Mercury Alpha, Bravo, MerCruiser Alpha 3.0L, MerCruiser Bravo 4.3L, MerCruiser Bravo 5.0L Installation Manual
...
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
Mercury MerCruiser, Mercury, Mercury
Marine, Quicksilver, Ride-Guide, Thruster
and Mercury Precision Parts.
GASOLINE ENGINE STERNDRIVE MODELS
INSTALLATION MANUAL
Models Covered
Alpha
Model Serial Number or Year
3.0L
Bravo
Notice
4.3L
5.0L
5.7L
Model Serial Number or Year
4.3L
5.0L
5.7L
NOTICE
After completing installation, these instructions should be placed with the
product for the owner’s future use.
NOTICE
Predelivery preparation instructions must be performed before delivering boat
to the product owner.
0M093621 and Above
0M093633 and Above
Page 1 of 137 Printed in U.S.A. - 2001, Mercury Marine 90-860172011 NOVEMBER 2001
GASOLINE STERNDRIVE INSTALLATION MANUAL
Table Of Contents
General Information 3. . . . . . . . . . . . . . . . .
Notice to Boat Manufacturer/Installer 3. . . . .
Torque Specifications 4. . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 5. . . . . . . . . .
Special Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alpha Notice: Increased Trim-In Range
Capability 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In Limit Insert 7. . . . .
Quicksilver Products 7. . . . . . . . . . . . . . . . . . . . . .
Accessories 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 8. . . . . . . . . . . .
Corrosion Protection 8. . . . . . . . . . . . . . . . . . . . . .
Anti-fouling Paint 9. . . . . . . . . . . . . . . . . . . . . .
Boat Construction 10. . . . . . . . . . . . . . . . . . . . . . .
Transom Thickness and Surface 10. . . . . . . .
Engine Bed 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Vertical Centerline 11. . . . . . . . . . .
Crankshaft Horizontal Centerline
(X-Dimension) 12. . . . . . . . . . . . . . . . . . . . . .
Transom Cutout 14. . . . . . . . . . . . . . . . . . . . . .
Seawater Connections - General
Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Pickup 16. . . . . . . . . . . . . . . . . . . . .
Preliminary Connections 18. . . . . . . . . . . . . . . . .
Power Trim Pump 18. . . . . . . . . . . . . . . . . . . .
Fuel Inlet Fitting 19. . . . . . . . . . . . . . . . . . . . . .
Transom Connections 20. . . . . . . . . . . . . . . . . . .
Installing Gimbal Housing 20. . . . . . . . . . . . . .
Installing Inner Transom Plate 21. . . . . . . . . .
Connecting Speedometer Pickup 22. . . . . . .
Fluid Connections 23. . . . . . . . . . . . . . . . . . . .
Installing Steering System 25. . . . . . . . . . . . .
Transom Preparation 35. . . . . . . . . . . . . . . . . .
Driveshaft Extension Models 39. . . . . . . . . . . . . .
Engine Preparation 39. . . . . . . . . . . . . . . . . . . . . .
Engine Installation 40. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 43. . . . . . . . . . . . . . . . . . . . . .
Methods for Measuring Exhaust
Elbow Height 46. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System Hose / Tube
Connections 48. . . . . . . . . . . . . . . . . . . . . . . .
Engine Alignment 49. . . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation 53. . . . . . . . . . .
Electrical Connections 55. . . . . . . . . . . . . . . . . . .
Installing Continuity Wire 55. . . . . . . . . . . . . .
Instrumentation Connections 56. . . . . . . . . . .
Trim Position Sender Connections 57. . . . . .
MerCathode Connections 57. . . . . . . . . . . . . .
Audio Warning System Connections 58. . . .
Power Trim Pump Connections 59. . . . . . . . .
Fluid Connections 61. . . . . . . . . . . . . . . . . . . . . . .
Gear Lube Monitor Hose 61. . . . . . . . . . . . . .
Power Steering Hoses 62. . . . . . . . . . . . . . . .
Bravo Models and Alpha Seawater
Cooled Models Using Sterndrive
Water Pickups 62. . . . . . . . . . . . . . . . . . . . . .
Alpha or Bravo Models Using
Alternative Water Pickups 63. . . . . . . . . . . .
Coolant Recovery System 66. . . . . . . . . . . . .
Shift Cable Installation 67. . . . . . . . . . . . . . . . . . .
Alpha Models - Drive Unit Not
Installed 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Models 72. . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation and
Adjustment 76. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit Installation 77. . . . . . . . . . . . . . . .
Alpha Models 79. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Models 82. . . . . . . . . . . . . . . . . . . . . . . .
All Models 86. . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Connection 87. . . . . . . . . . . . . . . .
Alpha Models 87. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Models 88. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 89. . . . . . . . . . . . . . . . . . .
Alpha Models - Drive Unit Installed 89. . . . . .
Troubleshooting Shift Problems 95. . . . . . . . .
Predelivery Preparation 98. . . . . . . . . . . . . . . . . .
Power Steering Fluid 98. . . . . . . . . . . . . . . . . .
Filling Coolant Recovery Bottle 99. . . . . . . . .
Power Trim Pump 99. . . . . . . . . . . . . . . . . . . .
Trim Position Sender Adjustment 100. . . . . .
Propeller Selection 101. . . . . . . . . . . . . . . . . . .
Propeller Installation 102. . . . . . . . . . . . . . . . .
Battery 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Running Engine 107. . . . . . . . . . . . . . . . .
Boat In The Water Tests 111. . . . . . . . . . . . . . .
Cold Weather and Extended Storage 114. . . . .
Draining Instructions 114. . . . . . . . . . . . . . . . . . . .
3.0L Single Point Drain 115. . . . . . . . . . . . . . .
V6 And V8 Seawater (Raw-Water)
Cooled Models 119. . . . . . . . . . . . . . . . . . . . .
V6 And V8 Closed Cooled Models 122. . . . .
All Models 124. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 126. . . . . . . . . . . . . . . . . . . . . . .
Instrumentation 126. . . . . . . . . . . . . . . . . . . . . .
Power Trim System 128. . . . . . . . . . . . . . . . . . . . .
MerCathode System Wiring Diagram 129. . . . .
MCM Gasoline Engine Wiring Diagrams 130. . .
3.0L Engines 130. . . . . . . . . . . . . . . . . . . . . . . .
MCM 4.3L, 5.0L And 5.7L Alpha
Engines 131. . . . . . . . . . . . . . . . . . . . . . . . . . .
MCM 4.3L Bravo Engines 132. . . . . . . . . . . . .
MCM 5.0L and 5.7L Bravo Engines 133. . . .
Water Flow Diagrams 134. . . . . . . . . . . . . . . . . . .
181 cid / 3.0L Engines 134. . . . . . . . . . . . . . . .
V8 Engines - Seawater Cooled 135. . . . . . . .
V6 and V8 Engines - Closed Cooled 136. . .
Predelivery Inspection 137. . . . . . . . . . . . . . . . . .
Page 2 of 137 90-860172011
General Information
Notice to Boat Manufacturer/Installer
Throughout this publication, Warnings and Cautions (accompanied by the International
Hazard Symbol ! ) are used to alert the manufacturer or installer to special instructions
concerning a particular service or operation that may be hazardous if performed incorrectly
or carelessly. –– Observe Them Carefully!
These Safety Alerts, alone, cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
Hazards or unsafe practices which could result in severe personal injury or death.
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
IMPORTANT: Indicates information or instructions that are necessary for proper
installation and/or operation.
GASOLINE STERNDRIVE INSTALLATION MANUAL
WARNING
CAUTION
NOTE: Refer to the Mercury MerCruiser Product Applications Manual - Gasoline Sterndrive
Models for application recommendations.
This installation manual has been written and published by Mercury Marine to aid the boat
manufacturer (OEM) in the installation of the products described herein.
It is assumed that these personnel are familiar with marine product installation.
Furthermore, it is assumed that they are familiar with, if not trained in, the recommended
installation procedures of Mercury MerCruiser product.
We could not possibly know of or advise the marine trade of all conceivable installations and
of the possible hazards and/or results of each installation. Therefore, the OEM is
responsible for any installation that does not fulfil the requirements of this manual.
It is the responsibility of the boat manufacturer to select the appropriate
engine/transom/drive package (including the correct gear ratio and propeller) for a given
boat. Mercury recommends that any new or unique hull/power package combination be
thoroughly water tested prior to sale, to verify that the boat performs as desired, and that
the engine runs in the appropriate rpm range.
It is recommended that a Mercury Marine Sales Application Engineer (SAE) be contacted
for assistance.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at time of publication. As required, revisions to this
manual will be sent to all OEM boat companies.
90-860172011 Page 3 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Description
Nm lb-in. lb-ft
Gear Lube Monitor Fitting 9 80
Speedometer Pickup Barb Fitting 1.5 13
Exhaust Pipe or Block-off Plate 31 23
Power Steering Hydraulic Hose Fittings 31 23
Power Trim Pump Hose Fittings 14 125
Propeller Nut Alpha One, Bravo One and Bravo Two
1
75 55
Front Propeller Nut Bravo Three 136 100
Rear Propeller Nut Bravo Three 81 60
Rear Engine Mounts 51 38
Steering Cable Coupler Nut 48 35
Steering System (Pivot Bolts) 34 25
Sterndrive Unit Fasteners 68 50
Transom Assembly Fasteners 31 23
Seawater Pickup Fitting 5 45
Finger tight + 1-3/4 to
Fuel Inlet Fitting
2-1/4 turns with a wrench.
DO NOT overtighten.
1
Amount specified is MINIMUM.
Page 4 of 137 90-860172011
Lubricants / Sealants / Adhesives
Description Where Used Part Number
GASOLINE STERNDRIVE INSTALLATION MANUAL
Coupler Splines
Engine Coupler Spline Grease
2-4-C Marine Lubricant With
Teflon
Special Lubricant 101
Dexron III - Automatic
Transmission Fluid
Power Trim and Steering Fluid
Liquid Neoprene
Drive Unit Pilot
U-Joint O-rings
92-816391A4
Drive Shaft Splines
Anchor Pins
Trim Cylinder Hardware
O-ring Seals
92-825407A3
Shift Cable End
Propeller Splines
Pivot Bolts
Power Steering Bushings
Clevis Pin
92-13872A1
Steering Cable End
Propeller Splines
Power Steering Pump Obtain Locally
Power Steering Pump
Power Trim Pump
92-90100A12
Battery Terminals
MerCathode Connections
92-25711-2
Speedometer Barb Fitting
Fuel Inlet Fitting
Loctite 592 PST
Seawater Inlet Hose Fitting
Obtain Locally
Threads
Seawater Inlet Plastic Plug
Threads
Loctite 271 Seawater Inlet Nut 92-809820
Power Trim Pump
SAE 30W Engine Oil
Shift Cable Pivot Points
Obtain Locally
SAE 10W40 Engine Oil Power Trim Pump Obtain Locally
Marine Caulking
Seawater Inlet Mounting
Surfaces
Obtain Locally
Power Tune Exhaust Tubes 92-802878-57
Quicksilver High Performance
Gear Lube
Sterndrive Unit 92-802853A1
Silicone Sealant Or Equivalent Screw Shaft Obtain Locally
Equivalent products may be used.
90-860172011 Page 5 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
Special Tools
Description Part Number
Transom Drilling Fixture 91-43693A2
Engine Alignment Tool 91-805475A1
Shift Cable Adjustment Tool 91-12427
Engine Mount Drilling Fixture 91-806794A1
Tapered Insert Tool 91-43579
Shift Shaft Slide Stabilizer Tool 91-809815A1
Alpha Notice: Increased Trim-In Range Capability
The Alpha trim cylinders provide the capability for an increased trim-in range. A spacer can
be removed from the trim cylinders to increase the trim-in range by approximately 1-1/2
degrees. This will improve the acceleration on some boats by forcing the bow down more
quickly. If the spacers are to be removed, the boat must be water tested to ensure that the
increased trim-in range does not cause any undesired boat handling characteristics
(bow-steer, chine-walk, etc.) if the sterndrive is trimmed in while the boat is operated at
higher speeds. The boat should be tested under all conceivable load conditions and
maneuvers to ensure that the additional trim-in does not pose a problem. The final decision
and responsibility for use of the additional trim-in range is left up to the boat manufacturer.
WARNING
It is recommended that only qualified personnel adjust the Trim-In Limit Spacer.
Boat must be water tested after adjusting or removing the device to ensure that the
modified trim-in range does not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is trimmed in at higher speeds. Increased
trim-in range may cause handling problems on some boats that could result in personal injury.
Page 6 of 137 90-860172011
GASOLINE STERNDRIVE INSTALLATION MANUAL
Bravo Three Notice: Trim-In Limit Insert
NOTE: Bravo One, Two and Three Models are equipped with a Trim-In Limit Insert.
It has been brought to our attention that some boats (predominantly deep-Vee heavy boats)
will roll up on their side under certain, specific, operating conditions. The roll can be either
to port or starboard and may be experienced while moving straight ahead, or while making
a turn. The roll occurs most frequently at or near maximum speed, with the sterndrive unit
trimmed at or near full trim-in. While the boat will not roll completely over, the roll may be
sufficient to unseat the operator or passengers, and thereby create an unsafe situation.
The roll is caused by stern-lift created from excessive sterndrive unit trim-in. Under these
extreme stern-lift / bow-down conditions instability can be created which may cause the boat
to roll. Weight distribution to the stern can reduce stern-lift and, in some circumstances, help
to control the condition. Weight distribution in the bow, port or starboard, may worsen the
condition.
The T rim-In Limit Insert reduces stern-lift by preventing the sterndrive unit from reaching the
last few degrees of full trim under. While this device should reduce the rolling tendency, it
may not eliminate the tendency entirely. The need for this Trim-In Limit Insert, and its
effectiveness, can only be determined through boat testing and is ultimately the
responsibility of the boat manufacturer.
It is recommended that only qualified personnel adjust the Trim-In Limit Insert. Boat
must be water tested after adjusting the device to ensure that the modified trim-in
range does not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is trimmed In at higher speeds. Increased trim-in range may
cause handling problems on some boats which could result in personal injury.
Quicksilver Products
Accessories
Quicksilver gauges, remote controls, steering systems, propellers and other accessories
are available for this product. Mercury MerCruiser recommends the use of Quicksilver parts
on all applications. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for a
complete listing.
This Guide is available from:
WARNING
Mercury Marine
Attn: Parts Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Outside of U.S.A., order through Distribution Center or Distributor.
90-860172011 Page 7 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
Serial Number Decal Placement
There are three sets of engine, transom assembly and sterndrive serial number decal strips
provided with each power package. One should be used for each of the following:
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance and Warranty Manual identification page.
Affix serial number decals to specification / serial number decal.
Corrosion Protection
Mercury MerCruiser power packages are equipped with anodes to help protect them from
galvanic corrosion under moderate conditions. However, for severe conditions or if using
a stainless steel propeller, it is recommended that a Quicksilver Anti-Corrosion Anode Kit
and/or a MerCathode System be installed (some models have a MerCathode System as
standard equipment). A MerCathode Monitor also is available to allow the operator to check
the operation of the MerCathode System with the push of a button. (Refer to “Quicksilver
Mercury Precision Parts / Quicksilver Accessories Guide” for part numbers.)
Boats which are connected to AC shore power require additional protection to prevent
destructive low voltage galvanic currents from passing through the shore power ground
wire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currents
while still providing a path to ground for dangerous fault (shock) currents. (Refer to Mercury
Precision Parts / Quicksilver Accessories Guide for part number.)
IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode
System and anodes may be unable to handle the increased galvanic corrosion
potential.
Refer to Marine Corrosion Protection Guide P/N 90-881813 01 for specific information about
marine corrosion.
Page 8 of 137 90-860172011
Anti-fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of
anti-fouling paint will not be covered by the limited warranty.
Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and
boat transom but you must observe the following precautions:
IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and
anode, as this will render them ineffective as galvanic corrosion inhibitors.
GASOLINE STERNDRIVE INSTALLATION MANUAL
IMPORTANT: If anti-fouling protection is required for boat hull or boat transom
copper or tin base paints, if not prohibited by law, can be used. If using copper or tin
based anti-fouling paints, observe the following:
• Avoid an electrical interconnection between the Mercury MerCruiser Product,
Anodic Blocks, or MerCathode System and the paint by allowing a minimum of
1-1/2 in. (40 mm) UNPAINTED area on transom of the boat around these items.
a
b
a-Painted Boat Transom
b-Minimum 1-1/2 in. (40 mm) UNPAINTED Area Around Transom Assembly
NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine
paint or an anti-fouling paint that DOES NOT
could conduct electrical current. Do not paint drain holes, anodes, MerCathode system or
items specified by boat manufacturer.
contain copper, tin, or any other material that
71176
,
90-860172011 Page 9 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
Boat Construction
Transom Thickness and Surface
IMPORTANT: Transom thickness and surface plane (flatness) must be controlled
where the sterndrive unit mounts.
Thickness Between 2 - 2-1/4 in. (51 - 57 mm) for 8 in. (203 mm) to either
side of the vertical centerline
Parallelism Inner and outer surfaces must be parallel within 1/8 in. (3 mm)
Flatness Transom surfaces in area where transom assembly will be
mounted (includes vertical as well as horizontal dimensions):
Inner Surface – Flat within1/8 in. (3 mm)
Outer Surface – Flat within1/16 in. (2 mm)
Angle 10 -16 Degrees
Transom Specifications
a
e
b
c
a-Transom Thickness
b-Inner Surface
c-Outer Surface
d-Transom Plate Coverage
e-Transom Angle
a
b
22170
d d
72700
a-Measuring Thickness
b-Measuring Flatness
c-Suitable Mandrel To Check For Uniform Transom Thickness
Page 10 of 137 90-860172011
70004
c
75479
Engine Bed
Difference Between Starboard and Port Engine Mount 22-1/2 in. (572 mm)
Mount Adjustment Up and Down (minimum) 1/4 in. (6 mm)
NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure
that the front and rear mount locations in the vessel are parallel and in the same plane. This
may be checked by tying a string from the left front mount location to the right rear mount
location and another from right front to left rear. The strings should touch where they cross
Crankshaft Vertical Centerline
1. Locate and mark boat vertical centerline on transom.
GASOLINE STERNDRIVE INSTALLATION MANUAL
.
a
71620
a-Vertical Centerline
2. For Dual Engines: Locate and mark crankshaft vertical centerlines “a” on transom.
b
a a
c
c
22033
a-Crankshaft Vertical Centerline
b-Minimum Distance Between Crankshaft Vertical Centerlines
c-Crankshaft Vertical Centerlines Must Be An Equal Distance From Boat Vertical
Centerline
Minimum Distance Between Crankshaft Vertical Centerlines (Dual Side-By-Side)
Model in. (mm)
181 cid / 3.0L 28 (710)
262 cid / 4.3L
305 cid / 5.0L
350 cid / 5.7L
90-860172011 Page 11 of 137
33 (838)
GASOLINE STERNDRIVE INSTALLATION MANUAL
Crankshaft Horizontal Centerline (X-Dimension)
X-Dimension can be measured by the 90 degree Tool Method or by the Tape Measure
Method.
90 DEGREE TOOL METHOD
1. Construct 90 degree tool.
a
90°
b
71621
a-13-9/16 in. (345 mm)
b-Measurement: 4 ft. (1.2 m)
To Lower Drive Unit - Subtract
To Raise Drive Unit - Add
from dimension “a.”
to dimension “a.”
IMPORTANT: This dimension should only be raised or lowered after proper testing.
71622
71623
Single Engine Dual Engine
2. Place 90 degree tool along boat bottom at vertical centerline.
3. Locate the point at which top of tool contacts transom on vertical centerline. This is the
crankshaft horizontal centerline or X-Dimension.
4. Draw a line perpendicular to vertical centerline at crankshaft horizontal centerline.
Page 12 of 137 90-860172011
TAPE MEASURE METHOD
1. Determine X-Dimension from the following chart.
GASOLINE STERNDRIVE INSTALLATION MANUAL
Transom Angle
(degrees)
This dimension should only be raised or lowered after proper
testing.
16 14-5/16 in. (364 mm)
15 14-1/4 in. (362 mm)
14 14-3/16 in. (360 mm)
13 14-1/8 in. (359 mm)
12 14-1/16 in. (357 mm)
11 14 in. (356 mm)
10 13-15/16 in. (354 mm)
2. Measure up from the boat bottom the amount shown on the chart for the appropriate
transom angle.
71622
71623
Single Engine Dual Engine
3. Draw a line perpendicular to vertical centerline at crankshaft horizontal centerline.
90-860172011 Page 13 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
Transom Cutout
IMPORTANT: The following instructions will provide a sterndrive unit mounting
location that is suitable for most boats. Best mounting location for a particular boat,
however, can be determined only by testing.
1. Below 25 mph (40 km/h):
2. Heavy Duty Applications:
3. Above 25 mph (40 km/h):
4. Above 50 mph (80 km/h):
Subtract 1/2 in. (13 mm) from X-Dimension.
Subtract 1 in. (25 mm) from X-Dimension.
Use X-Dimension shown.
The X-Dimension can be increased to improve performance
in some applications. However, pulling power for skiing will decrease. During testing,
X-Dimension should be increased 1/2 in. (13 mm) at a time until desired performance
is achieved but in no case should it ever be increased by more than:
Maximum Increase In X-Dimension
Alpha 2-1/2 in. (64 mm)
Bravo One and Two 3 in. (76 mm)
Bravo Three 1 in. (25 mm)
Extreme care should be taken when raising drive unit to ensure that water supply does not
become aerated. Use clear water inlet hose to monitor incoming water and monitor engine
temperature gauge to ensure engine does not overheat.
In applications where cooling water to the engine is supplied by a through the hull
or through the transom fitting, the sterndrive height will not cause cooling water aeration.
IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an
installed height will not be covered by Mercury MerCruiser warranty.
Page 14 of 137 90-860172011
GASOLINE STERNDRIVE INSTALLATION MANUAL
5. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased
separately).
90-79135--3
50017
22056
Transom Cutout Template Transom Drilling Fixture Kit
6. Follow instructions indicated on template or provided with drilling fixture.
7. Ensure that centerlines on either the template or transom drilling fixture align with lines
previously marked on transom.
8. Drill 1/4 in. (6 mm) pilot holes for hole saw guide at a 60 degree angle and cut on the
line when making transom cutout. If cutout is made incorrectly, drive unit steering lever
may contact transom, thus limiting steering travel.
9. Seal inside edge of transom cutout opening with a suitable sealant to prevent water
absorption and deterioration of transom.
10. Cut drain hole and install drain plug flange with appropriate fasteners.
90-860172011 Page 15 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
Seawater Connections - General Information
This section covers through the hull and through the transom water inlets only. For information on sterndrive water inlet connections, refer to the appropriate section after engine installation.
IMPORT ANT: Seal the inside edges of any hole made through the hull with a suitable
sealant to prevent water absorption and deterioration.
Seawater Pickup
THROUGH THE HULL MOUNTED
Description
A Marine Caulking Mounting Surfaces Obtain Locally
1. Seal inside edges of 1-3/4 in. (44 mm) hole in hull using a suitable sealer.
2. Apply marine caulking (sealer) to mounting surface on seawater pickup where hull
contact will occur when installed.
IMPORT ANT: Seawater inlet slots must face forward - parallel with the flow of water.
3. Ensure slots in seawater pickup are facing forward (toward bow of boat) and install
seawater pickup through hull.
4. Fasten pickup with four appropriate mounting screws (if so designed).
b
A
Where Used Part Number
d
c
a
72639
a-Seawater Pickup
b-Seawater Inlet Slots
c-Mounting Screw Holes (If Equipped)
d-Nut
5. Apply marine caulking as needed inside boat. Apply sealant to threads of nut and install
on pickup on inside of boat and torque nut.
Description
Loctite 271 Seawater Inlet Nut 92-809820
Description Nm lb-in. lb-ft
Nut 42 35
NOTE: If pickup being installed does not have mounting screws on underside where
mounted to hull, be certain, after nut is torqued, that slots are still facing forward.
Page 16 of 137 90-860172011
Where Used Part Number
TRANSOM MOUNTED
1. Seal the inside edges of the 1-1/2 in. (38 mm) hole hose fitting.
2. Ensure that the hose fitting and plastic plug are in place and threads have been sealed
GASOLINE STERNDRIVE INSTALLATION MANUAL
prior to tightening each securely.
Description
Where Used Part Number
Hose Fitting Threads
A Loctite 592 PST
Plastic Plug Threads
Obtain Locally
B Silicone Sealant Or Equivalent Screw Shaft
NOTE: Use a sharp knife or wood chisel to remove excess plastic plug material so that plug
is flush with pickup casting.
3. Position one flat washer and one rubber O-ring on each 5/16 in. x 4 in. (102 mm) long,
round head screw. Coat each screw shaft with sealant.
4. Place new gasket on pickup housing and hold pickup in place on transom. Install four
round head screws (with washers and O-rings in place) into pickup mounting holes and
through drilled 21/64 in. (8 mm) holes in transom.
b
d
A
a
e
B
f
c
g
A
h
i
j
72640
a-Hose Fitting
b-Nut (4)
c-Gasket
d-O-ring (4)
e-Washer (4)
f-Screw (4)
g-Plastic Pug
h-Pickup
i-Screen
j-Screw (2)
90-860172011 Page 17 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
NOTE: Some installations may have 7/32 in. (5 mm) holes drilled in transom using four 5/16
in. diameter stainless steel lag bolts in place of round head screws. In any case, flat washers
and O-rings are required as outlined.
Water Pickup Installed on Transom
a-Diagonal Mount - Leading Edge Of Pickup 1/8 in. (3.2 mm) From Boat Bottom.
b-Vertical Mount - Corner Of Leading Edge Of Pickup 1/8 in. (3.2 mm) From Boat
Bottom
5. Secure water pickup from inside with locknuts and washers (unless using lag bolts).
6. Tighten fasteners securely.
Preliminary Connections
Power Trim Pump
1. Select an appropriate mounting location for the trim pump that:
• Is within length limits of black and gray hydraulic hoses coming from gimbal housing
assembly.
a
b
72641
• Is close to the battery so that trim pump battery leads can be connected.
• Allows easy access to trim pump oil fill and vent locations.
• Is in an area where pump will not be exposed to water.
• Prevents the power steering booster cylinder from coming in contact with the trim pump
when the steering wheel is turned in either direction (right or left).
NOTE: Template 90-863152 provides mounting hole location for floor or transom mounting.
2. Remove the cap plug.
3. Mount the pump in the desired location.
Page 18 of 137 90-860172011
Fuel Inlet Fitting
IMPORTANT: The following information is provided to ensure proper installation of
brass fittings or plugs installed into fuel pump or fuel filter base:
• Use #592 Loctite Pipe Sealant with Teflon on threads of fuel inlet fittings or plugs.
• Fuel inlet fittings or plugs should first be threaded into fuel pump or fuel filter
• Fuel inlet fittings or plugs should then be tightened an additional 1-3/4 to 2-1/4
• To prevent over-tightening when installing a fuel line, the brass fittings should be
Boating standards (NMMA, ABYC and others) and Coast Guard regulations must
be adhered to when installing fuel delivery system.
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into
fuel pump or fuel filter base can crack casting and/or cause a fuel leak.
GASOLINE STERNDRIVE INSTALLATION MANUAL
DO NOT USE TEFLON TAPE.
base until finger tight.
turns using a wrench. DO NOT OVERTIGHTEN.
held with a suitable wrench as fuel inlet fittings are tightened securely.
WARNING
WARNING
1. Remove plastic plug from fuel inlet hole.
2. Apply sealant to threads of fuel inlet fitting. DO NOT USE TEFLON TAPE.
3. Install fuel inlet fitting. To prevent cracking the casting or causing fuel leaks, turn fuel inlet
fitting in by hand until finger tight, then tighten connector to 1-3/4 to 2-1/4 turns with
wrench. DO NOT overtighten.
a
A
b
A
a
78165
3.0L Model Typical V6 And V8 Models
a-Fuel Inlet Hose Connects Here
b-Fuel Outlet
77108
Description
A Loctite 592 Fuel Inlet Fitting Obtain Locally
90-860172011 Page 19 of 137
Where Used Part Number
GASOLINE STERNDRIVE INSTALLATION MANUAL
SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS
CAUTION
The electric fuel pump and factory installed water separating fuel filter have been
carefully designed to function properly together . Do not install additional fuel filters
and/or water separating fuel filters between fuel tank and engine.
The installation of additional filters may cause:
• Fuel Vapor Locking
• Difficult Warm-Starting
• Piston Detonation Due to Lean Fuel Mixture
• Poor Driveability
Transom Connections
Installing Gimbal Housing
1. Carefully remove transom assembly from shipping carton.
2. Remove and read all tags attached to transom assembly.
a
b
a-Dust Cover
b-Shipping Hardware
3. Remove the shipping hardware.
4. Remove the dust cover if boat will be shipped with drive installed.
5. Retain the serial number envelope.
22027
Page 20 of 137 90-860172011
Installing Inner Transom Plate
1. Insert wires, hoses and shift cable through appropriate openings in inner transom plate.
2. Position gimbal housing on transom and hold in place.
IMPORTANT: Tighten the transom assembly fasteners using an X-pattern torque
sequence, starting from the middle fasteners. Tighten in small increments and go
around the pattern several times until the proper torque is achieved.
3. Secure transom assembly with hardware as shown. Torque the hardware.
GASOLINE STERNDRIVE INSTALLATION MANUAL
Description
Nm lb-in. lb-ft
Transom Assembly Hardware 31 23
4. Attach continuity wires.
IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to
avoid stressing wire when steering lever moves.
5
3
7
2
b
a
71626
1
8
a
4
6
a
71628
c
a
70005
a-Locknuts And Flat Washers (8)
b-Torque Sequence
c-Continuity Wire
71627
c
a
71629
90-860172011 Page 21 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
5. Install the water inlet fitting and j-clip for the gear lube and the speedometer hose.
a
a-Water Inlet Fitting
b-J-clip
6. Torque J-clip fasteners.
Description
J-Clip Fasteners 5 45
Connecting Speedometer Pickup
Excess water in bilge can damage engine or cause boat to sink. Do not remove plug
from speedometer pickup tube fitting unless connection is to be utilized.
The connection for the speedometer pickup can be accessed through a hole and fitting in
the inner transom plate.
b
77916
Nm lb-in. lb-ft
CAUTION
1. Remove plug from speedometer pickup tube fitting.
b
a-Plug
b-Inner Transom Plate Fitting
a
70037
Page 22 of 137 90-860172011
GASOLINE STERNDRIVE INSTALLATION MANUAL
2. Apply sealant to threads of barb fitting. Install and torque the barb fitting.
Description
A Loctite 592 Speedometer Barb Fitting Obtain Locally
Description Nm lb-in. lb-ft
Barb Fitting 1.5 13
3. Connect a 5/32 in. (4 mm) speedometer hose (not provided) hose from speedometer
to barb fitting. Secure hose with cable tie.
4. Secure the hose to the transom with the hose clip and screw that are provided in the
parts bag.
NOTE: The hose must not come into contact with the steering system components or the
engine coupler and drive shaft.
Fluid Connections
1. Connect the gear lube monitor hose to the quick release 90 degree fitting.
a-Barb Fitting
a
A
70015
Where Used Part Number
CAUTION
Avoid sterndrive unit damage. Quick release button on gear lube monitor 90 degree
hose fitting may not lock on gimbal housing if touching or depressed by water inlet
fitting or block-off plate, if equipped. Failure to do so could result in a loose 90
degree fitting causing a loss of gear lube and damage to drive unit.
2. Connect 90 degree fitting to the gimbal housing.
a
b
77916
a-Water Inlet Fitting
b-90 Degree Fitting
90-860172011 Page 23 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
NOTE: The quick release button on hose fitting must be positioned away from water inlet
fitting, or block-off plate if equipped. Release button must not contact water fitting or
block-off plate, if equipped.
NOTE: The hose must not come into contact with the steering system components or the
engine coupler and drive shaft.
3. Select a mounting location for coolant recovery bottle and mounting bracket that meets
all of the following:
• Within limits of clear plastic tubing.
• Level with or above the heat exchanger fill neck.
• Accessible for observing coolant level and filling.
4. Mount coolant recovery bottle and mounting bracket in desired location using two
3/4 in. (19 mm) long screws and flat washers.
5. Route plastic tubing to recovery bottle. Ensure that tubing is positioned away from any
moving parts. Cut plastic tubing as required and connect to bottom connection on
recovery bottle and secure with tubing clamp provided.
6. Fasten plastic tubing to boat, as necessary , with 2 hose clips and 1/2 in. (13 mm) long
screws (provided).
b
a
c
d
a-Recovery Bottle And Mounting Bracket
b-Screws And Flat Washers
c-Plastic Tubing
d-Tubing Clamp
b
71712
Page 24 of 137 90-860172011
Installing Steering System
HYDRAULIC (HELM) STEERING
If your power package is equipped with Compact Hydraulic Steering, refer to the Compact
Hydraulic Steering Installation Instructions in the box with the compact hydraulic steering
components. Complete the installation of the hydraulic steering system before proceeding
to Transom Preparation.
POWER STEERING
NOTE: For dual installations, power steering unit can be mounted on port or starboard
transom assembly . Measure exact distance between power package centerlines. Select a
tie bar from Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar
installation instructions before proceeding.
1. Inspect the bushings for debris. Lubricate the bushings.
GASOLINE STERNDRIVE INSTALLATION MANUAL
a
A
b
73898
a-Bushings
b-Shipping Hardware
Description
Where Used Part Number
A Special Lubricant 101 Bushings 92-13872A1
2. Remove shipping hardware.
3. Remove the cotter pins.
4. Loosen the upper and lower pivot bolts and ensure that the threads are well lubricated..
Add lubricant as necessary.
Description Where Used Part Number
Special Lubricant 101 Pivot Bolts 92-13872A1
90-860172011 Page 25 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
5. Install steering assembly as follows:
a. Position steering assembly so that pivot bolts will enter bushings in pivot block or
power steering control valve.
b. Install upper and lower pivot bolts along with tab washers. Ensure that tab washer
tangs straddle the ridge on inner transom plate.
c. Turn pivot bolts all the way in by hand to ensure proper alignment.
d. Ensure steering assembly pivots freely.
6. Torque pivot bolts. Bend tab washer tangs against corresponding flats on bolt heads.
c
a
b
a
c
73900
a-Tab Washers
b-Ridge
c-Pivot Bolts
Description
Pivot Bolts 34 25
NOTE: It may be necessary to tighten further to align flats on pivot bolt with tangs on tab
washer.
Nm lb-in. lb-ft
73899
Page 26 of 137 90-860172011
GASOLINE STERNDRIVE INSTALLATION MANUAL
CAUTION
MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid
from the control valve ports. Wear eye protection.
7. The control valve ram may be stiff and difficult to move when you attempt to pull it out
or push it in for installation. Move the assembly in the directions shown below.
a
a
74145
74144
a-Control Valve Ports
8. Connect clevis to steering lever. Lubricate clevis pin. Be sure to spread both ends of
cotter pin.
NOTE: Make sure to insert clevis pin from the top to ensure that cotter pin hole is as shown
in the diagram.
c
b
a
a-Clevis
b-Steering Lever
c-Clevis Pin
d-Cotter Pin
Description
A Special Lubricant 101 Clevis Pin 92-13872A1
90-860172011 Page 27 of 137
d
71904
Where Used Part Number
GASOLINE STERNDRIVE INSTALLATION MANUAL
IMPORTANT: Quicksilver Ride Guide steering cable has a self-locking coupler nut
and does not require an external locking sleeve or locking plate.
a-Self-Locking Coupler Nut
Steering cable outer casing must be free to move back and forth for steering system
to function properly. Do not fasten any items to steering cable.
9. Coat steering cable end with a liberal amount of lubricant.
10. Install steering cable and secure with hardware.
a
22060
CAUTION
g
e
A
a-Steering Cable
b-Grease Fitting
c-Cable Coupler Nut
d-Cable Guide Tube
e-Steering Cable End
f-Clevis
g-Clevis Pin
h-Cotter Pin
f
h
71906
71901
d
73901
c
b
a
d
71903
Description
A Special Lubricant 101 Steering Cable End 92-13872A1
Page 28 of 137 90-860172011
Where Used Part Number
GASOLINE STERNDRIVE INSTALLATION MANUAL
IMPORTANT: Slight feedback in the steering system could be encountered if the
cable guide tube flat surfaces are not positioned vertically.
1 1. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical posi-
tion. Torque coupler nut. Be certain the flat surfaces are still aligned vertically after
torque is applied to coupler nut.
Description
Nm lb-in. lb-ft
Coupler Nut 47 35
CAUTION
Steering cable outer casing must be free to move back and forth for steering system
to function properly. Do not fasten any items to steering cable.
90-860172011 Page 29 of 137
GASOLINE STERNDRIVE INSTALLATION MANUAL
MANUAL STEERING
1. Inspect bushings for debris. Lubricate bushings with Special Lubricant 101.
a
Manual Steering
a-Bushings
b-Special Lubricant 101
2. Remove shipping hardware.
3. Remove upper and lower pivot bolts and ensure threads are well lubricated with Special
Lubricant 101.
a
B
NOTICE to INSTALLER
22946
Refer to “Installation Requirements - Steering Helm and Cable” for steering cable
selection and coupler nut locking requirements.
4. Install steering assembly as follows:
a. Position steering assembly so that pivot bolts will enter bushings in pivot block or
power steering control valve.
b. Install upper and lower pivot bolts along with tab washers. Ensure that tab washer
tangs straddle the ridge on inner transom plate.
c. Turn pivot bolts all the way in by hand to ensure proper alignment.
d. Ensure steering assembly pivots freely.
5. Torque pivot bolts to 25 lb-ft (34 Nm). Bend washer tabs against corresponding flats on
bolt heads.
bc
a
Manual Steering
a-Tab Washers
b-Ridge
c-Pivot Bolts
NOTE: It may be necessary to tighten further to align flats on pivot bolt with tabs on tab
washer.
Page 30 of 137 90-860172011
22033
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