttle lever end. (This plces slight prelod on shift cble to void slck in cble when moving remote control lever.) Adjust brrel on throttle cble to lign with hole in nchor plte. Position cble s shown. c Throttle Body EFI b b c Blck Scorpion -Throttle Lever b-anchor Plte c -Throttle Cble 5. Secure throttle cble with hrdwre s shown nd tighten securely Pge 26 of 48

27 ATTACHING/ADJUSTING SHIFT CABLE - ALL MODELS IMPORTANT: Velvet Drive Trnsmission Wrrnty is jeoprdized if the shift lever poppet bll or spring is permnently removed, if the shift lever is repositioned or chnged in ny mnner or if remote control nd cble do not position shift lever correctly. F N R e d b F R c Trnsmission Shift Lever b-shift Lever MUST BE Over This Letter When Propelling Bot FORWARD c -Shift Lever MUST BE Over This Letter When Propelling Bot IN REVERSE d-poppet Bll MUST BE Centered in Detent Hole for Ech F-N-R Position (Forwrd Ger Shown) e -Instll Shift Lever Stud in This Hole, If Necessry, To Center Poppet Bll in Forwrd nd Reverse Detent Holes IMPORTANT: When instlling shift cbles, be sure tht cbles re routed to void shrp bends nd/or contct with moving prts. All bends must mke greter thn n 8 inch (203 mm) rdius. DO NOT fsten ny items to shift cbles. NOTE: Refer to shift cble mnufcturer s instructions for djusting the cble. Shift lever must be positioned s stted in the preceding steps. b c Throttle Lever Stud b-cble End c -Locknut Pge 27 of 48

28 ROUTING OF SHIFT CABLES - BLACK SCORPION 1. Shift Cble - Route shift cble from the strbord to the port side of engine nd then between intke mnifold nd elbow. Position cble so it will not interfere with flme rrestor. b -St-Strps b-shift Cble Fuel Supply Connection CAUTION Remove plstic plug from fuel inlet hole in csting. Apply #592 Loctite Pipe Selnt with Teflon to threds of fuel inlet line connector. DO NOT USE TEFLON TAPE. To prevent crcking the csting nd/or fuel leks, turn inlet connector in by hnd until finger tight, then tighten connector to 1-3/4 to 2-1/4 turns with wrench. DO NOT OVERTIGHTEN. Inspect for fuel leks. IMPORTANT: A flexible fuel line must be used to connect fuel line to engine to bsorb deflection when engine is running. CAUTION Ensure tht the inlet hose to fuel pump does not interfere with drive belts. 1. Instll brbed fuel line fittings (obtin loclly) in wter seprting fuel filter dpter. b -Inlet b-outlet Pge 28 of 48

29 2. 5.7L Model if remote mounting wter seprting fuel filter: Instll inverted flre swivel (provided) into bse of fuel pump. Finger tighten nd then grip hex fitting on end of fuel pump with wrench while tightening swivel n dditionl 1-3/4 to 2-1/4 turns with wrench. -Fuel Pump Fitting Remove shipping cp from fuel fitting on wter seprting fuel filter brcket. NOTE: Mount wter seprting fuel filter in loction tht llows esy removl nd instlltion. 4. Attch fuel line to wter seprting fuel filter dpter. -Wter Seprting Fuel Filter Adpter Pge 29 of 48

30 Audio Wrning System 1. Instll udio wrning system horn s follows:. Select loction for udio wrning horn which meets ll of the following: horn cn be esily herd yet is out of sight. Accessible for instlltion or mintennce. horn will not get wet. Where the 18 in. (457 mm) long PURPLE wire cn be connected to n I terminl (terminl with PURPLE wire ttched to it) on one of the guges or to 12 volt source on switched side of ignition switch. WARNING horn is not externl ignition proof, therefore, DO NOT mount horn in engine or fuel tnk comprtments s this would be fire or explosion hzrd. b. Mount horn in desired loction. Secure horn to wire bundle with st-strp provided. c. Connect PURPLE wire from horn to ny I terminl or ignition switch. Tighten connection securely. (Refer To Wiring Digrm). d. Connect TAN/BLUE wire from horn to TAN/BLUE wire from instrument hrness (refer to Wiring Digrm). e. Plce the smll (trnsprent) decls on the bottom of the wter temperture guge nd the oil pressure guge. f. Plce the lrge decl on the instrument pnel or other pproprite loction in esy view of the opertor. ALARM INDICATES LOW OIL OR OVERHEATING 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 WATER TEMP. IS TOO HOT, OR 3. TRANSMISSION TEMPERATURE IS TOO HOT. TO TEST THE AUDIO WARNING HORN: TURN KEY TO ON POSITION (ENGINE OFF) -Smll Decl (Trnsprent) b-lrge Decl Test udio wrning system s indicted on dshbord decl. Pge 30 of 48

31 Electricl Connections 1. Connect instrumenttion wiring hrness to engine nd secure with clmp. -Instrumenttion Wiring Hrness Connection Exhust System Hoses/Tubes Connection 1. Exhust hoses/tubes must be connected to exhust elbows so tht they do not restrict the flow of dischrge wter from the elbow. If hoses/tubes re connected incorrectly, hot spot in the hose/tube cn occur, nd cn eventully burn through. 2. Exhust hoses/tubes should be secured t ech connection with t lest 2 hose clmps. -Correct b-incorrect b IMPORTANT: S-pipes must be routed under the trnsmission mounts. b -S-Pipe b-trnsmission Mount Pge 31 of 48

32 Predelivery Preprtion Bttery Connection Test Running Engine Bot-In-The-Wter Tests NOTICE to INSTALLER Before strting Predelivery, red Generl Informtion nd Instlltion Requirements completely. IMPORTANT: Engine electricl system is negtive ( ) ground. 1. Connect engine positive (+) bttery cble (usully red) to positive (+) bttery terminl. 2. Connect engine negtive ( ) bttery cble (usully blck) to negtive ( ) bttery terminl. 3. Mke sure tht ll bttery terminl connections re tight nd then cot connections nd terminls with bttery terminl nti-corrosion spry to help retrd corrosion. WARNING If engine is to be tested on lnd, propeller must be removed. IMPORTANT: If engine is to be tested on lnd, wter must be supplied to sewter pickup pump. DO NOT run engine bove 1500 rpm. IMPORTANT: Engine lignment MUST BE CHECKED with bot in the wter, fuel tnks filled nd with norml lod onbord. CAUTION Avoid engine dmge. Ensure tht cooling wter is supplied to the engine if it will be run with bot out of the wter. See instructions in the Opertion, Mintennce nd Wrrnty Mnul entitled Flushing Cooling System, for instructions on connecting flush device. ENGINE IDLE SPEED ADJUSTMENT (CARBURETED MODELS) The engine should idle t rpm (s specified in Opertion, Mintennce nd Wrrnty Mnul ) with engine t norml operting temperture. If idle speed is incorrect, proceed s follows: IMPORTANT: In order to properly set idle speed, the ignition module MUST BE locked in the Bse Timing Mode. This is necessry becuse of the Idle Speed Control feture tht exists in the ignition module. This must be done before the key switch is turned to the ON or START position. 1. Connect shop tchometer to engine. 2. Using jumper wire, connect the ignition system Timing Led (PUR/WHT wire) to good engine ground ( ). This locks the ignition module into the Bse Timing Mode. Refer to Engine Wiring Hrness digrm in this mnul. 3. Strt engine nd plce the remote control lever in NEUTRAL, idle position. 4. Adjust idle speed to 650 rpm. 5. Stop engine. Redjust cble brrel nd reinstll the throttle cble. Pge 32 of 48

33 IMPORTANT: Be sure to disconnect the jumper wire from the ignition system test led before ttempting to resume norml opertions. If the jumper wire is left in plce, the ignition module will operte in the Bse Timing Mode. This mens tht the dditionl timing dvnce fetures would not be functioning. 6. Remove the jumper wire from the timing led. ENGINE IDLE SPEED (EFI MODELS) WIDE-OPEN-THROTTLE TEST Engine should idle t rpm (s specified in Opertion, Mintennce nd Wrrnty Mnul) with engine t norml operting temperture. If idle speed is incorrect, proceed s follows: 1. Ensure tht throttle cble hs been djusted properly. 2. If idle speed is still not correct, it my be necessry to perform EFI System Dignostic Tests on the idle circuit. Refer to the pproprite MerCruiser Service Mnul for procedures. IMPORTANT: To run engine t full throttle before the brek-in period is complete, follow this procedure. 1. Strt engine nd run t idle rpm until norml operting temperture is reched. 2. Run bot up on plne. 3. Advnce engine rpm (in 200 rpm increments) until engine reches its mximum rted rpm. To test if the correct propeller hs been instlled, operte bot (with norml lod on bord) t WOT nd check rpm with n ccurte tchometer. Engine rpm should be ner top of the specified rnge so tht under hevy lod engine speed will not fll below specifictions. If engine speed is too high, replce propeller with higher pitch propeller. Normlly, 150 rpm chnge exists between propeller pitches. Cold Wether or Extended Storge Drining Instructions CAUTION If bot is to remin in wter fter drining, sewter inlet hose must be removed nd plugged to prevent syphoning ction tht my occur, llowing sewter to flow from the drin holes or removed hoses. CAUTION Sewter section of cooling system MUST BE COMPLETELY drined for winter storge, or immeditely fter cold wether use, if the possibility of freezing tempertures exist. Filure to comply my result in trpped wter cusing freeze nd/or corrosion dmge to engine. IMPORTANT: Bot must be s level s possible to ensure complete drining of cooling system. Pge 33 of 48

34 CARBURETED MODELS 1. Ensure engine is s level s possible to ensure complete drining of cooling system. 2. Remove drin plugs from following loctions:. Port Side - cylinder block. CAUTION Avoid product dmge. Do not disturb the Y-fitting when removing the drin plug. There is n ignition control Knock Sensor in the upper hole of the fitting. This sensor must not be loosened or removed. It is tightened to criticl specifiction t the fctory. b. Strbord Side - Y-fitting. -Y-fitting c. Bottom of exhust mnifolds Exhust Mnifold Drin Loction Pge 34 of 48

35 3. Repetedly clen out drin holes using stiff piece of wire. Do this until entire system is drined. NOTE: It my be necessry to lift or bend hoses to llow wter to drin completely. Crnk engine over slightly to purge ny wter trpped in sewter pickup pump. Do not llow engine to strt. 4. Loosen hose clmps nd remove the following hoses:. From trnsmission cooler Typicl Trnsmission Fluid Cooler -Trnsmission Cooler Hose b. From engine circulting pump or remove drin plug, if equipped. b -Engine Circulting Pump Hose b-drin Plug, if equipped Pge 35 of 48

36 c. From wter inlet hose (bottom) from sewter pickup pump. -Sewter Inlet Hose After cooling system hs been drined completely, instll drin plugs, reconnect hoses nd tighten ll hose clmps securely. IMPORTANT: MerCruiser recommends tht propylene glycol ( nontoxic nd environmentlly sfe) ntifreeze be used in the sewter section of the cooling system for cold wether or extended storge. Mke sure tht the propylene glycol ntifreeze contins rust inhibitor nd is recommended for use in mrine engines. Be certin to follow the propylene glycol mnufcturer s recommendtions. 6. For dditionl ssurnce ginst freezing nd rust, follow these steps.. Remove the thermostt housing nd thermostt. b. Fill the engine sewter cooling system with mixture of ntifreeze nd tp wter. Follow the mnufcturer s recommendtion to protect engine to the lowest temperture tht it will be exposed to during cold wether or extended storge. c. Reinstll thermostt nd cover. d. Torque screws with lockwshers to 30 lb. ft. (41 N m). b c d -Thermostt Housing b-gsket c -Thermostt d-spcer e -Thermostt Housing-to-Intke Mnifold Gsket e Pge 36 of 48

37 EFI AND MPI MODELS 1. Ensure engine is s level s possible to ensure complete drining of cooling system. 2. Remove drin plugs from the following loctions:. Port Side - cylinder block. CAUTION Avoid product dmge. Do not disturb the Y-fitting when removing the drin plug. There is n ignition control Knock Sensor in the upper hole of the fitting. This sensor must not be loosened or removed. It is tightened to criticl specifiction t the fctory. b. Strbord Side - Y-fitting. -Y-fitting c. Fuel cooler. d. Bottom of exhust mnifolds. c b Cylinder Block Drin Loction (port side) b-fuel Cooler Drin Loction c -Exhust Mnifold Drin Loction Pge 37 of 48

38 3. Repetedly clen out drin holes using stiff piece of wire. Do this until entire system is drined. NOTE: It my be necessry to lift or bend hoses to llow wter to drin completely. Crnk engine over slightly to purge ny wter trpped in sewter pickup pump. Do not llow engine to strt. 4. Remove hoses from the following loctions:. Wter inlet hose (bottom) from sewter pump Sewter Inlet Hose b. Hose from trnsmission cooler Typicl Trnsmission Fluid Cooler -Trnsmission Cooler Hose Pge 38 of 48

39 c. From engine circulting pump or remove drin plug, if equipped. b -Engine Circulting Pump Hose b-drin Plug, if equipped After cooling system hs been drined completely, instll drin plugs, reconnect hoses nd tighten ll hose clmps securely. IMPORTANT: MerCruiser recommends tht propylene glycol ( nontoxic nd environmentlly sfe) ntifreeze be used in the sewter section of the cooling system for cold wether or extended storge. Mke sure tht the propylene glycol ntifreeze contins rust inhibitor nd is recommended for use in mrine engines. Be certin to follow the propylene glycol mnufcturer s recommendtions. 6. For dditionl ssurnce ginst freezing nd rust, follow these steps.. Remove the thermostt housing nd thermostt. b. Fill the engine sewter cooling system with mixture of ntifreeze nd tp wter. Follow the mnufcturer s recommendtion to protect engine to the lowest temperture tht it will be exposed to during cold wether or extended storge. c. Reinstll thermostt nd cover. d. Torque screws with lockwshers to 30 lb. ft. (41 N m). c d b -Thermostt Housing b-gsket c -Thermostt d-spcer e -Thermostt Housing-to-Intke Mnifold Gsket e Pge 39 of 48