INSTALLATION MANUAL D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS

Transcription

1 The following re registered trdemrks of Brunswik Corportion: Mer, MerCthode, MerCruiser, Merury, Merury Mrine, Quiksilver, nd Ride-Guide. INSTALLATION MANUAL D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS NOTICE to INSTALLER After Completing Instlltion, These Instrutions Should Be Pled with the Produt for the Owner s Future Use. NOTICE to COMMISSIONING DEALER Predelivery Preprtion Instrutions Must e Performed Before Delivering Bot To The Produt Owner. Tle of Contents Generl Informtion Notie to Instller Brvo Three Notie: Trim-In Limit Pin Multiple Sterndrive Steering Tie Br Arrngements Quiksilver Produts Torque Speifitions Seril Numer Del Plement Corrosion Protetion Antifouling Pint Instlltion Requirements Bot Constrution Exhust System Fuel Delivery System Generl Bttery Bttery Cles EDI Eletril System Preutions Instrumenttion Power Trim Control Power Trim Pump Lotion Propeller Seletion Hot Wter Heter Instlltion Reommendtion Sewter Connetions Throttle/Shift Remote Control nd Cles.. 20 Steering Helm nd Cle Trnsom Cutout Finding Crnkshft Vertil Centerline Finding Crnkshft Horizontl Centerline ( X Dimension) Cutting Trnsom Cheking Trnsom Thikness Instlling Trnsom Assemly Giml Housing Inner Trnsom Plte Power Trim Pump Steering System Speedometer Pikup Drive Unit Ger Lue Monitor Hose Exhust Wter Bypss Drive Unit Sewter Routing Engine Instlltion Engine Preprtion Trnsom Preprtion Instlling Engine / Alignment Engine Connetions Quiksilver Sewter Pikup nd Seok. 46 Sewter Striner Closed Cooling Reovery Bottle Fuel Lines Power Steering Hydruli Hoses Exhust System Eletril Connetions Shift Cle Instlltion nd Adjustment Trouleshooting Shift Prolems Throttle Cle Instlltion nd Adjustment. 60 Sterndrive Unit Instlltion Predelivery Preprtion Power Trim System Wiring Digrm MerCthode System Wiring Digrm Quiksilver Instrumenttion Wiring Cooling System Flow Digrm Predelivery Inspetion SEPTEMBER 1999 Printed in U.S.A , Merury Mrine Pge 1 of 90

2 Generl Informtion Notie to Instller Throughout this pulition, Wrnings nd Cutions (ompnied y the Interntionl Hzrd Symol! ) re used to lert the instller to speil instrutions onerning prtiulr servie or opertion tht my e hzrdous if performed inorretly or relessly. Oserve Them Crefully! These Sfety Alerts, lone, nnot eliminte the hzrds tht they signl. Strit ompline to these speil instrutions when performing the servie, plus ommon sense opertion, re mjor ident prevention mesures. WARNING Hzrds or unsfe prties whih ould result in severe personl injury or deth. CAUTION Hzrds or unsfe prties whih ould result in minor personl injury or produt or property dmge. IMPORTANT: Indites informtion or instrutions tht re neessry for proper instlltion nd/or opertion. This instlltion mnul, inluding ll instlltion requirements, hs een written nd pulished y Merury Mrine to id ot mnufturers nd instllers involved in the pplition nd instlltion of the produts desried herein. It is ssumed tht these personnel re fmilir with the instlltion proedures of these produts, or like or similr produts mnuftured nd mrketed y Merury Mrine. Tht they hve een trined in the reommended instlltion proedures of these produts whih inludes the use of mehnis ommon hnd tools nd the speil Merury Mrine or reommended tools from other suppliers. It is the responsiility of the OEM to selet the pproprite engine/trnsom/drive pkge (inluding the orret ger rtio nd propeller) for given ot. Mking n pproprite seletion requires knowledge of the ot (weight, length, hull design, intended use nd duty yle, desired speed, et.) tht is uniquely in the possession of the OEM. While Merury employs people ple of ssisting the OEM on suh issues, the finl deision rests with the OEM. Merury reommends tht ny new or unique hull/power pkge omintion e thoroughly wter tested prior to sle, to verify (mong other things) tht the ot performs s desired, nd tht the engine runs in the pproprite rpm rnge. We ould not possily know of nd dvise the mrine trde of ll oneivle proedures y whih n instlltion might e performed, nd of the possile hzrds nd/or results of eh method. We hve not undertken ny suh wide evlution. Therefore, nyone who uses n instlltion proedure nd/or tool, whih is not reommended y the mnufturer, first must ompletely stisfy himself tht neither his nor the produt s sfety will e endngered y the instlltion proedure seleted. It is reommended tht Merury Mrine Field Produt Engineer e ontted for ssistne if speifi pplition or instlltion prolems re enountered. All informtion, illustrtions, nd speifitions ontined in this mnul re sed on the ltest produt informtion ville t time of pulition. As required, revisions to this mnul will e sent to ll OEM ot ompnies. Pge 2 of 90

3 WARNING D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Eletril system omponents on this engine re not externl ignition proteted. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE EN- GINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VA- PORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Filure to omply ould result in fire, explosion nd/or severe personl injury. Notie on Brvo Trim-In Limit NOTE: Brvo One, Two nd Three Models re equipped with Trim-In Limit Pin Insert. It hs een rought to our ttention tht some ots (predominntly deep-v hevy ots) will roll up on their side under ertin, speifi, operting onditions. The roll n e either to port or strord nd my e experiened while moving stright hed, or while mking turn. The roll ours most frequently t or ner mximum speed, with the drive unit trimmed t or ner full trim-in. While the ot will not roll ompletely over, the roll my e suffiient to unset the opertor or pssengers, nd therey rete n unsfe sitution. The roll is used y stern-lift reted from exessive drive unit trim-in. Under these extreme stern-lift / ow-down onditions instility n e reted whih my use the ot to roll. Weight distriution to the stern n redue stern-lift nd, in some irumstnes, help to ontrol the ondition. Weight distriution in the ow, port or strord, my worsen the ondition. The Trim-In Limit Pin Insert redues stern-lift y preventing the drive unit from rehing the lst few degrees of full trim-in. While this devie should redue the rolling tendeny, it my not eliminte the tendeny entirely. The need for this Trim-In Limit Pin Insert, nd its effetiveness, n only e determined through ot testing nd is ultimtely the responsiility of the ot mnufturer. WARNING It is reommended tht only qulified personnel djust the Trim-In Limit Pin Insert. Bot must e wter tested fter djusting or removing the devie to ensure tht the modified trim-in rnge does not use the ot to exhiit n undesirle ot hndling hrteristi if the drive unit is trimmed In t higher speeds. Inresed trim-in rnge my use hndling prolems on some ots whih ould result in personl injury. Pge 3 of 90

4 Multiple Sterndrive Steering Tie Br Arrngements INTERNAL TIE BAR ONLY With multiple sterndrives it is importnt to onsider whih of severl possile steering systems should e seleted. CAUTION Filure to oserve the reommended Tie Br Arrngements s presented in this setion ould result in serious dmge to the steering nd/or trim system omponents. This dmge ould dversely ffet ontrol of the ot. At the lower end of the performne spetrum (ots not ple of speeds in exess of 60 MPH) the si internl tie r is reommended. It onnets the slve sterndrive to the sterndrive tht is diretly onneted to the ftory power steering output. This internl tie r is ville in vriety of lengths from the sterndrive mnufturer. INTERNAL AND EXTERNAL TIE BAR EXTERNAL POWER STEERING As ot moves into moderte performne rnge (60-70 MPH) or for redution in steering klsh, n externl tie r should e dded. Externl tie rs re usully designed to tth t the ft power trim ylinder osses whih is n exellent lotion euse of its proximity to the propeller. HOWEVER, euse of the potentil overstress tht n our if one drive is trimmed muh differently thn the other, dul trim ontrol kit (Prt Numer 90362A3) should e instlled so s to limit this potentil tilt differentil to out 20. When ot speeds move pst 70 MPH or if dditionl steering klsh redution is desired, externl power steering is reommended. This normlly will inlude n externl tie r mounted t the sme generl lotion of the power steering ylinders whih re generlly tthed t the top of the sterndrive s drive shft housing. With this steering system, no internl tie r should e used. These steering ylinders n e tthed either inord (etween) or outord of the sterndrives. EXTERNAL POWER STEERING WITH LOW EXTERNAL TIE BAR For the fstest ots (over 80 MPH) or for the ultimte in steering klsh redution, use externl power steering, BUT (where mehnilly possile) with the externl tie r mounted t the trim ylinder oss lotion (s previously desried in Internl nd Externl Tie Br sttements). Agin this system does not use n internl tie r. Merury Mrine does not reommend the use of n externl tie r ONLY (no internl tie r) when using the internl power steering system. This n use exessive lods on the steering omponents on the drive onneted to the internl power steering system. These inresed lods n dmge the steering omponents, resulting in inresed ply in the steering of the ot. Pge 4 of 90

5 Quiksilver Produts D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS ACCESSORIES INSTALLATION PRODUCTS Quiksilver remote ontrols, steering systems, propellers, et. re ville for this produt. Refer to Quiksilver Aessories Guide for omplete listing. This Guide is ville from: Attn: Prts Deprtment Merury Mrine W6250 W. Pioneer Rod P.O. Box 1939 Fond du L, WI OR Outside of U.S.A., order through Distriution Center, or Distriutor. DESCRIPTION PART NUMBER Quiksilver Engine Coupler Spline Grese A4 Quiksilver 2-4-C Mrine Lurint With Teflon A3 Quiksilver U-Joint nd Giml Bering Grese A3 Quiksilver Speil Lurint A1 Quiksilver Liquid Neoprene Quiksilver Perfet Sel Trnsom Drilling Fixture A2 Engine Alignment Tool A1 Shift Cle Adjustment Tool Engine Lifting Eye Tool A1 Engine Mount Drilling Fixture A1 Pge 5 of 90

6 Torque Speifitions DESCRIPTION TORQUE l-in. l-ft Nm Speedometer Pikup Br Fitting Exhust Pipe or Blok-off Plte Power Steering Hydruli Hose Fittings Power Trim Pump Hose Fittings Propeller Nut (Brvo One nd Two) Front Propeller Nuts (Brvo Three) 1 Rer Rer Engine Mounts Steering Cle Coupler Nut Steering System (Pivot Bolts) Sterndrive Unit Fsteners Trnsom Assemly Fsteners Sewter Pikup Fitting 45 5 Power Trim Cylinder Fsteners 1 : Amount speified is MINIMUM. Seril Numer Del Plement Corrosion Protetion Tighten until they ottom out. There re three sets of engine, trnsom ssemly nd sterndrive seril numer del strips provided with eh power pkge. One set should e used for eh of the following: Engine Speifition Del Wrrnty Registrtion Crd Opertion nd Mintenne Mnul identifition pge. MerCruiser power pkges re equipped with nodes, to help protet them from glvni orrosion under moderte onditions. However, for severe onditions, or if using stinless steel propeller, it is reommended tht Quiksilver Anti-Corrosion Anode Kit nd/or Mer- Cthode System e instlled (some models hve MerCthode System s stndrd equipment). A MerCthode Monitor lso is ville to llow the opertor to hek the opertion of the MerCthode System with the push of utton. (Refer to Quiksilver Aessories Guide for prt numers.) Bots whih re onneted to AC shore power, require dditionl protetion to prevent destrutive low voltge glvni urrents from pssing through the shore power ground wire. A Quiksilver Glvni Isoltor n e instlled to lok the pssge of these urrents while still providing pth to ground for dngerous fult (shok) urrents. (Refer to Quiksilver Aessories Guide for prt numer.) IMPORTANT: If AC shore power is not isolted from ot ground, the MerCthode System nd nodes my e unle to hndle the inresed glvni orrosion potentil. Pge 6 of 90

7 Antifouling Pint D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS IMPORTANT: Corrosion dmge tht results from the improper pplition of ntifouling pint will not e overed y the limited wrrnty. Pinting Bot Hull or Bot Trnsom: Antifouling pint my e pplied to ot hull nd ot trnsom ut you must oserve the following preutions: IMPORTANT: DO NOT pint nodes or MerCthode System referene eletrode nd node, s this will render them ineffetive s glvni orrosion inhiitors. IMPORTANT: If nti-fouling protetion is required for ot hull or ot trnsom, opper or tin se pints, if not prohiited y lw, n e used. If using opper or tin sed nti-fouling pints, oserve the following: Avoid n eletril interonnetion etween the MerCruiser Produt, Anodi Bloks, or MerCthode System nd the pint y llowing minimum of 1-1/2 in. (40mm) UNPAINTED re on trnsom of the ot round these items Pinted Bot Trnsom -Minimum 1-1/2 in. (40 mm) UNPAINTED Are Around Trnsom Assemly NOTE: Drive unit nd trnsom ssemly n e pinted with good qulity mrine pint or n nti-fouling pint tht DOES NOT ontin opper, tin, or ny other mteril tht ould ondut eletril urrent. Do not pint drin holes, nodes, MerCthode system, nd items speified y ot mnufturer. Pge 7 of 90

8 Instlltion Requirements Bot Constrution TRANSOM f e e d Trnsom Thikness - 2 in. (51mm) Minimum to 2-1/4 in.(57mm) Mximum -Inner Surfe of Trnsom Must Be Prllel Within 1/8 in. (3mm) in Are Covered y Trnsom Plte (e) nd Remin Within Trnsom Thikness Limits. -Outer Surfe of Trnsom Must Be Prllel Within 1/16 in. (2 mm) in Are Covered y Trnsom Plte (e) nd Remin Within Trnsom Thikness Limits. d-remove Keel (if Equipped) 4 ft. (1.2m) Forwrd to Trnsom e -Trnsom Plte Covers 8 in. (203 mm) to either side of the vertil enterline f -Trnsom Angle - 10 Degrees to 16 Degrees ENGINE BED Distne etween strord nd port engine mount is 22-1/2 in. (572mm). Engine ed must position engine so tht minimum of 1/4 in. (6mm) up nd down djustment still exists on mounts fter performing finl engine lignment. This is neessry to llow for religning engine in the future. NOTE: Although the engine mounts llow some djustment, it is good prtie to insure tht the front nd rer mount lotions in the vessel re in prllel plnes. This my e heked y tying string from the left front mount lotion to the right rer mount lotion nd nother from right front to left rer. The strings should touh where they ross. Pge 8 of 90

9 ENGINE COMPARTMENT D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS WARNING Boting stndrds (NMMA, ABYC, et.) nd Cost Gurd regultions must e dhered to when onstruting the engine omprtment. Cre must e exerised in the design nd onstrution of the engine omprtment. Sems must e loted so tht ny rin wter, whih my lek through the sems, is direted wy from the ir intke system. Wter, tht runs onto the ir intke, my enter the engine nd use serious dmge to internl engine nd/or turohrger prts. IMPORTANT: MerCruiser will not honor ny wrrnty lim for engine dmge s result of wter entry. ENGINE COMPARTMENT VENTILATION Generl Informtion Aording to Boting stndrds (NMMA, ABYC, et.) nd Cost Gurd regultions the engine omprtment ventiltion system hs multiple tsks. Inluded re the following: 1. To supply the engine with omustion ir. 2. To mintin low temperture in the engine omprtment. Fresh ir should enter the engine omprtment s low s possile nd the heted ir should e dishrged from the highest point. If seprte ir shft (or similr) is used to provide engine omprtment ventiltion, or dditionl ventiltion, re must e tken to prevent sewter nd spry from entering it. Comustion Air Requirements Engine omprtments with nturl drft ventiltion must hve vent openings of suffiient size nd lotion to omplish the tsks previously outlined. Furthermore, in prt, nd ording to, ABYC H speifition - Comprtment Ventiltion (Diesel) sttes: Ventilting provisions nd openings to the mhinery spe provided for suppling omustion ir shll ommodte the ir requirements required y the engine mnufturer(s) for eh propulsion nd uxiliry engine in tht spe. These openings my lso funtion s mens of providing nturl ventiltion. IMPORTANT: The size of ventiltion openings must e inresed if ny uxiliry equipment is loted in the engine omprtment. The omustion ir requirement (per engine) for the speified engines t Wide Open Throttle re shown in the hrt elow: Comustion Air Requirements (Per Engine) Model Engine Air Requirements t Wide Open Throttle D7.3L D-Troni nd D7.3L D-Troni LD 1000 ft. 3 /min. (28.2 m 3 /min.) Pge 9 of 90

10 Multiplying the engine ir flow (fm) y 0.1 will generlly determine the omustion ir vent size requirement (per engine). Therefore: Engine Comustion Air Flow (fm) X 0.1 OR Engine Comustion Air Flow (m 3 /min.) X 22.8 = = Comustion Air Vent Are Per Engine (Squre Inhes) Comustion Air Vent Are Per Engine (Squre Centimeters) D7.3 D-Troni Exmple: 1000 X 0.1 = 100 Squre Inhes 1 OR 28.2 X 22.8 = Sq. Cm. 1 1 : For engine omustion ir only - NOT totl engine omprtment ventiltion requirement. IMPORTANT: The mount of vent re required, ording to Boting stndrds (NMMA, ABYC, et.) nd Cost Gurd regultions, for omplete (totl) engine omprtment ventiltion must inlude the engine vent re, determined y the ove formul, plus the engine omprtment ventiltion requirements. Comprtment Temperture - Speifitions Too high n inlet ir temperture lowers the engine performne. Therefore: Engine omprtment temperture shll not exeed outside ir temperture y more thn 30 F (17 C). Sine mny ftors influene engine omprtment temperture, temperture mesurements should lwys e rried out. Comprtment Temperture - Testing Test s follows: 1. The ot eing tested shll e stndrd prodution ot fitted s it would e for delivery to deler. 2. Temperture test meter used shll e of the type tht n e red without opening the engine over. 3. During the test, in Step 4, engine omprtments re to remin losed. No outside ir is to e fored into the engine omprtment during the test nd the ilge lower should not e running. 4. Engine Running nd Het Sok Test:. Use 1 meter nd 1 therml ouple. Position the therml ouple t the engine ir inlet (ir filter).. Strt engine to wrm it up. After engine is t its norml operting temperture, run engine t WOT rpm for 20 minutes. Reord temperture redings t 5 minute intervls. IMPORTANT: If the temperture t the engine ir inlet (ir filter) exeeds speifitions, the engine omprtment will need dditionl engine omustion ir openings, or n inrese in engine omprtment ventiltion re, until the temperture remins within speifition. Pge 10 of 90

11 Exhust System D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS IMPORTANT: It is the responsiility of the ot mnufturer or instlling deler to properly lote the engine nd instll the exhust system. Improper instlltion my llow wter to enter the exhust mnifolds nd omustion hmers nd severely dmge the engine. Dmge used y wter in the engine will not e overed y MerCruiser Wrrnty, unless this dmge is the result of defetive prt(s). Determine if n exhust riser kit or wter lift muffler kit is required, y tking mesurements () nd (), with ot t rest in the wter nd mximum lod ord. Sutrt () from () to find (). If () is less thn speified in hrt, n exhust riser kit must e instlled. Model All Models () = () Minus () () Must Be 13 in. (330 mm) or More d mercruiser Typil Engine Without Risers -From Wterline to Top of Trnsom -From Highest Point on Exhust Elow to Top of Trnsom -Equls () minus () d-wterline t Rest Pge 11 of 90

12 Some engines my e equipped with ftory instlled exhust riser. Verify tht the riser provides the required dimension, or distne greter thn, s indited. Model All Models () = () Minus () () Must Be 13 in. (330 mm) or More d mercruiser Typil Engine With Riser -From Wterline to Top of Trnsom -From Highest Point on Exhust Riser to Top of Trnsom -Equls () minus () d-wterline At Rest Fuel Delivery System GENERAL WARNING Boting stndrds (NMMA, ABYC, et.) nd Cost Gurd regultions must e dhered to when instlling fuel delivery system. The min onern of ot s fuel system is sfety; this must e hieved through tehnilly sound instlltion nd onstnt inspetion. The fuel system, from the filler pipe to the fuel pump is the sme, in priniple, for ll ots. The Fuel Tnk is n integrted omponent of the ot. Refer to the speil informtion on servie nd mintenne, whih you hve reeived from the thnk mnufturer. Only few points relted to funtion nd sfety re listed here [Refer to oting stndrds (NMMA, ABYC, et.) nd Cost Gurd regultions for omplete guidelines]: 1. All onnetions should e on the upper side of the tnk. 2. The drin plug t the lowest point on the tnk serves to permit the removl of wter nd sediment. 3. The filler pipe outer dimeter should e t lest 2 in. (50mm). Pge 12 of 90

13 FUEL CONNECTIONS D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 4. The tnk rether pipe must hve n inner dimeter of t lest 1/2 in. (13mm) nd must e fitted with swn nek to prevent wter from entering the tnk. It is reommended tht the ext route nd length of the fuel lines e estlished t the first instlltion of the engine to prevent prolems lter in onneting them to the engine. All fuel lines must e well seured. The holes where the lines run through the ulkheds should e refully rounded off, or proteted with ruer grommets. This prevents dmge to the lines from rsion. The following, ut not limited to the following, dditionl fuel onnetion relted points, pplying to ll engines unless otherwise stted, must e onsidered [Refer to oting stndrds (NMMA, ABYC, et.) nd Cost Gurd regultions for omplete guidelines]: 1. Fuel pikup should e t lest 1 in. (25mm) from the ottom of fuel tnk, to prevent piking up impurities. 2. Fuel supply lines must not e smller thn 3/8 in. (11 mm) I.D. tue for V8 model. A fuel return line etween engine nd fuel tnk is required, for ll models the return line must not e smller thn 5/16 in. (8 mm). 3. On Multi-Engine Instlltions: Use seprte tue for the fuel supply line nd fuel return line for eh engine. 4. Lrger dimeter (thn previously speified) lines, nd fittings must e used on instlltions requiring long lines or numerous fittings. 5. Fuel line(s) should e instlled free of stress nd firmly seured to prevent virtion nd/ or hfing. 6. Shrp ends in fuel lines should e voided. 7. A flexile fuel line must e used to onnet fuel supply line to fuel inlet fitting on engine, to sor defletion when engine is running. Injetion pump fuel return line must lso hve flexile ruer hose segment. DIESEL FUEL FILTERS AND FUEL ADDITIVES There is the possiility tht ontmintion of diesel fuel nd lge growth in the diesel fuel ould use the lokge of the lift pump resulting in poor performne. IMPORTANT: The engine is provided with n element type fuel filter, ut to help eliminte wter nd dirt it is reommended to use n dditionl 10 miron, 60 gl/min. (227 L/min.) flow rted filter tht hs wter trp. It is reommended tht in MerCruiser Diesel pplitions, n dditionl fuel filter equipped with wter trp e instlled efore the lift pump. MerCruiser reommends 10 miron, 60 gllon per minute (227 L/min.) rted filter, suh s Ror Model 500 (Quiksilver Prt Numer with SAE threds, nd with Metri threds) or equivlent. This will help to filter out ontminnts in diesel fuel. Selet suitle position in the fuel system etween the fuel feed pump nd the fuel tnk for the dditionl filter The position seleted must e free from virtions, nd llow for esy inspetion nd replement. It is lso reommended tht diesel fuel dditive e dded (to omt lge growth) prtiulrly in wrmer limtes. Additives redue the hnes of lge growth in the diesel fuel. Pge 13 of 90

14 Bttery IMPORTANT: Boting industry stndrds (BIA, ABYC, et.) federl stndrds nd Cost Gurd regultions must e dhered to when instlling ttery. Be sure ttery le instlltion meets the pull test requirements nd tht positive ttery terminl is properly insulted in ordne with regultions. IMPORTANT: It is reommended (required in some sttes) tht ttery e instlled in n enlosed se. Refer to regultions for your re. IMPORTANT: Engine eletril system is negtive ( ) ground. Selet ttery tht meets ll of the following speifitions: 12-volt mrine type. Tpered post onnetors or side terminl onnetors. Do not use ttery with wing nut onnetors. Bttery pity rting of t lest: Engine (Cyl./type) Minimum Required Crnking Bttery Size 8 / V, D7.3L D-Troni nd D7.3L D-Troni LD 1500, 1920 m or 300 Ah Bttery Cles Selet proper size positive (+) nd negtive ( ) ttery les, using hrt. Bttery should e loted s lose to engine s possile. IMPORTANT: Terminls must e soldered to le ends to ensure good eletril ontt. Use eletril grde (resin flux) solder only. Do not use id flux solder, s it my use orrosion nd susequent filure. Bttery Cle Length Minimum Cle Guge Up to 3 ft. (0.9m) 2 ( 35mm 2 ) 3-3-3/4 ft. ( m) 1 ( 50mm 2 ) 3-3/4-4-3/4 ft. ( m) 0 ( 50mm 2 ) 4-3/4-6 ft. ( m) 00 ( 70mm 2 ) 6-7-1/2 ft. ( m) 000 ( 95mm 2 ) 7-1/2-9-1/2 ft. ( m) 0000 (120mm 2 ) 9-1/2-12 ft. ( m) 00 ( 70mm 2 ) ft. ( m) 000 ( 95mm 2 ) ft. ( m) 0000 (120mm 2 ) :Two les of speified guge required for positive nd two required for negtive. Pge 14 of 90

15 EDI Eletril System Preutions Instrumenttion GENERAL NOTE: The following preutions pply to ll EDI model Engines. CAUTION D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Avoid dmge to the Eletroni Diret Injetion (EDI) eletril system nd omponents. Refer to the following preutions when working on or round the EDI eletril hrness or when dding other eletril essories: DO NOT tp essories into engine hrness. DO NOT punture wires for testing (Proing). DO NOT reverse ttery leds. DO NOT splie wires into hrness. DO NOT ttempt dignostis without proper, pproved Servie Tools. We reommend using Quiksilver Instrumenttion nd Wiring Hrnesses. Refer to Quiksilver Aessories Guide for seletion. NOTE: If using other thn Quiksilver instrumenttion nd hrnesses, refer to mnufturers instrutions. The six si guges tht must e used with the engine re: Thometer Oil Pressure Wter Temperture Voltmeter Cruise Log (Engine Hour Meter) Trim Guge When using the instrumenttion, instrument hrness wire onnetors re leled. It will e neessry to onnet them onto the individul Quiksilver instruments, swithes nd Engine System Monitor pnel. The instrumenttion hrness ends re provided for onnetion into the pproprite extension hrness ends. The wiring hrnesses will then e redy to route to the engine. On dul sttion pplitions, oil pressure nd wter temperture senders (on engine) must e hnged. Additionlly, hnges re needed in the primry sttion key swith wiring to llow use of strt nd stop swithes ommon on dul sttion pnels. Refer to instrutions in kit. When routing ny wiring extension hrness k to the engine, mke sure tht the hrness does not ru or get pinhed. Be sure ll extension hrness onnetor ollrs re seure. Fsten hrnesses to ot t lest every 18 in. (460 mm) using pproprite fsteners. Pge 15 of 90

16 76010 TACHOMETER SPECIAL INFORMATION Power Trim Control D7.3L D-Troni Shown - All Similr -Engine Hrness Connetor -Extension Hrness Connetor (From Instruments) -Eletril Brket IMPORTANT: If using thometer from nother mnufturer, do not use the mgneti thometer pikup (or relted wiring) mounted on the flywheel housing. If using the Quiksilver Thometer provided with the engine pkge, the pproprite setting of the swith loted on the k of the thometer is given in the following hrt. Thometer Swith Setting Model Swith Position (Teeth Count on Flywheel) D7.3L D-Troni nd D7.3L D-Troni LD 4 (155) Any of the Quiksilver pnel or in-hndle type trim ontrols (tht re speified for use with MerCruiser sterndrives) n e used with this Power Trim system. Instll trim ontrol in ordne with instrutions tht ompny it. Power Trim Pump Lotion Selet n pproprite mounting lotion for the trim pump tht meets the following requirements: Within limits of lk nd gry hydruli hoses (oming from giml housing ssemly). Close to the ttery so tht trim pump ttery leds n e onneted. Allow esy ess to trim pump oil fill nd vent lotions. Are where pump will not e exposed to wter. Trim pump must e mounted so tht when steering wheel is turned in either diretion (right or left), the power steering ooster ylinder does not ome in ontt with trim pump. Pge 16 of 90

17 Propeller Seletion D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS GENERAL INFORMATION RPM REV-LIMITER IMPORTANT: Instlled propeller must llow engine to run t its speified mximum wide-open-throttle revolutions per minute (rpm). Use n urte servie thometer to verify engine operting rpm. It is the responsiility of the ot mnufturer nd/or the selling deler to equip the power pkge with the orret propeller(s). Speified engine wide-open-throttle (WOT) nd operting rpm rnge re listed in the Opertion nd Mintenne Mnul tthed to the engine. Selet propeller tht will llow the engine power pkge to operte t or ner the top end of the reommended wide-open-throttle operting rpm rnge with norml lod. High rpm, used y n exessive trim ngle, should not e used in determining orret propeller seletion. If full throttle opertion is elow the reommended rnge, the propeller must e hnged to prevent loss of performne nd possile engine dmge. On the other hnd, operting n engine ove the reommended operting rpm rnge will use higher thn norml wer nd/or dmge. Generlly, there is 200 rpm hnge etween propeller pithes. After initil propeller seletion, the following ommon prolems my require tht the propeller e hnged to lower pith: Wrmer wether nd greter humidity use n rpm loss. Operting in higher elevtion uses n rpm loss. Operting with inresed lod (dditionl pssengers, pulling skiers, et.). For etter elertion, suh s is needed for wter skiing, use the next lower pith propeller. However, do not operte t full throttle when using the lower pith propeller ut not pulling skiers. Beuse of the mny vriles of ot design, only testing will determine the est propeller for prtiulr pplition. Aville propellers re listed in the Quiksilver Aessories Guide. See BOAT-IN-THE-WATER TESTS, Mximum rpm Test in the power pkge Instlltion Mnul. IMPORTANT: When seleting propeller onsider this dditionl informtion: The engines listed in the following hrt re equipped with devie tht limits engine rpm. Be sure tht propeller eing used does not llow engine to run ginst limiter, s signifint loss in performne will result. Engine rpm MCM Model Engine Reommended Rpm Limiter Setting Operting rpm Rnge (Begins At:) D7.3L D-Troni D7.3L D-Troni LD Pge 17 of 90

18 Hot Wter Heter Instlltion Reommendtion IMPORTANT: When onneting in heter or hot wter heter, ertin requirements must e met, inluding, ut 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 onnetions ONLY t lotions indited in the following informtion. Refer to mnufturers instrutions for omplete instlltion informtion nd proedures. IMPORTANT: Do not reposition engine temperture swith, it must remin where instlled y ftory. CAUTION Heter must e mounted lower thn the fill p on the het exhnger. If the heter is higher thn the fill p on the het exhnger nd some oolnt is lost from system, n ir poket my form in the losed ooling system. This n use the engine to overhet. A Hot Wter Heter Adptor Kit is ville from Quiksilver. This kit ontins instlltion instrutions. Lotions for fittings re shown following. PART NUMBER A1 DESCRIPTION Hot Wter Heter Adptor Kit SUPPLY HOSE CONNECTION Lotion for Wter Heter Supply Hose (Byonet Fitting Reples Plug) Pge 18 of 90

19 RETURN HOSE CONNECTION D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS -Lotion on Wter Cirultion Pump for Hot Wter Return (Byonet Fitting Reples Plug) Sewter Connetions D7.3L D-Troni nd D7.3L D-Troni LD models must e equipped with through hull or through trnsom wter supply to ensure suffiient wter flow to the engine. The trnsom ssemly needs to e modified with the wter pssge lok-off plte kit (P/N A1) provided. It is neessry to ut the wter hose tht is loted etween the ell housing nd the giml housing. This llows wter to ontinue through the drive for ooling. Refer to Drive Unit Sewter Routing. outlined lter. Red nd oserve the following to selet the proper sewter pikup hose, seok size nd sewter striner. Sewter Connetions - Generl Informtion SEAWATER PICKUP HOSE Sewter inlet hose onnetions must e mde with wire reinfored hose of dequte wll thikness to prevent it from ollpsing from pump sution. Be sure to seure hose onnetions with hose lmps. Seure hose to prevent ontt with ny moving prts of the engine. All Models Sewter Pikup Hose Inner Dimeter 1-1/2 in. (38mm) SEACOCK SIZE Seok used must hve n internl ross-setionl re equl to or greter thn sewter inlet hose to prevent restriting wter flow. Instll vlve in n re where it will e esily essile nd supported dequtely to prevent hose ftigue. A rss ll or gte vlve is required. Seok Size (Internl Cross-Setionl Are Equl to or Greter Thn Size Shown) All Models 1-1/2 in. (38mm) Pge 19 of 90

20 SEAWATER STRAINER Striner used must e of suffiient size to ensure tht n dequte supply of wter will e mintined for ooling the engine. Sewter Striner Minimum Flow Rte 1 All Models 40 (150) 1 Amount listed is in gllons per minute nd (liters per minute). Instll sewter striner in n re where it will e esily essile for inspetion nd lening. Striner should e instlled in wter inlet hose fter the seok (wter inlet vlve) to llow opertor to shut off wter when lening striner. Throttle/Shift Remote Control nd Cles To ensure proper shift nd throttle opertion, we reommend the use of Quiksilver remote ontrol nd les. Refer to Quiksilver Aessories Guide for seletion. However, if ontrol other thn Quiksilver is to e used, ontrol must provide the following: Shift Cle Trvel (At shift plte end.) Shift Cle Lod (Applied to the le end guide.) 2-7/8 in. (73mm) to 3-1/8 in. (80mm) l. (6.8-9 kg) Pge 20 of 90

21 Steering Helm nd Cle D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Trnsom ssemly is shipped with the steering le guide tue preset for les with end dimensions tht omply with ABYC stndrds s outlined in the NMMA ertifition hndook. The steering le oupler nut must lso hve mens of loking it to the guide tue s speified in ABYC requirements. WARNING Filure to use steering le loking devie ould use loss of steering, whih ould use dmge to the ot nd/or injury. All urrent prodution Quiksilver Ride Guide steering les hve self-loking oupler nut nd do not require n externl loking devie. (Other le mnufturers lso mke les with self-loking oupler nut.) Quiksilver Ride Guide Steering Cle Self-Loking Coupler Nut (Identified y Groove) If using steering le tht does not hve self-loking oupler nut, n externl loking devie must e used. e d f -Steering Cle -Grese Fitting -Cotter Pin d-loking Sleeve (If Required - Must Be Ordered Seprtely) e -Cle Coupler Nut f -Cle Guide Tue Pge 21 of 90

22 CAUTION POWER STEERING EQUIPPED UNITS ONLY: If steering le with improper dimensions is instlled, severe dmge to trnsom ssemly nd/or steering system my result. 1. Steering le must e the orret length, prtiulrly when instlled in lrger ots. 2. Avoid shrp ends, kinks or loops in le. 3. Fully extended steering le end dimension must e s shown. STEERING CABLE SPECIFICATIONS e f g d CL k l j i h Coupler Nut - 7/8-14 UNF - 28 Thred -11-3/4 in. (298 mm) Min. -Interfe Point d-1/2 in. ( mm) Mx. e in. ( mm) Min. Flt f in. (0.508 mm) Min. Rdius g-5/8 in. ( mm) Mx. Dimeter End Fitting h-3/8 in. (9.525 mm) i in. (9.779 mm) Dimeter Thru Hole, Chmfered Eh Side j -1-3/8 in. ( mm) Mx k -5/8 in. ( mm) Dimeter Tue l -Mid-Trvel Position /8 in. (428.6 mm) Totl Trvel To Be 8 in. (203.2 mm) Min. to 9 in. (228.6 mm) Mx Trvel Eh Side of Mid-Trvel Position - 4 in. (101.6 mm) Min., 4-1/2 in. (114.3 mm) Mx Steering Cle Mounting Flnge -Center of Hole in Steering Cle End -21-3/8 in. (543 mm) Mx. Pge 22 of 90

23 Trnsom Cutout D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS NOTICE to INSTALLER Before Strting Instlltion Red Generl Informtion nd Instlltion Requirements Setions Completely. IMPORTANT: The following instrutions will provide sterndrive unit mounting lotion tht is suitle for most ots. Best mounting lotion for prtiulr ot, however, n e determined only y testing. Brvo Models use items Below 25 m.p.h. (40 km/h): Sutrt 1/2 in. (13mm) from X Dimension Shown. 2. Hevy Duty Applitions: Sutrt 1 in. (25mm) from X Dimension shown. 3. Aove 25 m.p.h. (40 km/h): Use X Dimension shown. 4. Aove 50 m.p.h. (80 km/h): The X Dimension n e inresed to improve performne in some pplitions, ut pulling power (for skiing) will derese. During testing, X Dimension should e inresed 1/2 in. (13mm) t time until desired performne is hieved ut in no se should it ever e inresed y more thn: Brvo One/Two: 3 in. (76 mm) mximum. Brvo Three: 1 in. (25 mm) mximum. In ALL pplitions where ooling wter is supplied through the sterndrive unit to the engine, extreme re should e tken when rising drive unit to ensure tht the wter supply does not eome erted. Use ler, wter inlet hose to hek inoming wter for ertion. Monitor engine temperture guge to ensure engine does not overhet. In pplitions where ooling wter is supplied to the engine y fitting through the hull or trnsom, the sterndrive height will not use ooling wter ertion. IMPORTANT: Dmge to MerCruiser produts used y too high of n instlled height will not e overed y MerCruiser wrrnty. Pge 23 of 90

24 Finding Crnkshft Vertil Centerline SINGLE ENGINE Lote nd mrk vertil enterline on trnsom Vertil Centerline DUAL ENGINE 1. Lote nd mrk ot vertil enterline () on trnsom Vertil Centerline 2. Lote nd mrk rnkshft vertil enterlines () on trnsom Drw Crnkshft Vertil Centerline through Desired Mounting Lotions -Minimum Distne etween Crnkshft Vertil Centerlines -Crnkshft Vertil Centerlines Must Be n Equl Distne from Bot Vertil Centerline Minimum Distne Between Crnkshft Vertil Centerlines (Dul Side-By-Side) Chrt Model Mesurement [ in. (mm) ] D7.3L D-Troni nd D7.3L D-Troni LD 36-1/2 (927) Pge 24 of 90

25 Finding Crnkshft Horizontl Centerline ( X Dimension) D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS X Dimension n e mesured y the 90 Tool Method or y the Tpe Mesure Method. 90 TOOL METHOD 1. Construt 90 tool. 90 -Dimension from Chrt Below -Mesurement: 4 ft. (1.2 m) To Lower Drive Unit - Sutrt from dimension. To Rise Drive Unit - Add to dimension. 90 TOOL VERTICAL DIMENSION CHART Sterndrive Unit Lotion Brvo One/Two/Three 13-9/16 in. (345mm) IMPORTANT: This dimension should only e rised or lowered fter proper testing. 2. Determine X Dimension lotion of rnkshft enterline(s) Single Engine Dul Engine -Ple 90 Tool Along Bot Bottom t Vertil Centerline -Point t Whih Top of Tool Contts Trnsom on Vertil Centerline is Crnkshft Horizontl Centerline. -Drw Line Perpendiulr to Vertil Centerline t Crnkshft Horizontl Centerline Pge 25 of 90

26 TAPE MEASURE METHOD Trnsom ngle must e known, then mesure X Dimension with tpe mesure. 1. Determine X Dimension from the following hrt. Tpe Mesure Method Chrt Model Brvo One / Two / Three This dimension should only e rised or lowered fter proper Trnsom Angle testing /16 in. (364 mm) /4 in. (362 mm) /16 in. (360 mm) /8 in. (359 mm) /16 in. (357 mm) in. (356 mm) /16 (354 mm) 2. Mesure nd lyout horizontl enterlines s shown. d d Single Engine Dul Engine - X Dimension (from Chrt) tht Corresponds to Trnsom Angle - Mesure Up from Bot Bottom with Tpe Mesure -Crnkshft Horizontl Centerline -Vertil Centerline d-drw Line Perpendiulr to Vertil Centerline t Crnkshft Horizontl Centerline Pge 26 of 90

27 Cutting Trnsom D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Trnsom utout n e mde y either using the Templte [shipped with trnsom ssemly] or the Trnsom Drilling Fixture Kit (purhsed seprtely). Follow instrutions indited on templte or provided with drilling fixture. IMPORTANT: Red nd oserve the following informtion: Be ertin tht enterlines on either the templte or trnsom drilling fixture lign with lines previously mrked on trnsom. Be sure to drill 1/4 in. pilot holes (for hole sw guide) t 60 ngle nd to ut on the line when mking trnsom utout. If utout is mde inorretly, drive unit steering lever my ontt trnsom, thus limiting steering trvel. Sel inside edge of trnsom utout opening with suitle selnt to prevent wter sorption nd deteriortion of trnsom. Trnsom Cutout Templte Trnsom Drilling Fixture Kit Pge 27 of 90

28 Cheking Trnsom Thikness Ensure trnsom surfe thikness nd fltness onform to minimums speified in Instlltion Requirements listed previously. NOTE: Trnsom must e etween 2 (51 mm) nd 2-1/4 (57 mm) distne of 8 (203 mm) to either side of the vertil enterline. -Mesuring Thikness -Mesuring Fltness -Suitle Mndrel To Chek For Uniform Trnsom Thikness. Pge 28 of 90

29 Instlling Trnsom Assemly D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Giml Housing 1. Crefully remove trnsom ssemly from shipping rton. 2. Remove nd red ll tgs whih re tthed to trnsom ssemly. IMPORTANT: Red nd oserve the following regrding your engine nd the thrupropeller exhust system: With ny pplition, instlltion of n exhust tue will inrese exhust noise. With Brvo One, Brvo Two nd Brvo Three Drive Models the exhust ellows must e removed nd n exhust tue MUST BE INSTALLED. NOTE: Exhust tue prts (Quiksilver Prt Numer 78458A1) re provided with Brvo Three Drive. They re loted in the drive unit ox. 3. Instll exhust tue on giml housing s follows:. Remove nd disrd lmps nd exhust ellows. CAUTION Exhust tue lmp my orrode if grounding lip is not instlled.. Instll grounding lip on tue. NOTE: Bellows dhesive is not used when instlling n exhust tue.. Position tue so tht SIDE mrkings on tue re fing towrd the right nd left sides. d. Instll lmp. e. Tighten lmp. Torque to 35 l-in. (4 Nm). e d Exhust Tue -Clmp - Side Mrking d-exhust Tue e -Grounding Clip Pge 29 of 90

30 Inner Trnsom Plte 1. Insert wires, hoses nd shift le through pproprite openings in inner trnsom plte. 2. Position giml housing on trnsom nd hold in ple. NOTE: When tightening trnsom ssemly fsteners in the following step, strt in the enter nd, using irulr pttern, move outwrd. Tighten in smll inrements nd go round the pttern severl times until the proper torque is hieved. IMPORTANT: Steering lever ontinuity iruit wire must e positioned s shown to void stressing wire when steering lever moves d Loknuts nd Flt Wshers (8) -Bolt -Steering Lever Continuity Wire d-trnsom Plte Continuity Wire 3. Seure trnsom ssemly with hrdwre s shown. Torque to I-ft (27-34 Nm). Pge 30 of 90

31 Power Trim Pump D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 1. Mount pump in desired lotion. IMPORTANT: Mke hydruli onnetions s quikly s possile to prevent oil from leking out of system. Be reful not to ross-thred or overtighten hose fittings. d f g e Blk Hose (UP Ciruit) -Gry Hose (DOWN Ciruit) -Hrness Connetor d-clmp e -Trim Limit Swith Wire (with Blue Sleeve) - to BLUE/WHITE Hrness Wire f -Trim Limit Swith Wire (with Purple Sleeve) to PURPLE/WHITE Hrness Wire g-wire Retiner nd St-Strp 2. Connet hydruli hoses to trim pump. Torque fittings to l-in. (11-16 Nm). 3. Connet power trim pump ontrol hrness to trim pump. Seure with lmp. 4. Connet trim limit swith wires nd seure with wire retiner nd st-strp. Pge 31 of 90

32 Steering System NOTE: For Dul Instlltions, Power steering unit n e mounted on port or strord trnsom ssemly. Mesure ext distne etween power pkge enterlines. Selet tie r from Quiksilver Aessory Guide. Refer to tie r instlltion instrutions efore proeeding. 1. Inspet ushings for deris. Lurite ushings with Speil Lurint 101. B Bushings -Speil Lurint Remove upper nd lower pivot olts nd ensure threds re well lurited with Speil Lurint Instll steering ssemly s follows:. Position steering ssemly so tht pivot olts will enter ushings in pivot lok or power steering ontrol vlve.. Instll upper nd lower pivot olts long with t wshers. Ensure tht t wsher tngs strddle the ridge on inner trnsom plte.. Turn pivot olts ll the wy in y hnd to ensure proper lignment. d. Ensure steering ssemly pivots freely T Wshers -Ridge -Pivot Bolts Pge 32 of 90

33 4. Torque pivot olts to 25 l-ft (34 Nm). Bend wsher ts ginst orresponding flts on olt heds. CAUTION MOVING THE CONTROL VALVE RAM with the hoses disonneted will expel fluid from the ports. Wer eye protetion. 5. The ylinder rm my e stiff nd diffiult to move when you ttempt to pull it out or push it in for instlltion. First move the spool ssemly in the diretion(s) shown elow Ports 6. Connet levis to steering lever. Lurite levis pin with Speil Lurint 101. Be sure to spred oth ends of the otter pin. d -Clevis -Steering Lever -Clevis Pin d-cotter Pin Pge 33 of 90

34 7. Connet steering le s follows:. Remove shipping p from oth ends of steering le guide tue.. Cot steering le end with lierl mount of Speil Lurint Instll steering le nd seure with hrdwre s shown. g h e f d d Steering Cle -Grese Fitting -Cle Coupler Nut d-cle Guide Tue e -Steering Cle End f -Clevis g-clevis Pin h-cotter Pin IMPORTANT: Slight feedk in the steering system ould e enountered if the le guide tue flt surfes re not positioned vertilly. d. Using suitle wrenh hold the flt surfes on the le guide tue in the vertil position. Torque oupler nut to 35 l-ft (47 Nm). Be ertin the flt surfes re still ligned vertilly fter torque is pplied to oupler nut. CAUTION Steering le outer sing must e free to move k nd forth for steering system to funtion properly. Do not fsten ny items to steering le. Pge 34 of 90

35 Speedometer Pikup D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS IMPORTANT: Do not distur plug t speedometer fitting if no speedometer is to e fitted, or if n lternte speedometer pikup will e used. 1. Remove plug from speedometer pikup tue fitting Fitting Plug -Speedometer Pikup Tue Fitting 2. Apply Perfet Sel to threds of r fitting. Instll nd torque to I. in. ( N m). -Br Fitting Connet hose from speedometer to r fitting. Seure hose with le tie. 4. Mount speedometer hose to trnsom with hose lip nd srew. Hose must not ome in ontt with steering system omponents or the engine oupler nd drive shft. Drive Unit Ger Lue Monitor Hose 1. Connet ger lue monitor hose to 90 hose fitting. Seure with hose lmp. -Hose -Fitting -Clmp Connet 90 hose fitting nd hose to giml housing fitting. CAUTION Avoid drive unit dmge. Ensure ger lue monitor hose is not kinked when onneted. If hose is kinked, monitor will not funtion properly nd dmge to drive unit ould our. Pge 35 of 90

36 3. Route hose to monitor ottle mounted on engine nd ut off exess hose. IMPORTANT: Avoid using exessive hose when routing to ger lue monitor. Hose should e routed diretly, in s stright line s possile, to void low spots (trps) in the system. d Exhust Wter Bypss Hose -90 Hose Fitting -Giml Housing Fitting d-ger Lue Monitor IMPORTANT: Hose must not ome in ontt with steering system omponents or the engine oupler nd drive shft. MerCruiser D7.3L D-Troni Models re equipped with n exhust wter ypss system. The purpose of this exhust wter ypss system is to lirte the exhust k pressure nd to provide dditionl ooling to the drive ssemly. The exhust wter ypss outlet (provided with instrutions for instlltion) must e instlled within the Preferred or Alterntive Are s indited on the templte. Refer to the full sle templte (provided). Ensure tht the wter outlet snout is positioned in suh wy tht the wter will flow over the top (preferred lotion) or upper side (lterntive lotion) of the Drive Assemly. -Templte -Preferred Exhust Wter Bypss Routing 1. Cut templte outline s required. Position on trnsom. 2. Drill or ut hole s indited on templte. 3. Use silione or other Mrine seler nd instll exhust wter outlet on ot trnsom. 4. Exhust outlet on trnsom must e grounded to inner trnsom plte ssemly. Instll ground strp provided. 5. Cut hose to required length. Instll etween exhust elow fitting nd exhust wter ypss outlet. Use doule lmps on hose onnetions. Pge 36 of 90

37 Drive Unit Sewter Routing BLOCK-OFF PLATE D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Sewter for engine ooling is supplied through seprte sewter pikup, not through the drive unit. Therefore, it is neessry to lok the drive unit sewter pssge nd to ut the wter hose tht is loted etween the ell housing nd the giml housing. This llows wter to ontinue to irulte through the drive unit for ooling. 1. Instll lok-off plte with gsket. Torque srews with str wshers to 45 l-in. (5 Nm) Plte -Gsket -Srew And Wsher CAUTION Avoid drive unit dmge. Quik relese utton on ger lue monitor 90 hose fitting my not lok on giml housing if touhing or depressed y lok-off plte. Ensure quik relese utton does not ontt lok-off plte. Filure to do so ould result in loose 90 fitting using loss of ger lue nd dmge to drive unit. 2. Position quik relese utton on hose fitting wy from lok-off plte. Relese utton must not ontt lok-off plte. OK d d -Wter Inlet Fitting -Str Wsher nd Srew -90 Hose Fitting d-quik Relese Button Pge 37 of 90

38 SEAWATER HOSE NOTE: The trim limit swith wires nd speedometer hose re tthed to the wter hose. Prior to utting the hose, move the wires nd speedometer hose to void utting them when utting wter hose. The existing st-strp nd lip n e reused if they re moved out of the wy while utting the wter hose. 1. Move existing st-strp nd lip. Cut the wter hose in the re shown. Loosen lmp nd remove short piee of hose remining on giml housing. 2. Seure the trim limit swith wires nd speedometer hose to remining hose piee on trnsom ssemly. e f d -St-Strp -Clip -Sewter Inlet Hose d-speedometer Hose e -Trim Limit Wire Hrness f -Cut Wter Hose Here g-hose Piee To Be Removed g Pge 38 of 90

39 Engine Instlltion D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Engine Preprtion 1. Remove nd red ll tgs tthed to engine. 2. Remove ll hrdwre tht seures engine to shipping ontiner. 3. Loosen fsteners nd remove exhust pipe nd exhust hose from pllet. 4. Connet ttery les to engine. Be sure to oserve the following:. Mke sure tht grounding stud nd strter solenoid terminl re free of pint or ny other mteril tht ould use poor eletril onnetion.. After ttery les re onneted, pply thin ot of Liquid Neoprene to the terminls.. Be sure to slide ruer oot over positive (+) terminl fter mking onnetion. 5. Drpe ttery les over top of engine to prevent them from getting in the wy during instlltion. d e Typil -Grounding Stud (Strord Side - Port Similr) -Negtive ( ) Bttery Cle -Positive (+) Bttery Cle d-ruer Boot (Slide Over Terminl) e -Strter Solenoid 6. Remove shipping plug from oupler nd lurite splines with Engine Coupler Spline Grese. Typil -Shipping Plug Pge 39 of 90

40 Trnsom Preprtion IMPORTANT: Exhust pipe nd giml housing mting surfes must e len nd free of niks nd srthes, nd O-ring must e properly seted in groove, or wter nd exhust my lek into ot Giml Housing Mting Surfe -O-ring 1. Instll exhust pipe ssemly s shown, using four (4) olts nd thik lokwshers. Torque olts to l-ft (27-34 Nm). 2. Position rer engine mount tthing hrdwre on inner trnsom plte mounts s shown. d e Exhust Pipe -Bolts nd Thik Lokwshers (4) -Fier Wshers d-doule-wound Lokwshers e -Loknuts Pge 40 of 90