Mercury D7.3L, D-TRONIC INSTALLATION MANUAL
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, and Ride-Guide.
INSTALLATION MANUAL D7.3L D-TRONIC
DIESEL 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 Installer 2. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In Limit Pin 3. . . . . .
Multiple Sterndrive Steering Tie Bar
Arrangements 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Products 5. . . . . . . . . . . . . . . . . . . . .
Torque Specifications 6. . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 6. . . . . . . . . . .
Corrosion Protection 6. . . . . . . . . . . . . . . . . . . . .
Antifouling Paint 7. . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 8. . . . . . . . . . . . . . . . .
Boat Construction 8. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 11. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 12. . . . . . . . . . . . . . . . . . .
General 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables 14. . . . . . . . . . . . . . . . . . . . . . . . .
EDI Electrical System Precautions 15. . . . . . . .
Instrumentation 15. . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Control 16. . . . . . . . . . . . . . . . . . . . .
Power Trim Pump Location 16. . . . . . . . . . . . . .
Propeller Selection 17. . . . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation
Recommendation 18. . . . . . . . . . . . . . . . . . . . . .
Seawater Connections 19. . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and Cables 20. .
Steering Helm and Cable 21. . . . . . . . . . . . . . . .
Transom Cutout 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Finding Crankshaft Vertical Centerline 24. . . . .
Finding Crankshaft Horizontal Centerline
(“X” Dimension) 25. . . . . . . . . . . . . . . . . . . . . . . .
Cutting Transom 27. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transom Thickness 28. . . . . . . . . . . . .
Installing Transom Assembly 29. . . . . . . . . . . . .
Gimbal Housing 29. . . . . . . . . . . . . . . . . . . . . . . .
Inner Transom Plate 30. . . . . . . . . . . . . . . . . . . .
Power Trim Pump 31. . . . . . . . . . . . . . . . . . . . . .
Steering System 32. . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Pickup 35. . . . . . . . . . . . . . . . . . . .
Drive Unit Gear Lube Monitor Hose 35. . . . . . .
Exhaust Water Bypass 36. . . . . . . . . . . . . . . . . .
Drive Unit Seawater Routing 37. . . . . . . . . . . . .
Engine Installation 39. . . . . . . . . . . . . . . . . . . . . . .
Engine Preparation 39. . . . . . . . . . . . . . . . . . . . .
Transom Preparation 40. . . . . . . . . . . . . . . . . . . .
Installing Engine / Alignment 41. . . . . . . . . . . . .
Engine Connections 46. . . . . . . . . . . . . . . . . . . . . .
Quicksilver Seawater Pickup and Seacock 46.
Seawater Strainer 47. . . . . . . . . . . . . . . . . . . . . .
Closed Cooling Recovery Bottle 48. . . . . . . . . .
Fuel Lines 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Hydraulic Hoses 49. . . . . . . . . .
Exhaust System 50. . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 50. . . . . . . . . . . . . . . . . . .
Shift Cable Installation and Adjustment 54. . . .
Troubleshooting Shift Problems 58. . . . . . . . . . .
Throttle Cable Installation and Adjustment 60.
Sterndrive Unit Installation 62. . . . . . . . . . . . . . .
Predelivery Preparation 69. . . . . . . . . . . . . . . . . . .
Power Trim System Wiring Diagram 84. . . . . . .
MerCathode System Wiring Diagram 85. . . . . .
Quicksilver Instrumentation Wiring 86. . . . . . . .
Cooling System Flow Diagram 88. . . . . . . . . . . .
Predelivery Inspection 90. . . . . . . . . . . . . . . . . . . .
90-861180990 SEPTEMBER 1999 Printed in U.S.A. - 1999, Mercury Marine Page 1 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
General Information
Notice to Installer
Throughout this publication, “Warnings” and “Cautions” (accompanied by the International
!
Hazard Symbol
ular 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.
) are used to alert the installer to special instructions concerning a partic-
WARNING
CAUTION
This installation manual, including all installation requirements, has been written and published by Mercury Marine to aid boat manufacturers and installers involved in the application
and installation of the products described herein.
It is assumed that these personnel are familiar with the installation procedures of these products, or like or similar products manufactured and marketed by Mercury Marine. That they
have been trained in the recommended installation procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.
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.
We could not possibly know of and advise the marine trade of all conceivable procedures
by which an installation might be performed, and of the possible hazards and/or results of
each method. We have not undertaken any such wide evaluation. Therefore, anyone who
uses an installation procedure and/or tool, which is not recommended by the manufacturer,
first must completely satisfy himself that neither his nor the product’s safety will be endangered by the installation procedure selected.
Page 2 of 90
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.
Electrical system components on this engine are not external ignition protected.
DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.
Notice on Bravo Trim-In Limit
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-V 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 drive 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 drive 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.
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
WARNING
The Trim-In Limit Pin Insert reduces stern-lift by preventing the drive unit from reaching the
last few degrees of full trim-in. While this device should reduce the rolling tendency, it may
not eliminate the tendency entirely. The need for this Trim-In Limit Pin Insert, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of
the boat manufacturer.
WARNING
It is recommended that only qualified personnel adjust the Trim-In Limit Pin Insert.
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 drive 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 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
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 as presented in this
section 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.
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 drive 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°.
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 internal 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.
Mercury Marine does not recommend the use of an external tie bar ONLY (no internal tie
bar) when using the internal power steering system. This can cause excessive loads on the
steering components on the drive 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.
Page 4 of 90
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.
INSTALLATION PRODUCTS
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
DESCRIPTION
PART NUMBER
Quicksilver Engine Coupler Spline Grease 92-816391A4
Quicksilver 2-4-C Marine Lubricant 92-825407A3
Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A3
Quicksilver Special Lubricant 101 92-13872A1
Quicksilver Liquid Neoprene 92-25711-2
Quicksilver Perfect Seal 92-34227-1
Transom Drilling Fixture 91-43693A2
Engine Alignment Tool 91-805475A1
Shift Cable Adjustment Tool 91-12427
Engine Lifting Eye Tool 91-806451A1
Engine Mount Drilling Fixture 91-807903A1
Page 5 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
DESCRIPTION
P
)
1
Torque Specifications
Speedometer Pickup Barb Fitting 10-15 1.2-1.6
Exhaust Pipe or Block-off Plate 20-25 27-34
Power Steering Hydraulic Hose Fittings 20-25 27-34
Power Trim Pump Hose Fittings 100-150 11-16
Propeller Nut (Bravo One and Two)
TORQUE
lb-in. lb-ft Nm
1
55 75
ropeller Nuts (Bravo Three
p
Rear Engine Mounts 35-40 47-54
Steering Cable Coupler Nut 35 47
Steering System (Pivot Bolts) 25 34
Sterndrive Unit Fasteners 50 68
Transom Assembly Fasteners 20 25 27-34
Seawater Pickup Fitting 45 5
Power Trim Cylinder Fasteners Tighten until they bottom out.
1
: Amount specified is MINIMUM.
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 and Maintenance Manual identification page.
Corrosion Protection
Front 100 136
Rear 60 81
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 6 of 90
Antifouling 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 T ransom: Antifouling 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.
D7.3L D-TRONIC DIESEL 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 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: Drive 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, and items
specified by boat manufacturer.
Page 7 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Installation Requirements
Boat Construction
TRANSOM
a
f
ENGINE BED
c
b
d
a-Transom Thickness - 2 in. (51mm) Minimum to 2-1/4 in.(57mm) Maximum
b-Inner Surface of Transom Must Be Parallel Within 1/8 in. (3mm) in Area
Covered by Transom Plate (e) and Remain Within Transom Thickness Limits.
c-Outer Surface of Transom Must Be Parallel Within 1/16 in. (2 mm) in Area
Covered by Transom Plate (e) and Remain Within Transom Thickness Limits.
d-Remove Keel (if Equipped) 4 ft. (1.2m) Forward to Transom
e-Transom Plate Covers 8 in. (203 mm) to either side of the vertical centerline
f-Transom Angle - 10 Degrees to 16 Degrees
22170
e e
22033
Page 8 of 90
Distance between starboard and port engine mount is 22-1/2 in. (572mm). 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.
NOTE: Although the engine mounts allow some adjustment, it is a good practice to insure
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
.
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 and/or turbocharger parts.
IMPORTANT: MerCruiser will not honor any warranty claim for engine damage as a
result of water entry.
ENGINE COMPARTMENT VENTILATION
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.
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
WARNING
2. To maintain a low temperature 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.
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.
Combustion Air Requirements
Engine compartments with natural draft ventilation must have vent openings of sufficient
size and location to accomplish the tasks previously outlined.
Furthermore, in part, and according to, ABYC H-32-89 specification - “Compartment Ventilation (Diesel)” states:
“Ventilating provisions and openings to the machinery space provided for suppling combustion air shall accommodate the air requirements required by the engine manufacturer(s) for
each propulsion and auxiliary engine in that space. These openings may also function as
means of providing natural ventilation.”
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 shown in the chart below:
Combustion Air Requirements (Per Engine)
Model
D7.3L D-Tronic and D7.3L D-Tronic LD
Engine Air Requirements at
Wide Open Throttle
1000 ft.3/min. (28.2 m3/min.)
Page 9 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Multiplying the engine air flow (cfm) by 0.1 will
generally
determine the combustion air vent
size requirement (per engine). Therefore:
Engine Combustion
Air Flow (cfm) X 0.1
Combustion Air Vent Area Per Engine
=
(Square Inches)
OR
Engine Combustion Air Flow (m
22.8
D7.3 D-Tronic Example: 1000 X 0.1 = 100 Square Inches
OR 28.2 X 22.8 = 642.9 Sq. Cm.
1
: For engine combustion air only -
3
/min.) X
NOT
Combustion Air Vent Area Per Engine
=
1
(Square Centimeters)
1
total engine compartment ventilation requirement.
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 vent area, determined by the above
formula, plus the engine compartment ventilation requirements.
Compartment Temperature - Specifications
Too high an inlet air temperature lowers the engine performance. Therefore:
Engine compartment temperature shall not exceed outside air temperature by more than
30
° F (17° C).
Since many factors influence engine compartment temperature, temperature measurements should always be carried out.
Compartment Temperature - Testing
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. Temperature 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 1 thermal couple. Position the thermal couple at the engine air inlet
(air filter).
b. Start engine to warm it up. After engine is at its normal operating temperature, run
engine at WOT rpm for 20 minutes. Record temperature readings at 5 minute intervals.
IMPORTANT: If the temperature at the engine air inlet (air filter) exceeds specifications, the engine compartment will need additional engine combustion air openings,
or an increase in engine compartment ventilation area, until the temperature remains
within specification.
Page 10 of 90
Exhaust System
IMPORTANT: It is the responsibility of the boat manufacturer or installing dealer to
properly locate the engine and install the exhaust system. Improper installation may
allow water to enter the exhaust manifolds and combustion chambers and severely
damage the engine. Damage caused by water in the engine will not be covered by
MerCruiser Warranty, unless this damage is the result of defective part(s).
Determine if an exhaust riser kit or a water lift muffler kit is required, by taking measurements
(a) and (b), with boat at rest in the water and maximum load aboard. Subtract (b) from (a)
to find (c). If (c) is less than specified in chart, an exhaust riser kit must be installed.
All Models (c) Must Be 13 in. (330 mm) or More
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Model (c) = (a) Minus (b)
b
a
c
merCruiser
d
Typical Engine Without Risers
a-From Waterline to Top of Transom
b-From Highest Point on Exhaust Elbow to Top of Transom
c-Equals (a) minus (b)
d-Waterline at Rest
Page 11 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Some engines may be equipped with a factory installed exhaust riser. Verify that the
riser provides the required dimension “c”, or a distance greater than “c”, as indicated.
Model (c) = (a) Minus (b)
All Models (c) Must Be 13 in. (330 mm) or More
b
Typical Engine With Riser
a-From Waterline to Top of Transom
b-From Highest Point on Exhaust Riser to Top of Transom
c-Equals (a) minus (b)
d-Waterline At Rest
Fuel Delivery System
merCruiser
a
c
d
76076
GENERAL
Page 12 of 90
WARNING
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when installing fuel delivery system.
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 thank 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]:
1. All connections should be on the upper side of the tank.
2. The drain plug at the lowest point on the tank serves to permit the removal of water and
sediment.
3. The filler pipe outer diameter should be at least 2 in. (50mm).
4. The tank breather pipe must have an inner diameter of at least 1/2 in. (13mm) and must
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.
FUEL CONNECTIONS
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
be fitted with a swan neck to prevent water from entering the tank.
The following, but not limited to the following, additional fuel connection related points,
plying to all engines unless otherwise stated
dards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:
1. Fuel pickup should be at least 1 in. (25mm) from the bottom of fuel tank, to prevent picking up impurities.
2. Fuel supply lines must not be smaller than 3/8 in. (11 mm) I.D. tube for V8 model. A fuel
return line between engine and fuel tank is
not be smaller than 5/16 in. (8 mm).
3. On Multi-Engine Installations: Use a
return line for each engine.
4. Larger diameter (than previously specified) lines, and fittings must be used on installations requiring long lines or numerous fittings.
5. Fuel line(s) should be installed free of stress and firmly secured to prevent vibration and/
or chafing.
6. Sharp bends in fuel lines should be avoided.
7. 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. Injection pump fuel return line must also
have a flexible rubber hose segment.
DIESEL FUEL FILTERS AND FUEL ADDITIVES
, must be considered [Refer to boating stan-
required
separate
, for all models the return line must
tube for the fuel supply line and fuel
ap-
There is the possibility that contamination of diesel fuel and algae growth in the diesel fuel
could cause the blockage of the lift pump resulting in poor performance.
IMPORTANT: The engine is provided with an element type fuel filter, but to help eliminate water and dirt it is recommended to use an additional 10 micron, 60 gal/min. (227
L/min.) flow rated filter that has a water trap.
It is recommended that in MerCruiser Diesel applications, an additional fuel filter equipped
with a water trap be installed before the lift pump. MerCruiser recommends a 10 micron, 60
gallon per minute (227 L/min.) rated filter, such as a Racor Model 500(Quicksilver Part
Number 35-850481 with SAE threads, and 35-809867 with Metric threads) or equivalent.
This will help to filter out contaminants in diesel fuel.
Select a suitable position in the fuel system between the fuel feed pump and the fuel tank
for the additional filter The position selected must be free from vibrations, and allow for easy
inspection and replacement.
It is also recommended that a diesel fuel additive be added (to combat algae growth) particularly in warmer climates. Additives reduce the chances of algae growth in the diesel fuel.
Page 13 of 90
D7.3L D-TRONIC DIESEL 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.
Battery Cables
• Tapered post connectors or side terminal connectors. Do
connectors.
• Battery capacity rating of at least:
Engine
(Cyl./type)
8 / V, D7.3L D-Tronic and D7.3L D-Tronic LD 1500 cca, 1920 mca or 300 Ah
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.
Battery Cable Length
Up to 3 ft. (0.9m) 2 ( 35mm2)
3 - 3-3/4 ft. (0.9 - 1.1m) 1 ( 50mm2)
3-3/4 - 4-3/4 ft. (1.1 - 1.4m) 0 ( 50mm2)
not
use a battery with wing nut
Minimum Required Cranking
Battery Size
Minimum Cable
Gauge
Page 14 of 90
4-3/4 - 6 ft. (1.4 - 1.8m) 00 ( 70mm2)
6 - 7-1/2 ft. (1.8 - 2.3m) 000 ( 95mm2)
7-1/2 - 9-1/2 ft. (2.3 - 2.9m) 0000 (120mm2)
9-1/2 - 12 ft. (2.9 - 3.7m)
12 - 15 ft. (3.7 - 4.6m)
15 - 19 ft. (4.6 - 5.8m)
:Two cables of specified gauge required for positive and two required for negative.
00 ( 70mm2)
000 ( 95mm2)
0000 (120mm2)
EDI Electrical System Precautions
NOTE: The following precautions apply to all EDI model Engines.
Avoid damage to the Electronic Direct Injection (EDI) electrical system and components. Refer to the following precautions when working on or around the EDI 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
GENERAL
We recommend using Quicksilver Instrumentation and Wiring Harnesses. Refer to “Quicksilver Accessories Guide” for selection.
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
CAUTION
NOTE: If using other than Quicksilver instrumentation and harnesses, refer to manufactur-
ers’ instructions.
The six basic gauges that must be used with the engine are:
• Tachometer
• Oil Pressure
• Water Temperature
• Voltmeter
• Cruise Log (Engine Hour Meter)
• Trim Gauge
When using the instrumentation, instrument harness wire connectors are labeled. It will be
necessary to connect them onto the individual Quicksilver instruments, switches and Engine System Monitor panel. The instrumentation harness ends are provided for connection
into the appropriate extension harness ends. The wiring harnesses will then be ready to
route to the engine.
On dual station applications, oil pressure and water temperature senders (on engine) must
be changed.
Additionally, changes are needed in the primary station key switch wiring to allow use of start
and stop switches common on dual station panels. Refer to instructions in kit.
When routing any wiring extension harness back to the engine, make sure that the harness
does not rub or get pinched. Be sure all extension harness connector collars are secure.
Fasten harnesses to boat at least every 18 in. (460 mm) using appropriate fasteners.
Page 15 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
c
a
D7.3L D-Tronic Shown - All Similar
a-Engine Harness Connector
b-Extension Harness Connector (From Instruments)
c-Electrical Bracket
TACHOMETER SPECIAL INFORMATION
IMPORTANT: If using a tachometer from another manufacturer,
netic tachometer pickup
If using the Quicksilver Tachometer provided with the engine package, the appropriate setting of the switch located on the back of the tachometer is given in the following chart.
b
76010
do not use the mag-
(or related wiring) mounted on the flywheel housing.
D7.3L D-Tronic and D7.3L D-Tronic LD 4 (155)
Power Trim Control
Any of the Quicksilver panel or in-handle type trim controls (that are specified for use with
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 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.
Tachometer Switch Setting
Model
Switch Position
(Teeth Count on Flywheel)
Page 16 of 90
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 and Maintenance 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.
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. Generally, there is a 200 rpm change between propeller pitches.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
RPM REV-LIMITER
• 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.
IMPORTANT: When selecting a propeller consider this additional information:
The engines listed in the following chart are equipped with a device that limits engine
rpm. Be sure that propeller being used does not allow engine to run against limiter,
as a significant loss in performance will result.
Engine rpm
MCM Model
Engine Recommended
Operating rpm Range
Rpm Limiter Setting
(Begins At:)
D7.3L D-Tronic 3600-3800 3850
D7.3L D-Tronic LD 3400-3600 3650
Page 17 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Hot Water Heater Installation Recommendation
IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met, including, but not limited to the following:
• 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.
IMPORT ANT: Do not reposition engine temperature switch, it must remain where installed by factory.
CAUTION
Heater must be mounted lower than the fill cap on the heat exchanger. If the heater
is higher than the fill cap on the heat exchanger and some coolant is lost from system, an air pocket may form in the closed cooling system. This can cause the engine
to overheat.
A Hot Water Heater Adaptor Kit is available from Quicksilver. This kit contains installation
instructions. Locations for fittings are shown following.
PART NUMBER
854570A1 Hot Water Heater Adaptor Kit
SUPPLY HOSE CONNECTION
a-Location for Water Heater Supply Hose (Bayonet Fitting Replaces Plug)
DESCRIPTION
a
71898
76024
Page 18 of 90
RETURN HOSE CONNECTION
a-Location on Water Circulation Pump for Hot Water Return (Bayonet Fitting
Replaces Plug)
Seawater Connections
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
a
76023
D7.3L D-Tronic and D7.3L D-Tronic LD models must be equipped with a through hull or
through transom water supply to ensure sufficient water flow to the engine. The transom
assembly needs to be modified with the water passage block-off plate kit (P/N 818304A1)
provided. It is necessary to cut the water hose that is located between the bell housing and
the gimbal housing. This allows water to continue through the drive for cooling. Refer to
“Drive Unit Seawater Routing.” outlined later. Read and observe the following to select the
proper seawater pickup hose, seacock size and seawater strainer.
Seawater Connections - General Information
SEAWATER 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.
Seawater Pickup Hose Inner Diameter
All Models 1-1/2 in. (38mm)
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.
Seacock Size
(Internal Cross-Sectional Area Equal to or Greater Than Size Shown)
All Models 1-1/2 in. (38mm)
Page 19 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
SEAWATER STRAINER
Strainer used must be of sufficient size to ensure that an adequate supply of water will be
maintained for cooling the engine.
Seawater Strainer Minimum Flow Rate
All Models 40 (150)
1
Amount listed is 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.
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 the following:
Shift Cable Travel
(At shift plate end.)
2-7/8 in. (73mm) to 3-1/8 in. (80mm) 15-20 lb. (6.8-9 kg)
1
Shift Cable Load
(Applied to the cable end guide.)
Page 20 of 90
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.
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.)
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
WARNING
a
22060
a-Quicksilver Ride Guide Steering Cable Self-Locking Coupler Nut (Identified by
Groove)
If using a steering cable that does not have a self-locking coupler nut, an external locking
device must be used.
c
b
e
a
f
d
a-Steering Cable
b-Grease Fitting
c-Cotter Pin
d-Locking Sleeve (If Required - Must Be Ordered Separately)
e-Cable Coupler Nut
f-Cable Guide Tube
Page 21 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
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.
STEERING CABLE SPECIFICATIONS
CAUTION
a
b
k
l
a-Coupler Nut - 7/8 - 14 UNF - 28 Thread
b-11-3/4 in. (298 mm) Min.
c-Interface Point
d-1/2 in. (12.700 mm) Max.
e-.420 in. (10.668 mm) Min. Flat
f-.102 in. (0.508 mm) Min. Radius
g-5/8 in. (15.875 mm) Max. Diameter End Fitting
h-3/8 in. (9.525 mm)
i-.385 in. (9.779 mm) Diameter Thru Hole, Chamfered Each Side
j-1-3/8 in. (34.925 mm) Max
k-5/8 in. (15.875 mm) Diameter Tube
l-Mid-Travel Position - 16-7/8 in. (428.6 mm) Total Travel To Be 8 in. (203.2 mm)
Min. to 9 in. (228.6 mm) Max Travel Each Side of Mid-Travel Position - 4 in.
(101.6 mm) Min., 4-1/2 in. (114.3 mm) Max.
c
d
e
f
j
g
C
L
h
i
21435
Page 22 of 90
a
a-Steering Cable Mounting Flange
b-Center of Hole in Steering Cable End
c-21-3/8 in. (543 mm) Max.
b
c
21436
Transom Cutout
Before Starting Installation Read “General Information” and “Installation Requirements”
Sections Completely.
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.
Bravo Models use items 1 - 4.
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
NOTICE to INSTALLER
1. Below 25 m.p.h. (40 km/h):
2. Heavy Duty Applications:
3. Above 25 m.p.h. (40 km/h):
4. Above 50 m.p.h. (80 km/h):
ance in some applications, but pulling power (for skiing) will decrease. During testing,
“X” Dimension should be increased 1/2 in. (13mm) at a time until desired performance
is achieved but in no case should it ever be increased by more than:
Bravo One/Two:
Bravo Three:
In ALL applications where cooling water is supplied through the sterndrive unit to the
engine, extreme care should be taken when raising drive unit to ensure that the water
supply does not become aerated. Use a clear, water inlet hose to check incoming water for
aeration. Monitor engine temperature gauge to ensure engine does not overheat.
In applications where cooling water is supplied to the engine by a fitting through the
hull or transom, the sterndrive height will not cause cooling water aeration.
IMPORTANT: Damage to MerCruiser products caused by too high of an installed
height will not be covered by MerCruiser warranty.
Subtract 1/2 in. (13mm) from “X” Dimension Shown.
Subtract 1 in. (25mm) from “X” Dimension shown.
Use “X” Dimension shown.
The “X” Dimension can be increased to improve perform-
3 in. (76 mm) maximum.
1 in. (25 mm) maximum.
Page 23 of 90
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Finding Crankshaft Vertical Centerline
SINGLE ENGINE
Locate and mark vertical centerline on transom.
a-Vertical Centerline
DUAL ENGINE
1. Locate and mark boat vertical centerline (a) on transom.
a
71620
a
a-Vertical Centerline
2. Locate and mark crankshaft vertical centerlines (a) on transom.
b
a a
c
c
a-Draw Crankshaft Vertical Centerline through Desired Mounting Locations
b-Minimum Distance between Crankshaft Vertical Centerlines
c-Crankshaft Vertical Centerlines Must Be an Equal Distance from Boat Vertical
Centerline
71620
22033
Page 24 of 90
Minimum Distance Between Crankshaft
Vertical Centerlines (Dual Side-By-Side) Chart
Model Measurement [ in. (mm) ]
D7.3L D-Tronic and D7.3L D-Tronic LD 36-1/2 (927)
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Finding Crankshaft Horizontal Centerline (“X” Dimension)
“X” Dimension can be measured by the “90° Tool Method” or by the “Tape Measure Method.”
90
° TOOL METHOD
1. Construct 90° tool.
a
90°
b
71621
a-Dimension from Chart Below
b-Measurement: 4 ft. (1.2 m)
To Lower Drive Unit - Subtract
To Raise Drive Unit - Add
90° TOOL VERTICAL DIMENSION CHART
Sterndrive Unit Location
Bravo One/Two/Three 13-9/16 in. (345mm)
IMPORTANT: This dimension should only be raised or lowered after proper testing.
2. Determine “X” Dimension location of crankshaft centerline(s).
from dimension “a”.
to dimension “a”.
b
c
c
b
a
71622
Single Engine Dual Engine
a-Place 90
b-Point at Which Top of Tool Contacts Transom on Vertical Centerline is Crank-
shaft Horizontal Centerline.
c-Draw a Line Perpendicular to Vertical Centerline at Crankshaft Horizontal
Centerline.
° Tool Along Boat Bottom at Vertical Centerline
a
Page 25 of 90
71623
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
TAPE MEASURE METHOD
Transom angle must be known, then measure “X” Dimension with tape measure.
1. Determine “X” Dimension from the following chart.
Tape Measure Method Chart
Model
Transom Angle
16°
15°
14°
13°
12°
11°
10°
This dimension should only be raised or lowered after proper
Bravo One / Two / Three
testing.
14-5/16 in. (364 mm)
14-1/4 in. (362 mm)
14-3/16 in. (360 mm)
14-1/8 in. (359 mm)
14-1/16 in. (357 mm)
14 in. (356 mm)
13-15/16 (354 mm)
2. Measure and layout horizontal centerlines as shown.
b
c
d
d
a
71622
b
c
a
71623
Single Engine Dual Engine
a-“X” Dimension (from Chart) that Corresponds to Transom Angle - Measure Up
from Boat Bottom with Tape Measure
b-Crankshaft Horizontal Centerline
c-Vertical Centerline
d-Draw a Line Perpendicular to Vertical Centerline at Crankshaft Horizontal
Centerline
Page 26 of 90
Cutting Transom
Transom cutout can be made by either using the Template [shipped with transom assembly]
or the Transom Drilling Fixture Kit (purchased separately).
Follow instructions indicated on template or provided with drilling fixture.
IMPORTANT: Read and observe the following information:
• Be certain that centerlines on either the template or transom drilling fixture align
with lines previously marked on transom.
• Be sure to drill 1/4 in. pilot holes (for hole saw guide) at a 60° angle and to cut on
the line when making transom cutout. If cutout is made incorrectly, drive unit
steering lever may contact transom, thus limiting steering travel.
• Seal inside edge of transom cutout opening with a suitable sealant to prevent wa-
ter absorption and deterioration of transom.
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS
Transom Cutout Template
Transom Drilling Fixture Kit
50017
22056
Page 27 of 90
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