Mercury Mercruiser Marine Engine 4.3 5.0 MPI & Seacore 4.3 5.0 Installation Manual – PDF DOWNLOAD
FILE DETAILS:
Mercury Mercruiser Marine Engine 4.3 5.0 MPI & Seacore 4.3 5.0 Installation Manual – PDF DOWNLOAD
Language : English
Pages : 268
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mercury Mercruiser Marine Engine 4.3 5.0 MPI & Seacore 4.3 5.0 Installation Manual – PDF DOWNLOAD
90-899883178_FM pdf 1
4 3, 5 0 MPI & SeaCore 4 3, 5 0 Models 1
Notice 1
Notice to Boat Manufacturer/Installer 1
Manual Outline 3
90-899883178_1 pdf 5
Important Information 5
Torque Specifications 6
Quicksilver Products 6
Accessories 6
Remote Controls and Instrumentation for the DTS System 7
Identification 7
Serial Number Decal Placement 7
Bravo Sterndrive Serial Number and Identification 7
Bravo Transom Serial Number 8
Bravo Three Notice: Trim-in Limit Insert 9
Multiple Sterndrive Steering Tie Bar Arrangements 9
Internal Power Steering With Internal Tie Bar Only 10
Internal Power Steering With Internal and External Tie Bar 10
External Power Steering 10
External Power Steering With Low External Tie Bar 10
SeaCore Components and Castings 10
Stainless Steel Fasteners 10
Corrosion Protection 11
Anti-fouling Paint 11
Emission Control Information Label 13
Owner Responsibility 14
Star Label 14
Hang Tag 15
90-899883178_2 pdf 17
Boat Construction 17
Boat Construction 18
Transom Thickness and Surface Plane 18
Transom Cutout 18
Checking Transom Thickness 18
Engine Bed 18
90-899883178_3 pdf 19
Exhaust System 19
Exhaust System 20
Important Information 20
Carbon Monoxide Poisoning 20
Good Ventilation 20
Poor Ventilation 21
Measuring Exhaust Elbow Height 21
General Information 21
Exhaust Angle Measurement 22
Boat Requirements 22
Loading Requirements 23
Loading the Boat with a Capacity Plate 23
Example 24
Loading the Boat—Without a Capacity Plate 25
Example 26
Clear Hose Measurement Method 28
Clear Hose Measurement Method from Seacock or Muffler Drain 29
90-899883178_4 pdf 31
Fuel System 31
Fuel Delivery System 32
California Regulations for 2007—Low-Permeation Fuel Hose 32
Fuel Lines and Fittings 32
Special Information About Electric Fuel Pumps 34
90-899883178_5 pdf 35
Cooling System 35
General Information 36
Seawater Supply System 36
Seawater Supply Hose 36
Seawater Inlet Hose 36
Through-Hull Seawater Pickup System 37
Seawater Pickup 38
Seacock 39
Sea Strainer 40
Sterndrives With Closed Cooling Engines 41
Bravo Models with Closed Cooling 41
SeaCore Models 41
SeaCore Bravo One and Bravo Three Models 41
SeaCore Bravo Two Models 41
Seawater Pickups for SeaCore Sterndrive Engine Models 42
Installing the Y-Fitting 43
Installing the Seawater Supply Hose 43
Closed Cooling 44
Description 44
Antifreeze Recommendations 44
Coolant Recovery System 45
Hot Water Heater Hose Connections – MPI Models 45
Supply Hose Connection 46
Return Hose Connection 47
Water Flow Diagrams 48
V-6 and V-8 48
V-8 Bravo Models With Closed Cooling and Risers 48
V-6 Alpha Models With Closed Cooling and Risers 49
V-8 Bravo Models With Closed Cooling 50
V-6 Sterndrive Models With Closed Cooling 51
V-6 Bravo MPD Models With Seawater Cooling 52
V-8 Bravo MPD Models With Seawater Cooling 53
V-8 Bravo Models With Seawater Cooling (Except MPD Models) 54
V-6 Bravo Models With Seawater Cooling (Except MPD Models) 55
V-6 and V-8 Alpha MPD Models With Seawater Cooling 56
V-6 and V-8 Alpha Models With Seawater Cooling (Except MPD Models) 57
90-899883178_6 pdf 59
Drive System and Engine Installation 59
Transom Cutout 63
Finding The Crankshaft Vertical Center Line 63
Single Engine 63
Dual Engine 64
Finding Crankshaft Horizontal Center Line (X-dimension) 64
90 Degree Tool Method 65
Tape Measure Method 65
Cutting Out the Transom 66
Checking The Transom Thickness 68
General Information 69
Drive Shaft Extension Models 69
Rear Engine Mounts 69
All Bravo Models 70
SeaCore and Closed Cooling Engine Models Seawater Inlets 70
Alternative Mounting Of Gear Lube Monitor On Transom 70
Air Pump 71
Transom Assembly Installation 71
Installing Gimbal Housing Assembly 71
Installing the Alpha Inner Transom Plate 72
Installing Inner Transom Plate 72
Connecting Speedometer Pickup 74
Water Inlet Block-Off Plate Installation 75
Models With Alpha Sterndrive and Alternative Water Pickups 75
Alpha Models 76
Alternative Water Pickups 78
Bravo Models 78
Exhaust Preparation 80
Seawater Inlet Fitting and Gear Lube Monitor Fitting 81
Alpha Gear Lube Monitor Connection At Gimbal Housing 81
Seawater Inlet Fitting Installation 82
Gear Lube Monitor Connection At Gimbal Housing 83
Exhaust at Transom 84
Transom Exhaust Connections 84
Power Trim Pump Installation 85
Power Trim Pump 85
Power Trim Pump Connections and Filling 85
Filling 86
Trim Limit Switch Connection 87
Steering System Installation 87
Hydraulic (Helm) Steering 87
Steering Helm and Cable 87
Steering Cable Specifications 88
Installing Steering System 88
Sensor Steering Assembly 92
Installing the Pitot Sensor 93
Preliminary Transom Harness Connections 94
Transom Harness 94
Engine Installation 95
Transom Preparation 95
Shift Cable Routing 95
Engine Preparation 96
Gen II Cool Fuel with Boost Pump Inlet Fitting 97
Gen III Cool Fuel Module Inlet Fitting 98
Exhaust System Hose Connections 102
Engine Alignment Sterndrive Models 103
Electrical Connections 105
Boat Harness and Instrumentation Connections 106
SmartCraft Product 107
Audio Warning System Connections 107
MerCathode Connections 108
Power Trim Electrical Connection 108
Power Trim Pump Connections 109
Battery Cables Connection 109
Fluid Connections 109
Gear Lube Monitor Connection 109
Power-Assisted Steering Hoses 110
Alpha Seawater Inlet Hose Connection 111
Seawater Inlet Fitting Connection 111
Coolant Recovery System 114
Alpha Shift Cable Installation 115
Alpha Sterndrive Shift Cable Installation 115
Shift Cable Travel 116
Separate Shift and Throttle Controls 116
Installation 117
Bravo Shift Cable Installation and Adjustment 120
Bravo Models Shift Cable Installation 120
Bravo Models Shift Cable Adjustment 121
DTS System Installation 124
Shift Cable Installation For DTS System 124
Throttle Cable Installation 125
Throttle Cable Installation And Adjustment 125
Alpha Sterndrive Installation 126
Speedometer Connection – Alpha Models 132
Alpha Notice: Increased Trim-in Range Capability 133
Alpha Trim Cylinder Spacer Removal 133
Alpha Trim Cylinder Disassembly 134
Alpha Trim Cylinder Reassembly 135
Alpha Trim Cylinder Installation 136
Bravo Sterndrive Installation 138
Speedometer Connections – Bravo Models 147
Trim Limit and Trim Position Settings 148
Bravo Sterndrive Shift Check (Engine Running) 148
Troubleshooting Shift Problems 149
Paddle Wheel Speed Sensor Installation (If Equipped) 152
Parts Provided 152
Selecting Location 152
Transom Angle Requirements 152
Installing Bracket 153
Routing the Cable 153
Drilling Hole Through Transom (optional) 153
Without Drilling Hole Through Transom (optional) 154
Installing and Removing the Paddle Wheel 154
Wiring Connections 154
Template – Paddle Wheel Speed Sensor 155
90-899883178_7 pdf 157
Electrical System 157
General Information 159
Boat Harness and Accessories Information 159
Power Trim Electrical Connection 159
Batteries 160
Battery 160
Battery Cables 160
Multiple MPI Engine Battery Information 161
Boat Harness and Installation Connections 161
Engine Harness and Accessory Power Supply 161
Boat Wiring 161
Single Station 162
Dual Station 162
Boat Harness Installation Guidelines—MPI Sterndrive 162
Boat Harness Deutsch Connector to Engine 162
Key Switch Connector 163
Trim Switch 164
Neutral Switch 165
Lanyard Stop Switch 165
Optional E Stop 166
Warning Horn 166
Accessory Relay Connection 166
Additional Relay Kit 166
Gauge Connection 166
CAN P (CAN 1) Connections 168
CAN V (CAN 3) Connection 168
General Repower Information 168
Transom Harness—MPI 169
Transom Harness—DTS 170
Transom Ground Connection 171
Wiring Diagrams 172
Transom Harness—MPI 172
Transom Harness—DTS 173
Boat Harness 174
Drawing 174
Diagram 175
Analog Gauge Harness 176
Drawing 176
Diagram 176
Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly) 177
Power Trim System 179
Adaptor Harness for Power Trim Pump—DTS 180
14-Pin Engine Harness Connector 180
DTS Information and Installation 180
Special Tools – DTS Installation 180
Installation Guidelines for DTS System Components 180
Data Harness 181
Connectors 181
Weather Caps 181
DTS Battery Specifications 181
Junction Box (if Equipped) 182
Data Harness Installation 183
Data Harness Pulling Procedure 183
Connecting 14 Pin Data Harness – Single Engine 184
Single Helm 184
Dual Helm 184
Connecting 14 Pin Data Harness – Dual Engine 185
Single Helm 185
Dual Helm 185
DTS Command Module and Harness Installation 186
Installing DTS Command Module and Harness – Single Engine 186
Harness Installation 186
Module Installation 187
Installing DTS Command Module and Harness – Dual Engine 188
Harness Installation 188
Module Installation 190
Analog Gauge Interface (AGI) 191
Analog Gauge Interface (AGI) Installation 191
Configuring Analog/Digital Tachometer Signal through PCM 192
PCM Configuration with CDS 192
90-899883178_8 pdf 195
Remote Controls 195
Remote Control Installation 198
Locating and Drilling Mounting Area 198
Installing DTS Panel Mount Control 198
Installing DTS Single Handle Console Control 200
Installing DTS Dual Handle Console Control 203
Installing DTS Zero Effort Control 206
Steering System Information 208
High Speed Or Twin Engine Applications Steering Recommendation 208
Steering Helm and Cable 209
Steering Cable Specifications 210
Hydraulic (Helm) Steering 210
Sterndrive Shift Cable Information 211
Propeller Rotation 211
Checking Alpha Shift Cable Installation and Adjustment 211
Bravo Sterndrive Shift Check (Engine Running) 215
Troubleshooting Shift Problems 216
DTS Remote Control – Sterndrive 219
DTS Calibration 219
Special Tools – DTS Calibration 219
Methods of Calibration 219
Setting Trailer and Trim Limit 219
Setting Trailer Limit with CDS 219
Setting Trim Limit with CDS 220
Troubleshooting Procedure 220
Troubleshooting Information 220
Default Sensor Values 220
Fault Conditions 221
Sticky/Non-Sticky Faults 221
Engine Guardian 221
Warning Horn Signals 221
Special Tools – DTS Troubleshooting 221
90-899883178_9 pdf 223
Predelivery Preparation and Storage 223
Predelivery Preparation 226
Engine Oil 226
Checking 226
Adding Engine Oil 226
Power Steering Fluid 227
Power Trim Pump 227
Drive unit gear lube monitor 228
Filling Coolant Recovery Bottle 229
Alpha Trim Limit Switch Adjustment 229
Analog Guages 229
Bravo Trim Limit Switch Adjustment – Analog Gauges 230
Trim Position Sender Adjustment – Analog Gauges 232
Trim Position Sender Adjustment – SmartCraft Gauges Scan Tool Method 233
Trim Position Sender Adjustment – SmartCraft Gauges Multimeter Method 234
Propeller Selection 234
Alpha Sterndrive Propeller Installation 235
Alpha Models 236
Bravo Sterndrive Propeller Installation 236
Bravo One Models 237
Bravo Two Models 238
Bravo Three 239
Battery Connection 240
Priming the Fuel System 240
Test Running Engine 241
Boat Out Of the Water 241
Boat In the Water 241
Testing Preparation 242
Testing 243
Boat In The Water Tests 243
Engine Idle Speed 243
Wide Open Throttle Test 243
Checking Shift Operation 244
Flushing the Power Package 244
SeaCore Power Package Flushing Procedure 247
Models Using The Sterndrive Water Pickup 247
Cold Weather or Extended Storage 251
Preparing Power Package for Storage 251
Engine and Fuel System Preparation 252
Draining the Seawater System 253
Drain System Identification 254
Air Actuated Single Point Drain System 254
Manual Single Point Drain System 254
Three Point Manual Drain System 255
Multi-Point Drain (MPD) System 255
Air-Actuated Single-Point Drain System 256
Boat in the Water 256
Boat out of the Water 258
Manual Single-Point Drain System 260
Boat in the Water 260
Boat out of the Water 261
Three Point Manual Drain System 262
Boat in the Water 262
Boat out of the Water 263
Multi-Point Drain (MPD) System 264
Boat out of the Water 264
Boat in the Water 266
Battery Storage 268
Power Package Recommissioning 268
VIDEO PREVIEW OF THE MANUAL:
S.V 05/24