Mercury BRAVO, 3.0L, 4.3L, 4.3LH, 4.3L EFI User Manual
...
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, and Ride-Guide.
GASOLINE ENGINES BRAVO MODELS
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owner’s Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information 2. . . . . . . . . . . . . . . . . . . . .
Notice to Boat Manufacturer/Installer 2. . . .
Bravo Three Notice: Trim-In Limit Pin 3. . .
MCM 454 & 502 Magnum MPI Application
Recommendations 4. . . . . . . . . . . . . . . . . . .
Multiple Steering Tie Bar Arrangements 5.
Quicksilver Products 6. . . . . . . . . . . . . . . . . .
Installation Products 7. . . . . . . . . . . . . . . . . .
Torque Specifications 7. . . . . . . . . . . . . . . . .
Serial Number Decal Placement 8. . . . . . . .
Corrosion Protection 8. . . . . . . . . . . . . . . . . .
Antifouling Paint 9. . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 10. . . . . . . . . . . . . . . .
Boat Construction 10. . . . . . . . . . . . . . . . . . . .
Exhaust System 14. . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 20. . . . . . . . . . . . . . . . .
Battery 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFI Electrical System Precautions 24. . . . . .
Instrumentation 24. . . . . . . . . . . . . . . . . . . . . . .
Power Trim Control 25. . . . . . . . . . . . . . . . . . .
Power Trim Pump Location 25. . . . . . . . . . . .
Propeller Selection 26. . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation
Recommendation 27. . . . . . . . . . . . . . . . . . . .
Seawater Connections - General
Information 29. . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and Cables 30
Steering Helm and Cable 30. . . . . . . . . . . . . .
Transom Cutout 32. . . . . . . . . . . . . . . . . . . . . . . . .
Finding Crankshaft Vertical Centerline 33. . .
Finding Crankshaft Horizontal
Centerline (“X” Dimension) 34. . . . . . . . . . . .
Cutting Transom 36. . . . . . . . . . . . . . . . . . . . . . . .
Checking Transom Thickness 37. . . . . . . . . . . . .
Installing Transom Assembly 37. . . . . . . . . . . . .
Installing Gimbal Housing 37. . . . . . . . . . . . . .
Installing Inner Transom Plate 39. . . . . . . . . .
Installing Power Trim Pump 40. . . . . . . . . . . .
Installing Steering System 41. . . . . . . . . . . . .
Hydraulic (Helm) Steering 41. . . . . . . . . . . . .
Connecting Speedometer Pickup 44. . . . . . .
Connecting Drive Unit Gear Lube
Monitor Hose 45. . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation 46. . . . . . . . . . . . . . . . . . . . . . .
Driveshaft Extension Models 46. . . . . . . . . . .
Engine Preparation 46. . . . . . . . . . . . . . . . . . .
Transom Preparation 47. . . . . . . . . . . . . . . . . .
Installing Engine/Alignment 49. . . . . . . . . . . .
Coolant Recovery System (If Equipped) 53.
Engine Connections 54. . . . . . . . . . . . . . . . . . . . .
Quick Drain Oil Installation 62. . . . . . . . . . . . . . .
Shift/Throttle Cables Installation and
Adjustments 63. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Sterndrive Unit Shift Cable 63. . . .
Troubleshooting Shift Problems 67. . . . . . . . .
Throttle Cable Installation and Adjustment 69
Sterndrive Unit Installation 76. . . . . . . . . . . . . . . .
Predelivery Preparation 84. . . . . . . . . . . . . . . . . .
Battery Connection 84. . . . . . . . . . . . . . . . . . .
Power Trim Pump 84. . . . . . . . . . . . . . . . . . . .
Trim Position Sender Adjustment 85. . . . . . .
Power Steering 87. . . . . . . . . . . . . . . . . . . . . . .
Propeller Installation (Bravo One and Two) 87
Propeller Installation (Bravo Three) 89. . . . .
Test Running Engine 90. . . . . . . . . . . . . . . . . .
Boat-ln-The-Water Tests 92. . . . . . . . . . . . . . .
Cold Weather or Extended Storage
Draining Instructions 94. . . . . . . . . . . . . . . . . .
Quicksilver Instrumentation Wiring Diagrams 100
Power Trim System Wiring Diagram 102. . . . . . .
MerCathode System Wiring Diagram 103. . . . . .
MCM Gasoline Engine Wiring Diagrams 104. . . .
Water Flow Diagrams 112. . . . . . . . . . . . . . . . . . . .
Predelivery Inspection 116. . . . . . . . . . . . . . . . . . .
90-860172001 APRIL 2000 Printed in U.S.A. - 2000, Mercury Marine Page 1 of 116
GASOLINE ENGINES BRAVO MODELS
General Information
Notice to Boat Manufacturer/Installer
Throughout this publication, “Warnings” and “Cautions” (accompanied by the International
!
Hazard Symbol
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 com-
pliance 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.
) are used to alert the manufacturer or installer to special instructions
WARNING
CAUTION
This installation requirements manual has been written and published by Mercury Marine
to aid the boat manufacturer involved in the application and installation of the products described herein.
It is assumed that these personnel are familiar with marine product application and the
installation procedures of these products, or like or similar products manufactured and marketed by Mercury Marine. Furthermore, it is assumed that they are familiar with, if not trained
in, the recommended installation procedures of these products.
We could not possibly know of and advise the marine trade of all conceivable applications
and installations which might be achieved, and of the possible hazards and/or results of
each conceivable application or installation. We have not undertaken any such wide evaluation. Therefore, any manufacturer which, or person who, applies or installs the product in
a manner which does not fulfil the requirements listed herein, first must completely satisfy
themselves that neither their safety nor the product will be endangered by the application
or installation procedure selected.
It is the responsibility of the OEM to select the appropriate engine/transom/drive package
(including the correct gear ratio and propeller) for a given boat. Making an appropriate selection requires knowledge of the boat (weight, length, hull design, intended use and duty cycle,
desired speed, etc.) that is uniquely in the possession of the OEM. While Mercury employs
people capable of assisting the OEM on such issues, the final decision rests with the OEM.
Mercury recommends that any new or unique hull/power package combination be thoroughly water tested prior to sale, to verify (among other things) that the boat performs as
desired, and that the engine runs in the appropriate rpm range.
It is recommended that a Mercury Marine Field Product Engineer be contacted for assistance if specific application or installation problems are encountered.
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.
Page 2 of 116
Bravo Three Notice: Trim-In Limit Pin Insert
NOTE: Bravo One, Two and Three Models are equipped with a Trim-In Limit Pin 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 Pin 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 Pin, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of
the boat manufacturer.
WARNING
GASOLINE ENGINES BRAVO MODELS
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.
Page 3 of 116
GASOLINE ENGINES BRAVO MODELS
MCM 454 & 502 MPI Application Recommendations
BOAT TYPES
The MCM 454 and 502 MPI models are recommended for use in most sport boat applications with the exception of the following.
• Bravo applications which require that the sterndrive unit be mounted more than 3 in.
(75mm) above the standard “X” dimension (i.e., catamarans, certain stepped bottom
boats, etc.). For those applications, we recommend our Performance Products models
with a Super Speedmaster sterndrive unit which are designed specifically for surfaced
propeller operation.
• Applications which require other than standard Quicksilver propellers to get the boat up
on plane or to keep the propeller from ventilating when up on plane.
• Boats that require that the engine be run above 3200 rpm to keep them on plane.
• Racing applications or other highly abusive applications where the boat and the stern-
drive units will come out of the water frequently. These, again, are applications where
we recommend our Performance Products models with Super Speedmaster sterndrive
units.
STEERING
Mercury MerCruiser power packages come standard with Mercury MerCruiser’s internal
power steering. This durable system provides precise effortless steering control and is recommended for most sport boat applications. On certain applications, however, Mercury
MerCruiser recommends the use of an external power steering system where the power
steering cylinders connect directly to the sterndrive unit on the outside of the boat. This arrangement gives additional support for even tighter, more firm steering control, and is recommended for the following applications:
• High speed single or twin engine applications and/or boats with unusual handling characteristics. It is virtually impossible to give a specific recommendation as to when external power steering should be used, as this varies from boat design to boat design. Generally speaking, it is recommended to use external power steering on boats which run
in excess of 70 MPH. However, there are boats which run 60 MPH that would benefit
from the use of external power steering. Because of the many variables involved, the
final decision as to whether or not external power steering is required rests with the boat
manufacturer and must be made after a thorough test and evaluation of each specific
boat. If there is any question whether or not external power steering is necessary , Mercury MerCruiser recommends that it be installed.
• Any Hi-Performance sport boat powered by three or more engines.
• Offshore boats or other applications where the boat and sterndrive units may come out
of the water occasionally.
• All III SSM and V SSM High Performance Sterndrive applications.
External power steering systems are generally either mechanical cable actuated or hydraulic actuated. If cable actuation is selected, combining dual steering cables with an internal
control valve kit (Part Number 89645A35) will provide an even tighter feel (less steering
backlash). This kit cannot be used with hydraulic actuation.
Page 4 of 116
ENGINE MOUNTS
GASOLINE ENGINES BRAVO MODELS
External power steering and hydraulic helm systems can be obtained from the following
after market suppliers:
Latham Marine Inc.
280 S.W. 32nd Court
Ft. Lauderdale, FL 33315
Phone: (305) 462-3055
Fax: (305) 462-3081
Mayfair Marine Machine
12890 N. W. 30th Avenue
Opalocka, FL 33054
Phone: (305) 681-1815
On dual or triple engine high speed applications, Mercury MerCruiser recommends the use
of a Quicksilver Priority Valve Kit (Part Number 79691A4). This kit allows two power steering
pumps to be used and helps to ensure that power assist will be maintained if one engine
or power steering pump should stop functioning (engine runs out of fuel, etc.).
The 454 and 502 models come standard with heavy-duty pedestal-type front engine
mounts. These mounts include provisions for isolating engine vibrations and can be used
in most sport boat applications. On offshore boats or boats which will be used in rough water
areas, however, Mercury MerCruiser recommends the use of a solid plate engine mount.
Multiple Sterndrive Steering - Tie Bar Arrangements
With multiple sterndrives it is important to consider which of several possible steering systems should be selected.
CAUTION
Failure to observe the recommended Tie Bar Arrangements could result in serious
damage to the steering and/or trim system components. This damage could adversely affect control of the boat.
INTERNAL TIE BAR ONLY
At the lower end of the performance spectrum (boats not capable of speeds in excess of
60 MPH) the basic internal tie bar is recommended. It connects the slave sterndrive to the
sterndrive that is directly connected to the factory power steering output. This internal tie
bar is available in a variety of lengths from the sterndrive manufacturer.
Page 5 of 116
GASOLINE ENGINES BRAVO MODELS
INTERNAL AND EXTERNAL TIE BAR
As a boat moves into a moderate performance range (60-70 MPH) or for a reduction in steering backlash, an external tie bar should be added. External tie bars are usually designed
to attach at the aft power trim cylinder bosses which is an excellent location because of its
proximity to the propeller. HOWEVER, because of the potential overstress that can occur
if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part Number 90362A3) should be installed so as to limit this potential tilt differential to about 20°.
IMPORTANT: Mercury Marine does not recommend the use of an external tie bar
ONLY with no internal tie bar when using the internal power steering system. This can
cause excessive loads on the steering components on the sterndrive connected to
the internal power steering system. These increased loads can damage the steering
components, resulting in increased play in the steering of the boat.
EXTERNAL POWER STEERING
When boat speeds move past 70 MPH or if additional steering backlash reduction is desired,
external power steering is recommended. This normally will include an external tie bar
mounted at the same general location of the power steering cylinders, which are generally
attached at the top of the sterndrive’s drive shaft housing. With this steering system, no inter-
nal tie bar should be used. These steering cylinders can be attached either inboard (between) or outboard of the sterndrives.
EXTERNAL POWER STEERING WITH LOW EXTERNAL TIE BAR
For the fastest boats (over 80 MPH) or for the ultimate in steering backlash reduction, use
external power steering, BUT (where mechanically possible) with the external tie bar
mounted at the trim cylinder boss location (as previously described in “Internal and External
Tie Bar” statements). Again this system does not use an internal tie bar.
Quicksilver Products
ACCESSORIES
Quicksilver remote controls, steering systems, propellers, etc. are available for this product.
Refer to “Quicksilver Accessories Guide” for complete listing.
This “Guide” is available from:
Attn: Parts Department
Mercury Marine
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
OR –
Outside of U.S.A., order through
Distribution Center, or Distributor.
Page 6 of 116
Installation Products
Quicksilver Engine Coupler Spline Grease 92-816391A4
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2
Quicksilver Special Lubricant 101 92-13872A1
Quicksilver Liquid Neoprene 92-25711-2
Quicksilver Power Trim and Steering Fluid 92-90100A12
Dexron III - Automatic Transmission Fluid Obtain Locally
Quicksilver Perfect Seal 92-34227-1
Transom Drilling Fixture 91-43693A2
Engine Alignment Tool 91-805475A1
Shift Cable Adjustment Tool 91-12427
Engine Mount Drilling Fixture 91-806794A1
Torque Specifications
GASOLINE ENGINES BRAVO MODELS
Description Part Number
Description
sterndrive Unit Gear Lube Monitor - 90°
Hose Barb Fitting
lb-in. lb-ft Nm
80 9
Speedometer Pickup Barb Fitting 13 1.5
Exhaust Pipe or Block-off Plate 23 31
Power Steering Hydraulic Hose Fittings 23 31
Power Trim Pump Hose Fittings 125 14
Torque
Propeller Nut (Bravo One and Two)
Propeller Nuts (Bravo Three)
1
1
55 75
Front 100 136
Rear 60 81
Rear Engine Mounts 38 51
Steering Cable Coupler Nut 35 47
Steering System (Pivot Bolts) 25 34
Sterndrive Unit Fasteners 50 68
Transom Assembly Fasteners 23 31
Seawater Pickup Fitting 45 5
Power Trim Cylinder Fasteners Tighten until they contact.
Fuel Line Inlet Fitting See Note.
1
: Amount specified is MINIMUM.
NOTE: Refer to Fuel Delivery System - “Special Information For All Gasoline Engines.”
Page 7 of 116
GASOLINE ENGINES BRAVO MODELS
Serial Number Decal Placement
There are three sets of engine, transom assembly and sterndrive serial number decal strips
provided with each power package. One set should be used for each of the following:
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance and Warranty Manual identification page.
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
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 “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.
Page 8 of 116
Anti-fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of antifouling 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 ENGINES BRAVO MODELS
IMPORT ANT: 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. (40mm) UNPAINTED area on transom of the boat around these items.
a
b
71176
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
contain copper, tin, or any other material that
could conduct electrical current. Do not paint drain holes, anodes, MerCathode system or
items specified by boat manufacturer.
Page 9 of 116
GASOLINE ENGINES BRAVO MODELS
Installation Requirements
Boat Construction
TRANSOM THICKNESS AND SURFACE
IMPORTANT: Transom thickness and surface plane (flatness) must be controlled
where the sterndrive unit mounts.
Transom thickness and surface must conform to the following:
Thickness Between 2 - 2-1/4 in. (51 - 57 mm)
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
ENGINE BED
a
e
b
d d
c
22170
a-Transom Thickness
b-Inner Surface
c-Outer Surface
d-Transom Plate Coverage
e-Transom Angle
Engine bed must position engine so that a minimum of 1/4 in. (6mm) up and down
adjustment still exists on mounts after performing final engine alignment. This is necessary
to allow for realigning engine in the future.
72700
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 in parallel planes. 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
Page 10 of 116
.
ENGINE COMPARTMENT
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when constructing the engine compartment.
Care must be exercised in the design and construction of the engine compartment. Seams
must be located so that any rain water, which may leak through the seams, is directed away
from the air intake system. Water that runs onto the air intake may enter the engine and
cause serious damage to internal engine parts.
Over the last several years, engine compartments have been designed to be quieter. The
most common material used to deaden the engine sound is some type of insulation material.
Normally, the quieter the engine compartment is, the more insulation material used which
results in less air space inside. The less air space inside the engine compartment, the hotter
the inside air temperature. Attention must be given to the air temperature that is inside this
engine compartment while the engine is running or after a period of time after the engine
is shut off (heat soak). Refer to the following information on Engine Compartment Ventilation.
ENGINE COMPARTMENT VENTILATION
GASOLINE ENGINES BRAVO MODELS
WARNING
General Information
According to Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations the engine compartment ventilation system has multiple tasks. Included are the following:
1. To supply the engine with combustion air.
2. To maintain a low temperature in the engine compartment.
3. To vent the air and fumes in the engine compartment.
Fresh air should enter the engine compartment as low as possible and the heated air should
be discharged from the highest point.
When sufficient ventilation is not provided, too much heat can build-up inside of engine
compartment and cause vapor locking. The engine will not want to restart after it has been
shut of f for a short period of time. If it does restart, the engine will quit when given the throttle
to get the boat up on plane or to pull up a water skier.
For engines utilizing fuels containing alcohol and the newer “reformulated gasolines” (See
OEM Service Bulletin 95-2.) proper ventilation is more critical to prevent vapor locking.
If a separate air shaft (or similar) is used to provide engine compartment ventilation or additional ventilation, care must be taken to prevent seawater and spray from entering it.
Page 11 of 1 16
GASOLINE ENGINES BRAVO MODELS
Combustion Air Requirements
Engine compartments with natural draft ventilation must have vent openings of sufficient
size and location to accomplish the tasks previously outlined.
IMPORTANT: The size of ventilation openings must be increased if any auxiliary
equipment is located in the engine compartment.
The combustion air requirement (per engine) for the specified engines at Wide Open
Throttle are given in the chart below:
Combustion Air Requirements (Per Engine) and Ventilation Information
Engine Air
Model
Requirements
at W O T
3.0L
4.3L
4.3LH
4.3L EFI
5.0L
5.0L EFI
5.7L
5.7L EFI
350 Mag MPI
MX6.2L MPI
454 Mag MPI
7.4L MPI
502 Mag MPI
1
: For engine combustion air only - NOT total engine compartment ventilation requirement.
251 ft.3/Min.
(0.118 m
364 ft.3/Min.
(0.172m
3
424 ft.3/Min
(0.200 m
486 ft.3/Min.
(0.229 m
506 ft.3/Min.
(0.239 m
545 ft.3/Min.
(0.257 m
657 ft.3/Min.
(0.310 m
726 ft.3/Min.
(0.342m
3
3
/sec.)
/sec.)
3
/sec.)
3
/sec.)
3
/sec.)
3
/sec.)
3
/sec.)
/sec.)
MINIMUM
Combustion Air Vent
Area Per Engine
1
25 in2 (161 cm2) 2.4 ft.
36 in2 (232 cm2)
42 in2 (271 cm2)
49 in2 (316 cm2)
51 in2 (329 cm2)
2
55 in
(355 cm2)
66 in2 (426 cm2)
73 in2 (471 cm2)
Engine Physical
Volume
3
(68.0 l)
3
4.6 ft.
(130.3 l)
3
5.0 ft.
(141.6 l)
3
5.0 ft.
(141.6 l)
3
5.8 ft.
(164 l)
3
5.8 ft.
( 164 l)
3
6.0 ft.
(170 l)
3
6.0 ft.
(170 l)
Page 12 of 116
IMPORTANT: The amount of vent area required, according to boating standards
(NMMA, ABYC, etc.) and Coast Guard regulations, for complete (total) engine
compartment ventilation must include the engine combustion air vent area plus the
engine compartment ventilation requirements.
The pressure differential between outside and inside the engine compartment must not
exceed the following value.
Maximum Pressure Differential at Wide Open Throttle
2 in. (51 mm) of water (measured with a manometer)
GASOLINE ENGINES BRAVO MODELS
Compartment Temperature - Specifications
Air temperatures inside engine compartments have been measured in excess of 200° F (82°
C). The long term effect to fuel system components running at these excessive temperatures is not known at this time.
According to specification SAE J1223 for Marine Carburetors:
“The carburetor shall be capable of operation throughout an ambient (air temperature)
range from +20° to +176° F (–7° to +80° C) without failure.”
Carburetors, throttle body injection (TBI) units and components for multi-port EFI systems
used by Mercury MerCruiser meet this specification.
Under the hottest outside air temperature condition at which the boat will be operated, the
air temperature inside the engine compartment, measured at the flame arrestor, shall not
exceed176° F (80° C). Also, the temperature of the fuel being supplied to the engine shall
not exceed 110° F (43° C) at any location between the fuel tank and the engine’s fuel pump.
Since many factors influence engine compartment temperature, temperature measurements should always be carried out.
Test as follows:
1. The boat being tested shall be a standard production boat fitted as it would be for deliv-
ery to a dealer.
2. T emperature test meter used shall be of the type that can be read without opening the
engine cover.
3. During the test, in Step 4, engine compartments are to remain closed. No outside air is
to be forced into the engine compartment during the test and the bilge blower should not
be running.
4. Engine Running and Heat Soak Test:
a. Use 1 meter and 2 thermo couple. Place one thermo couple at the flame arrestor
to measure the inlet air temperature. Place the second thermo couple at the fuel
pump to measure the inlet fuel temperature. A third thermo couple is needed if the
fuel supply line between the tank and the fuel pump is higher than the fuel pump.
Place the third thermo couple at the highest point of the supply line to measure the
temperature of the fuel at that point.
b. Start engine to warm it up. After engine is at its normal operating temperature, run
engine at 1500 rpm (in neutral gear) for 15 minutes. Record both temperature readings at 5 minute intervals.
c. After 15 minutes running at 1500 rpm, shut engine off and continue to record both
temperature readings at 5 minute intervals for the next 45 minutes.
d. After the 45 minute heat soak test, start engine and idle (in neutral gear) for 20 min-
utes. Continue to record both temperature readings at 5 minute intervals.
IMPORT ANT: If the temperature at either location exceeds specifications, the engine
compartment will need additional ventilation until both temperatures remain below
these specifications.
Page 13 of 116
GASOLINE ENGINES BRAVO MODELS
Exhaust System
MEASURING PROCEDURE
1. Fill all fuel, water, gray water and heater tanks to maximum capacity.
NOTE: Weight can be added in these locations to simulate full loaded condition.
2. Add maximum allowable cargo weight to boat in areas where it will be stowed, including
refrigerator and lockers.
3. Add 190 lb (86 kg) of weight in all locations where each passenger will sit during normal
operation.
4. Measure exhaust elbow height. Also, measure exhaust system slope on applications
with through the hull or through the transom exhaust.
a
72429
b
Using A Universal Protractor (Inclinometer) To Measure Slope
a-Protractor
b-Exhaust Hose Or Tube
5. Follow instructions a. or b.:
a. On applications with through the propeller exhaust: Proceed to Step 6.
b. On applications with through the hull or through the transom exhaust:
(1.)Move load weight to bow to simulate greatest “bow-down” attitude the boat will
encounter in normal operation.
(2.)Recheck exhaust system slope.
(3.)Proceed to Step 6.
75203
Page 14 of 116
GASOLINE ENGINES BRAVO MODELS
6. On all applications:
a. Move load weight and cargo weight to stern of boat to simulate greatest “stern-down”
attitude the boat will encounter such as when loading.
IMPORTANT: Be sure to consider swim platform loading and PWCs.
b. Recheck exhaust system measurements.
7. Measurements must be equal to or greater than, the following:
On All Applications:
Minimum Exhaust Elbow Height from Top of Elbow to Waterline
Model Measurement
All V6 and V8 13 in. (330 mm)
a
b
c
d
71533
MCM 454/502 MPI Engine Shown (All V-6 and V-8 Engines Similar)
a-Top Of Transom
b-Highest Point On Exhaust Elbow
c-Measurement
d-Waterline
Additional Requirements for Through The Hull and
Through The Transom Exhaust System Applications:
Minimum Continuous Downward Slope (Exhaust Hoses, Collector, Etc.)
Model / Application Measurement
All Sterndrive 6°
Page 15 of 116
GASOLINE ENGINES BRAVO MODELS
8. If measurements are less than shown in Step 7., exhaust elbow risers must be installed
to achieve proper dimension.
Typical Riser Installation
a-Exhaust Elbow
b-Restrictor Gasket
c-Riser
d-Open Gasket (4 Slots)
e-Exhaust Manifold
a
b
c
d
e
70621
Additional information:
• No risers are available for the V6 engine with Single-Piece Exhaust Manifolds.
• Up to a maximum of 9 in. (229 mm) of riser height can be added, except on those engines
listed previously.
Page 16 of 116
THROUGH THE TRANSOM OR HULL EXHAUST
Refer to Exhaust Resonators in this SECTION for additional information on 454 and
502 cid (7.4 L and 8.2 L) engine exhaust requirements.
When designing and installing an exhaust system, in addition to other model specific
requirements, Mercury MerCruiser requires the following to be observed:
• Exhaust fittings (flanges and outlets) must be of proper size to accommodate 4 in.
(102 mm) inner diameter exhaust hoses.
• Exhaust fittings must be equipped with internal water shutters.
• An exhaust flapper must be used over each outlet.
• Exhaust outlet must be slightly above the water line with boat at rest in the water and
a full load aboard.
• Exhaust hoses, collectors and pipes must not be higher than exhaust elbows at any
point.
• The drop in the exhaust system must be continuously sloping so that a low spot does
not exist at any point in the exhaust hose or pipe.
GASOLINE ENGINES BRAVO MODELS
NOTICE
• The exhaust system on Mercury MerCruiser engines must have a minimum of 6°
downward slope between the exhaust elbow outlet and the exhaust outlet of the boat.
• The exhaust system on Mercury MerCruiser engines must have a minimum of 4 in.
(102 mm) of vertical drop between the exhaust elbow outlet and the exhaust outlet
of the boat.
e
a
d
c
Example Of Sterndrive (MCM) Through The Transom or Hull Exhaust Models
a-Minimum Continuous Exhaust System Slope
b-Exhaust Hose
c-Exhaust Fitting
d-Flapper
e-Exhaust Elbow
f-Minimum Exhaust System Vertical Drop
b
75203
• Back pressure must not exceed 2 psi (14 kPa) when measured at exhaust elbow
outlets.
Page 17 of 116
GASOLINE ENGINES BRAVO MODELS
EXHAUST RESONATOR
The exhaust resonators (provided with the engine package or available separately) are
designed to provide increased resistance to water ingestion due to the tuning effects of the
exhaust system. Quicksilver resonators are designed to break up the exhaust pulses.
Avoid severe engine damage. Water ingestion by the 454 and 502 cid (7.4L
and 8.2L) engines may occur in some instances without the use of specially
designed exhaust resonators. Install exhaust resonators in the exhaust
system when specified.
IMPORTANT: Exhaust resonators must be installed on 7.4L MPI, 454 Mag MPI and 502
Mag MPI Models of sterndrive engines with through the transom (or through the hull)
exhaust
On 454 and 502 cid (7.4 and 8.2L) sterndrive engines using through the transom or hull
exhaust systems, special care must be exercised in system design and construction to
prevent an adverse tuning effect on engine exhaust output.
Exhaust system tuning can be affected by various factors that are beyond the control of
Mercury MerCruiser. Following are several factors that can affect exhaust system tuning:
• Type and configuration of exhaust outlet.
CAUTION
• Length of exhaust hose.
• Amount of back-pressure in exhaust system.
Exhaust Resonator Kit use on Sterndrive Models:
CAN Be Used With:
1. Transom mounted muffler tips.
2. Waterlift mufflers or other mufflers that
are mounted outboard of exhaust
1. Silent Choice Exhaust System.
2. Below swim platform exhaust.
3. Mufflers that mount between exhaust
elbows.
3. Open exhaust.
CANNOT Be Used With:
elbow and exhaust tip.
Page 18 of 116
INSTALLATION
GASOLINE ENGINES BRAVO MODELS
The resonator is installed in exhaust hose with open end toward exhaust elbow. Resonator
is positioned so that inside flat surface is approximately 17 in. (432 mm) from front edge
of exhaust hose, but no closer than 2 in. (51 mm) to exhaust outlet on sterndrive. The
17 in. (432 mm) dimension can be reduced, if necessary, to a minimum of no less than
13 in. (330 mm).
A clamp is then installed and tightened around the hose so that it clamps around center of
resonator. This position is 1 in. (25 mm) less than the position of the resonator as discussed
in the previous paragraph.
g
c
f
b
e
a
d
Through The Transom Exhaust With Resonator
a-Exhaust Resonator
b-Exhaust Hose
c-Dimension To Inside Flat Surface Of Resonator Approximately 17 in. (432 mm),
But No Less Than 13 in. (330 mm)
d-No Less Than 2 in. (51 mm) Between Fitting And Resonator
e-Clamp Position - Around Center Of Resonator
f-Exhaust Fitting
g-Exhaust Elbow
454 AND 502 MAG BRAVO MODEL EXHAUST RECOMMENDATION
IMPORT ANT: T o get maximum performance from Magnum Bravo Models, through the
transom or hull exhaust is required.
NOTE: If noise regulations do not allow the use of through the transom or hull exhaust, an
exhaust pipe kit (Quicksilver Part Number 44266A6) must be installed for through the prop
exhaust. This kit also contains an exhaust tube that is used in place of the exhaust bellows.
IMPORTANT: It is recommended that the exhaust bellows on the transom assembly
be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the
propeller at higher boat speeds. This vacuum could degrade propeller performance
on some boats.
75203
Page 19 of 116
GASOLINE ENGINES BRAVO MODELS
Fuel Delivery System
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when constructing the engine compartment.
GENERAL
The main concern of a boat’s fuel system is safety; this must be achieved through a technically sound installation and constant inspection.
The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.
The fuel tank is an integrated component of the boat. Refer to the special information on
service and maintenance, which you have received from the tank manufacturer.
Only a few points related to function and safety are listed here [Refer to boating standards
(NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:
• All connections should be on the upper side of the tank.
• The drain plug at the lowest point on the tank serves to permit the removal of water and
sediment.
• The filler pipe outer diameter should be at least 2 in. (50 mm).
WARNING
• The tank breather pipe must have an inner diameter of at least 1/2 in. (13 mm) and must
be fitted with a swan neck to prevent water from entering the tank.
It is recommended that the exact route and length of the fuel lines be established at the first
installation of the engine to prevent problems later in connecting them to the engine.
All fuel lines must be well secured. The holes where the lines run through the bulkheads
should be carefully rounded off or protected with rubber grommets. This prevents damage
to the lines from abrasion.
The following, but not limited to the following, additional fuel connection related points, ap-
plying to all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:
1. On Gasoline Engines: Fuel tank should be mounted below carburetor level (if possible)
or gravity feed may cause carburetor fuel inlet needle to unseat and flooding may result.
2. Fuel pickup should be at least 1 in. (25 mm) from the bottom of fuel tank to prevent picking up impurities.
3. On Gasoline Engines: The maximum measured vacuum at the engine’s fuel inlet must
not exceed 2 in. Hg or 1 psi (6.9 kPa) at 600, 3000, full throttle rpm, and idle rpm.
IMPORTANT: Vacuum reading higher than specified can cause vapor locking with
some of today’s fuels. It can also cause poor engine performance because of fuel
starvation.
4. On Gasoline Engines: Fuel lines used must be Coast Guard approved (USCG Type
A1).
Diameter of fittings and lines must not be smaller than 5/16 in. (8 mm) ID on 262 CID/4.3L
and 305 CID/5.0L and 350 CID/5.7L engines.
Diameter of fittings and lines must not be smaller than 3/8 in. (10 mm) I.D. on 377 CID/6.2L,
454 CID/7.4L and 502 CID/8.2L engines.
5. On Multi-Engine Gasoline Installations: It is best to use a fuel pickup and supply line
for each engine. If a single pickup and line is used, line must not be smaller than 1/2 in.
(13mm) I.D.
Page 20 of 116
6. Larger diameter (than previously specified) lines and fittings must be used on installa-
tions requiring long lines or numerous fittings.
7. Fuel line(s) should be installed free of stress and firmly secured to prevent vibration and/
or chafing.
8. Sharp bends in fuel lines should be avoided.
9. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine
to absorb deflection when engine is running.
SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS
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
GASOLINE ENGINES BRAVO MODELS
CAUTION
• Poor Driveability
SPECIAL INFORMATION FOR ALL GASOLINE ENGINES
Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. NEVER use gasoline as a cleaning solvent.
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 brass fittings or plugs. DO
NOT USE TEFLON TAPE.
• Brass fittings or plugs should first be threaded into fuel pump or fuel filter base
until finger tight.
• Fittings or plugs should then be tighten an additional 1-3/4 to 2-1/4 turns using
a wrench. DO NOT OVERTIGHTEN.
• To prevent over-tightening when installing a fuel line, the brass fittings should be
held with a suitable wrench as fuel line connectors are tightened securely.
WARNING
Page 21 of 116
GASOLINE ENGINES BRAVO MODELS
Battery
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and
Coast Guard regulations must be adhered to when installing battery. Be sure battery
cable installation meets the pull test requirements and that positive battery terminal
is properly insulated in accordance with regulations.
IMPORT ANT: It is recommended (required in some states) that battery be installed in
an enclosed case. Refer to regulations for your area.
IMPORTANT: Engine electrical system is negative (–) ground.
Select a battery that meets all of the following specifications:
• 12-volt marine type.
• Tapered post connectors or side terminal connectors.
IMPORTANT: Do NOT use a battery with wing nut connectors.
• Battery capacity rating of at least:
Gasoline Engines
BATTERY CABLES
Select proper size positive (+) and negative (–) battery cables, using chart. Battery should
be located as close to engine as possible.
IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical
contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as
it may cause corrosion and a subsequent failure.
Engine
(Cyl./Type)
cid (l) Minimum Required Cranking Battery Size
V6 EFI 262 (4.3) 550 cca/700 mca/120 Ah
V6 Carb
V8 Carb
V8 Carb
V8 EFI
V8 MPI
V8 MPI
V8 MPI
262 (4.3)
305 (5.0)
350 (5.7)
305 (5.0)
350 (5.7)
377 (6.2)
454 (7.4)
375 cca/475 mca/90 Ah
550 cca/700 mca/120 Ah
650 cca/825 mca/150 Ah
502 (8.2)
Gasoline Engines
Up to 3-1/2 ft. (1.1m) 4 (25mm2)
3-1/2 - 6 ft. (1.1-1.8m) 2 (35mm2)
6 - 7-1/2 ft. (1.8-2.3m) 1 (50mm2)
7-1/2 - 9-1/2 ft. (2.3-2.9m) 0 (50mm2)
9-1/2 - 12 ft. (2.9-3.7m) 00 (70mm2)
12 - 15 ft. (3.7-4.6m) 000 (95mm2)
15 - 19 ft. (4.6-5.8m) 0000 (120mm2)
Page 22 of 116
Cable Length
Cable Gauge
MULTIPLE EFI ENGINE BATTERY PRECAUTIONS
Situation
Alternators: Alternators are designed to charge the battery that supplies electrical power
to the engine that the alternator is mounted on. When batteries for two different engines are
connected, one alternator will supply all of the charging current for both batteries. Normally,
the other engine’s alternator will not be required to supply any charging current.
EFI Electronic Control Module (ECM): The ECM requires a stable voltage source. During
multiple engine operation, an onboard electrical device may cause a sudden drain of voltage
at the engine’s battery. The voltage may go below the ECM’s minimum required voltage.
Also, the alternator on the other engine may now start charging. This could cause a voltage
spike in the engine’s electrical system.
In either case, the ECM could shut off. When the voltage returns to the range that the ECM
requires, the ECM will reset itself. The engine will now run normally. This ECM shut down
usually happens so fast that the engine just appears to have an ignition miss.
Recommendations
Batteries: Boats with multi-engine EFI power packages require each engine be connected
to its own battery. This ensures that the engine’s Electronic Control Module (ECM) has a
stable voltage source.
GASOLINE ENGINES BRAVO MODELS
Battery Switches: Battery switches should always be positioned so each engine is running
off its own battery . DO NOT operate engines with switches in BOTH or ALL position. In an
emergency, another engine’s battery can be used to start an engine with a dead battery.
Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering
accessories in the boat. They should not be used to charge the battery of another engine
in the boat unless the type of isolator is specifically designed for this purpose.
NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.
1. The boat may have 2 engines connected to a single Model 32023A battery isolator.
2. The Model 32023A battery isolator is connected to 2 banks of batteries.
3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.
4. The second battery in each bank is connected in parallel to the cranking battery.
5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2
charging sources, 120 amps (maximum alternator output).
6. When the engines are running, either engine’s alternator could be charging either bank
of batteries through the Model 32023A battery isolator.
Any other manufacturer’s battery isolator that is the same type as the Sure Power Inc.,
Model 32023A could also be used.
Generators: The generator’s battery should be considered another engine’s battery.
Page 23 of 116
GASOLINE ENGINES BRAVO MODELS
EFI Electrical System Precautions
NOTE: All references to EFI models apply to all EFI and MPI engines.
Avoid damage to the EFI electrical system components: Refer to the following precautions when working on or around the EFI electrical harness, or when adding other electrical accessories:
• DO NOT tap accessories into engine harness.
• DO NOT puncture wires for testing (Probing).
• DO NOT reverse battery leads.
• DO NOT splice wires into harness.
• DO NOT attempt diagnostics without proper, approved Service Tools.
Instrumentation
We recommend the use of Quicksilver Instrumentation and Wiring Harnesses which have
been specifically designed for compatibility with our engines, and to the same high quality
and performance standards. Refer to Mercury Precision Parts / Quicksilver Accessories
Guide for selection.
CAUTION
GAUGES
Refer to Instrumentation Wiring Diagrams for specific wiring diagrams.
ABYC standards recommend a group of four gauges.
The basic four gauges that must be used with the engine are:
1. Tachometer
2. Oil Pressure
3. Water Temperature
4. Voltmeter
Page 24 of 116
HARNESSES
GASOLINE ENGINES BRAVO MODELS
CAUTION
If Quicksilver wiring harness is used and a fused accessory panel is to be installed
(40-amp current draw maximum), be sure to connect it as shown in the wiring diagrams. Do not connect accessory panel at any other location, as wires in wiring harness may not be of sufficient size to handle current load.
Instrumentation wiring extension harnesses that can be routed from instruments to engine
are available in several lengths. Refer to Mercury Precision Parts / Quicksilver Accessories
Guide.
When designing the craft and harness wiring, consider the following:
• Ensure that the harnesses will not be rubbed or pinched.
• Avoid routing the harness in areas where it could be damaged or short circuited later
in the assembly process, such as when a screw is inserted, or a hole is drilled.
IMPORTANT: Harness receptacles can be damaged by overtightened clamps.
• If an extension harness is required, be certain to secure connection properly. All cannon
plug style electrical connectors, including the one at the engine, should be secured with
a hose clamp to avoid a loose connection or water entry.
• It is an ABYC recommendation that harnesses be fastened to boat at least every 18 in.
(460 mm).
Power Trim Control
Any of the Quicksilver panel or in-handle type trim controls (that are specified for use with
Mercury MerCruiser sterndrives) can be used with this Power Trim system. Install trim control in accordance with instructions that accompany it.
Power Trim Pump Location
Select an appropriate mounting location for the trim pump that meets the following requirements:
• Within length limits of black and gray hydraulic hoses coming from gimbal housing
assembly.
• Close to the battery so that trim pump battery leads can be connected.
• Allow easy access to trim pump oil fill and vent locations.
• Area where pump will not be exposed to water.
• Trim pump must be mounted so that when steering wheel is turned in either direction
(right or left), the power steering booster cylinder does not come in contact with trim
pump.
• Pump can be mounted on floor or transom.
Page 25 of 116
GASOLINE ENGINES BRAVO MODELS
Propeller Selection
GENERAL INFORMATION
IMPORTANT: Installed propeller must allow engine to run at its specified maximum
wide-open-throttle revolutions per minute (rpm). Use an accurate service tachometer
to verify engine operating rpm.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power
package with the correct propeller(s). Specified engine wide-open-throttle (WOT) and operating rpm range are listed in the “Operation, Maintenance and Warranty Manual” attached
to the engine.
Select a propeller that will allow the engine power package to operate at or near the top end
of the recommended wide-open-throttle operating rpm range with a normal load. High rpm,
caused by an excessive trim angle, should not be used in determining correct propeller
selection.
There is a change in rpm between propeller pitches that is generalized in the following chart:
MCM Models
Pitch Change RPM Change
Gasoline 2 in. 150-200
If full throttle operation is below the recommended range, the propeller must be changed
to prevent loss of performance and possible engine damage. On the other hand, operating
an engine above the recommended operating rpm range will cause higher than normal wear
and/or damage.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:
• Warmer weather and greater humidity cause an rpm loss.
• Operating in a higher elevation causes an rpm loss.
• Operating with increased load (additional passengers, pulling skiers, etc.)
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. However , do not operate at full throttle when using the lower pitch propeller but not pulling skiers.
Because of the many variables of boat design, only testing will determine the best propeller
for a particular application. Available propellers are listed in the “Quicksilver Accessories
Guide.”
See “BOAT-IN-THE-WATER TESTS, Maximum rpm Test” in the power package Installation
Manual.
Page 26 of 116
RPM REV-LIMITER
GASOLINE ENGINES BRAVO MODELS
IMPORTANT: When selecting a propeller consider this additional information, if applicable:
The engines listed in the following chart are equipped with a rpm rev-limiter that is
set to an upper (or limited) rpm amount. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine rpm. Once the rpm drop into the recommended operating rpm range normal engine operation resumes.
Engine Rev-Limiter
Model
Engine Recommended Operating
RPM Range
4.3L
4.3LH
4.3L EFI
5.0L
4400-4800 4950
5.0L EFI
5.7L
5.7L EFI
MX 6.2L MPI 4800-5200 5350
7.4L MPI 4200-4600 4680
350 Mag MPI
454 Mag MPI
4600-5000 5080
502 Mag MPI
Hot Water Heater Installation Recommendation
IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met:
Rev-Limit RPM Setting
• Supply hose (from engine to heater) and return hose (from heater to engine)
MUST NOT EXCEED 5/8 in. (16 mm) I.D. (inside diameter).
• Make heater connections ONLY at locations indicated in the following informa-
tion.
• Refer to manufacturers’ instructions for complete installation information and
procedures.
• Do not reposition engine temperature switch; it must remain where installed by
factory.
Avoid a performance loss and/or possible engine damage. Engine coolant must
flow continuously from the engine intake manifold to the engine water circulating
pump. NEVER close-off or block the coolant flow to or from a heater.
All heater installations must be plumbed in series with the supply and return connections.
CAUTION
Page 27 of 116
GASOLINE ENGINES BRAVO MODELS
Avoid engine overheating which could result in engine damage. On models
equipped with Closed Cooling, an air pocket may form in the closed cooling system
if some coolant is lost from the system and the cabin heater or hot water is mounted
higher than the fill cap on the heat exchanger. Heater must be mounted lower
the fill cap of the heat exchanger on models so equipped.
SUPPLY HOSE CONNECTION
CAUTION
than
a
75473
Seawater Cooling - If Location Is Available
a-Location For Hot Water Supply
a
71758
Seawater Cooling - Alternate Location
a-Location For Hot Water Supply (Install Bayonet Fitting Here)
b
74973
a
Closed Cooling Models - If Location Is Available
a-Location for Hot Water Supply (Bayonet Fitting Replaces Brass Plug)
b-Thermostat Housing
Page 28 of 116
a
b
74639
RETURN HOSE CONNECTION
Seawater or Closed Cooling System
a-Location For Hot Water Return
Seawater Connections - General Information
SEA WATER PICKUP HOSE
Seawater inlet hose connections must be made with wire reinforced hose of adequate wall
thickness to prevent it from collapsing from pump suction. Be sure to secure hose connections with hose clamps. Secure hose to prevent contact with any moving parts of the engine.
Select the proper hose from the following chart:
GASOLINE ENGINES BRAVO MODELS
a
75480
Gasoline Engines 1-1/4 in. (32 mm)
SEACOCK SIZE
Seacock used must have an internal cross-sectional area equal to or greater than seawater
inlet hose to prevent restricting water flow . Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue. A brass ball or gate valve is required. Select a proper seacock based on the following chart:
Gasoline Engines 1-1/4 in. (32 mm)
SEAWATER STRAINER
Strainer used must be of sufficient size to ensure that an adequate supply of water will be
maintained for cooling the engine. Select a proper seawater strainer based on the following
chart:
Seawater Pickup Hose Inner Diameter
Seacock Size
(Internal Cross-Sectional Area Equal to or Greater Than Size Shown)
Seawater Strainer Minimum Flow Rate
1
Gasoline Engines 30 (114)
1
Amounts listed are in gallons per minute and (liters per minute).
Install seawater strainer in an area where it will be easily accessible for inspection and
cleaning. Strainer should be installed in water inlet hose after the seacock (water inlet valve)
to allow operator to shut off water when cleaning strainer.
Page 29 of 116
GASOLINE ENGINES BRAVO MODELS
Throttle/Shift Remote Control and Cables
To ensure proper shift and throttle operation, we recommend the use of a Quicksilver remote
control and cables. Refer to “Quicksilver Accessories Guide” for selection. However, if a
control other than Quicksilver is to be used, control must provide a shift cable travel (at the
shift plate end) of 2-7/8 in. (73 mm) to 3-1/8 in. (80 mm) with a 15-20 lb. (6.8-9 kg) load
applied to the cable end guide.
Steering Helm and Cable
Transom assembly is shipped with the steering cable guide tube preset for cables with end
dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. The steering cable coupler nut must also have a means of locking it to the guide tube
as specified in ABYC requirements.
Failure to use a steering cable locking device could cause loss of steering, which
could cause damage to the boat and/or injury.
NOTE: All current production Quicksilver Ride Guide steering cables have a self-locking
coupler nut and do not require an external locking device. (Other cable manufacturers also
make cables with self-locking coupler nut.)
WARNING
a
22060
a-Quicksilver Ride Guide Steering Cable Self-Locking Coupler Nut (Identified by
Groove)
IMPORTANT: If using a steering cable that does not have a self-locking coupler nut,
an external locking device must be used.
a
b
Example Of External Locking Device
a-Steering Cable
b-Locking Sleeve
POWER STEERING EQUIPPED UNITS ONLY: If steering cable with improper dimensions is installed, severe damage to transom assembly and/or steering system may
result.
1. Steering cable must be the correct length, particularly when installed in larger boats.
2. Avoid sharp bends, kinks or loops in cable.
3. Fully extended steering cable end dimension must be as shown.
Page 30 of 116
CAUTION
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