Mercury MX 6.2 MPI, 350 MAG MPI Horizon, 350 MAG MPI, MX 6.2 MPI Horizon Installation Manual
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
Mercury MerCruiser, Mercury, Mercury
Marine, Quicksilver, RideGuide, Thruster
and Mercury Precision Parts.
GASOLINE ENGINE TOW SPORTS AND
INBOARD MODELS INSTALLATION MANUAL
Models Covered
Inboard
Model Serial Number or Year
Tow Sports
Horizon
Notice
350 MAG MPI
MX 6.2 MPI
Model Serial Number or Year
350 MAG MPI 0M310000 and Above
Model Serial Number or Year
350 MAG MPI Horizon
MX 6.2 MPI Horizon
NOTICE
After completing installation, these instructions should be placed with the
product for the owner’s future use.
0M310000 and Above
0M310000 and Above
Predelivery preparation instructions must be performed before delivering boat
to the product owner.
Page 1 of 77 Printed in U.S.A. - 2002, Mercury Marine 90-864198020 MARCH 2002
NOTICE
INSTALLATION MANUAL
Table Of Contents
General Information 3. . . . . . . . . . . . . . . . . . . . . .
Notice to Boat Manufacturer/Installer 3. . . . .
Torque Specifications 4. . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 4. . . . . . . . . .
Quicksilver Products 5. . . . . . . . . . . . . . . . . . . . . .
Accessories 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 5. . . . . . . . . . . .
Engine Rotation 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Transmissions 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Velvet Drive Transmissions 6. . . . . . . . . . . . .
ZF / Hurth Transmissions 7. . . . . . . . . . . . . . .
Propeller Rotation 8. . . . . . . . . . . . . . . . . . . . .
Boat Construction 10. . . . . . . . . . . . . . . . . . . . . . .
Engine Bed 10. . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Connections 11. . . . . . . . . . . . . . . . . . . .
Seawater Pickup 11. . . . . . . . . . . . . . . . . . . . . .
Preliminary Connections 14. . . . . . . . . . . . . . . . .
Fuel Inlet Fitting 14. . . . . . . . . . . . . . . . . . . . . .
Inline Fuel Filter 15. . . . . . . . . . . . . . . . . . . . . .
Coolant Recovery System
Connections 17. . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount Pre-Adjustment 18. . . . . . . . . . . .
Engine Preparation 19. . . . . . . . . . . . . . . . . . . . . .
Engine Oil Dipstick Relocation 19. . . . . . . . .
Engine Installation and Initial Engine
Alignment 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models With 8 Degree Down Angle
Transmissions 20. . . . . . . . . . . . . . . . . . . . . .
Models with V-Drive Transmissions 22. . . . .
All Models 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation 24. . . . . . . . . . .
Exhaust System 26. . . . . . . . . . . . . . . . . . . . . . . . .
Measurement Methods 29. . . . . . . . . . . . . . . .
Exhaust System Hose / Tube
Connections 32. . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 33. . . . . . . . . . . . . . . . . . .
Instrumentation Connections 33. . . . . . . . . . .
Audio Warning System Connections 34. . . .
Fluid Connections 35. . . . . . . . . . . . . . . . . . . . . . .
Coolant Recovery Bottle 35. . . . . . . . . . . . . . .
Final Engine Alignment 36. . . . . . . . . . . . . . . . . .
Throttle Cable Installation and
Adjustment 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation And Adjustment 40. . . .
Velvet Drive Transmissions 41. . . . . . . . . . . .
ZF / Hurth Transmissions 49. . . . . . . . . . . . . .
Predelivery Preparation 54. . . . . . . . . . . . . . . . . .
Propeller Selection 54. . . . . . . . . . . . . . . . . . . .
Fuel Line Connection 55. . . . . . . . . . . . . . . . .
Battery 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Running Engine 57. . . . . . . . . . . . . . . . . .
Boat In The Water Tests 58. . . . . . . . . . . . . . .
Cold Weather and Extended Storage 59. . . . . .
Draining Instructions 59. . . . . . . . . . . . . . . . . . . . .
Identification 60. . . . . . . . . . . . . . . . . . . . . . . . .
Boat In Water 61. . . . . . . . . . . . . . . . . . . . . . . .
Boat Out Of The Water 65. . . . . . . . . . . . . . . .
All Models 67. . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrumentation 68. . . . . . . . . . . . . . . . . . . . . . . . .
ECM 555 EFI System
Engine Wiring Diagrams 70. . . . . . . . . . . . . . . . .
Water Flow Diagrams 74. . . . . . . . . . . . . . . . . . . .
Predelivery Inspection 77. . . . . . . . . . . . . . . . . . .
Page 2 of 77 90-864198020
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 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 manufacturer or installer to special instructions
INSTALLATION MANUAL
WARNING
CAUTION
NOTE: Refer to the Mercury MerCruiser Product Applications Manual - Gasoline Inboard
Models for application recommendations.
This installation manual has been written and published by Mercury Marine to aid the boat
manufacturer (OEM) in the installation of the products described herein.
It is assumed that these personnel are familiar with marine product installation.
Furthermore, it is assumed that they are familiar with, if not trained in, the recommended
installation procedures of Mercury MerCruiser product.
We could not possibly know of or advise the marine trade of all conceivable installations and
of the possible hazards and/or results of each installation. Therefore, the OEM is
responsible for any installation that does not fulfil the requirements of this manual.
It is the responsibility of the boat manufacturer to select the appropriate
engine/transom/drive package (including the correct gear ratio and propeller) for a given
boat. Mercury recommends that any new or unique hull/power package combination be
thoroughly water tested prior to sale, to verify that the boat performs as desired, and that
the engine runs in the appropriate rpm range.
It is recommended that a Mercury Marine Sales Application Engineer (SAE) be contacted
for assistance.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at time of publication. Mercury Marine reserves the right
to make changes at any time without obligation. As required, revisions to this manual will
be sent to all OEM boat companies.
90-864198020 Page 3 of 77
INSTALLATION MANUAL
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Description
Engine Mount Bracket Screws 64 47
Trunnion Clamping Bolt and Nut 68 50
Propeller Shaft Nut 68 50
Exhaust Manifold Screw 27 20
Coupler Bolts 68 50
1
Refer to Fuel Delivery System.
Lubricants / Sealants / Adhesives
Description Where Used Part Number
Marine Caulking Mounting Surfaces Obtain Locally
Loctite 271 Seawater Pickup Nut 92-809820
Loctite 592 PST
Liquid Neoprene Battery Terminals 92-25711-2
Nm lb-in. lb-ft
Hose Fitting Threads
Plastic Plug Threads
Fuel Inlet Fitting
Obtain Locally
Engine Coupler Spline Grease Coupler Splines 92-816391A4
Page 4 of 77 90-864198020
Quicksilver Products
Accessories
Quicksilver gauges, remote controls, steering systems, propellers and other accessories
are available for this product. Mercury MerCruiser recommends the use of Quicksilver parts
on all applications. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for a
complete listing.
This Guide is available from:
Attn: Parts Department
W6250 W. Pioneer Road
Fond du Lac, WI 54936-1939
Outside of U.S.A., order through Distribution Center or Distributor.
Serial Number Decal Placement
There are three engine serial number decal strips provided with each power package. One
should be used for each of the following:
INSTALLATION MANUAL
Mercury Marine
P.O. Box 1939
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance and Warranty Manual identification page.
Affix engine serial number decal to specification / serial number decal in position shown.
a-Engine Serial Number Location
Engine Rotation
Engine rotation is described when observed from the rear of the engine (transmission end)
looking forward (water pump end). Engine rotation is indicated on engine specifications and
serial number decal.
a
77962
90-864198020 Page 5 of 77
INSTALLATION MANUAL
Transmissions
Velvet Drive Transmissions
On the Velvet Drive 71C and 72C In-Line and 72C Remote V-Drive Transmissions the gear
ratio (in FORWARD gear) is marked on transmission identification plate. Transmission output shaft rotation and propeller rotation required (in FORWARD gear) are indicated on a decal on the transmission case. Transmission rotation is described when viewed from the rear
of transmission.
22556
In-Line Transmission Shown (Remote V-Drive Similar)
a-Transmission Identification Plate
b-Gear Ratio (In FORWARD Gear)
c-Output Flange Rotation Decal (In FORWARD Gear)
On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate
indicates gear ratio, serial number and model.
a
71778
Velvet Drive 5000A 8 Degree Down-Angle Transmission Shown (5000V V-Drive
Similar)
a-Transmission Identification Plate
Page 6 of 77 90-864198020
ZF / Hurth Transmissions
On the ZF / Hurth 630A 8 Degree Down-Angle and 630V V-Drive Transmissions the
transmission identification plate indicates gear ratio, serial number and model.
Typical ZF / Hurth Down-Angle Transmission Shown (V-Drive Similar)
a-Transmission Identification Plate
INSTALLATION MANUAL
a
73587
90-864198020 Page 7 of 77
INSTALLATION MANUAL
Propeller Rotation
Propeller rotation is not necessarily the same as engine rotation. Refer to the appropriate
following information and drawings for specific information.
These transmissions are full power reversing transmissions, allowing a standard (LH
rotation) engine to be used for both propeller rotations. Propeller rotation (output shaft
rotation) is determined by shift cable attachment at the remote control. Be sure to use
correct rotation propeller and shift cable hook up for direction desired.
a
c
b
Velvet Drive 5000A - 8 Degree Down-Angle Transmission
b
a
b
f
g
d
e
71888
d
b
Velvet Drive 5000V - V-Drive Transmissions
a-Direction of Shift Lever Engagement (Toward Flywheel)
b-Engine/Transmission Input Shaft Rotation Direction (LH)
c-Transmission Output/Propeller Shaft Rotation Direction (LH)
d-Direction of Shift Lever Engagement (Away From Flywheel)
e-Transmission Output/Propeller Shaft Rotation Direction (RH)
f-Transmission Output/Propeller Shaft Rotation Direction (LH as viewed at
propeller)
g-Transmission Output/Propeller Shaft Rotation Direction (RH as viewed at the
propeller)
74604
Page 8 of 77 90-864198020
INSTALLATION MANUAL
a
d
b
c
e
ZF / Hurth 630A or 800A - 8 Degree Down-Angle Transmissions
a
b
c
d
e
b
25506
b
72959
ZF / Hurth 630V - V-Drive Transmissions
a-Direction Of Shift Lever Engagement (Toward Flywheel)
b-Engine/Transmission Input Shaft Rotation Direction (LH)
c-Transmission Output/Propeller Shaft Rotation Direction (LH)
d-Direction Of Shift Lever Engagement (Away From Flywheel)
e-Transmission Output/Propeller Shaft Rotation Direction (RH)
90-864198020 Page 9 of 77
INSTALLATION MANUAL
DUAL INSTALLATIONS
Best all-around performance usually is obtained by installing engines so that propellers turn
outboard (looking at the stern).
a
c
a-Outboard Propeller Rotation
b-RH Rotation
c-LH Rotation
b
VELVET DRIVE IN-LINE AND V-DRIVE TRANSMISSIONS (EXCEPT 5000 SERIES)
IMPORTANT: Velvet Drive In-Line and V-Drive Transmissions Only – Use of proper
rotation propeller (specified on transmission output flange rotation decal) is critical
since the transmission must be operated in FORWARD gear selector position only
to drive boat forward. If the wrong rotation propeller is installed and transmission is
operated in REVERSE to propel the boat forward, transmission failure WILL occur.
IMPORT ANT: On engines which are equipped with Velvet Drive In-line transmissions,
a LH propeller is required.
Boat Construction
Engine Bed
Difference Between Starboard and Port Engine Mount 22-1/2 in. (572 mm)
Mount Adjustment Up and Down (minimum) 1/4 in. (6mm)
22457
NOTE: Although the engine mounts allow some adjustment, ensure that the front and rear
mount locations in the vessel are in the same plane and parallel. 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 77 90-864198020
.
Seawater Connections - General Information
NOTICE
Refer to manufacturer’s instructions for information on removal and installation of
other than Quicksilver Seawater Pickups.
IMPORT ANT: Seal the inside edges of any hole made through the hull with a suitable
sealant to prevent water absorption and deterioration.
Seawater Pickup
THROUGH THE HULL MOUNTED
1. Seal inside edges of 1-3/4 in. (44 mm) hole in hull using a suitable sealer.
2. Apply marine caulking (sealer) to mounting surface on seawater pickup where hull
contact will occur when installed.
IMPORT ANT: Seawater inlet slots must face forward - parallel with the flow of water .
3. Ensure slots in seawater pickup are facing forward (toward bow of boat) and install
seawater pickup through hull.
4. Fasten pickup with four appropriate mounting screws (if so designed).
INSTALLATION MANUAL
5. Apply marine caulking as needed inside boat.
b
A
a-Seawater Pickup
b-Seawater Inlet Slots
c-Mounting Screw Holes (If Equipped)
d-Nut
Description
A Marine Caulking Mounting Surfaces Obtain Locally
6. Apply sealant to threads of nut and install on pickup on inside of boat and torque nut.
Where Used Part Number
d
c
a
72639
Description
Loctite 271 Seawater Inlet Nut 92-809820
Description Nm lb-in. lb-ft
Nut 42 35
NOTE: If pickup being installed does not have mounting screws on underside where
mounted to hull, be certain, after nut is torqued, that slots are still facing forward.
90-864198020 Page 11 of 77
Where Used Part Number
INSTALLATION MANUAL
TRANSOM MOUNTED
1. Seal the inside edges of the 1-1/2 in. (38 mm) hole hose fitting.
2. Ensure that the hose fitting and plastic plug are in place and threads have been sealed
prior to tightening each securely.
NOTE: Use a sharp knife or wood chisel to remove excess plastic plug material so that plug
is flush with pickup casting.
3. Position one flat washer and one rubber O-ring on each 5/16 in. x 4 in. (102 mm) long,
round head screw. Coat each screw shaft with sealant.
4. Place new gasket on pickup housing and hold pickup in place on transom. Install four
round head screws (with washers and O-rings in place) into pickup mounting holes and
through drilled 21/64 in. (8 mm) holes in transom.
b
d
A
a
e
B
f
c
g
A
h
i
j
a-Hose Fitting
b-Nut (4)
c-Gasket
d-O-ring (4)
e-Washer (4)
Description
A Loctite 592 PST
B Silicone Sealant Or Equivalent Screw Shaft
Hose Fitting Threads
Plastic Plug Threads
72640
f-Screw (4)
g-Plastic Pug
h-Pickup
i-Screen
j-Screw (2)
Where Used Part Number
Obtain Locally
Page 12 of 77 90-864198020
INSTALLATION MANUAL
NOTE: Some installations may have 7/32 in. (5 mm) holes drilled in transom using four 5/16
in. diameter stainless steel lag bolts in place of round head screws. In any case, flat washers
and O-rings are required as outlined.
a
b
72641
Water Pickup Installed on Transom
a-Diagonal Mount - Leading Edge Of Pickup 1/8 in. (3.2 mm) From Boat Bottom.
b-Vertical Mount - Corner Of Leading Edge Of Pickup 1/8 in. (3.2 mm) From Boat
Bottom
5. Secure water pickup from inside with locknuts and washers (unless using lag bolts).
6. Tighten fasteners securely.
90-864198020 Page 13 of 77
INSTALLATION MANUAL
Preliminary Connections
Fuel Inlet Fitting
IMPORTANT: The following information is provided to ensure proper installation of
brass fittings or plugs installed into fuel pump or fuel filter base:
• Use #592 Loctite Pipe Sealant with Teflon on threads of fuel inlet fittings or plugs.
DO NOT USE TEFLON TAPE.
Boating standards (NMMA, ABYC and others) and Coast Guard regulations must
be adhered to when installing fuel delivery system.
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into
fuel pump or fuel filter base can crack casting and/or cause a fuel leak.
1. Remove plastic plug from fuel inlet hole.
2. Apply sealant to threads of fuel inlet fitting. DO NOT USE TEFLON TAPE.
WARNING
WARNING
WARNING
Overtightening the fuel inlet fitting can lead to fuel leaks, avoid severe personal
injury or death from a gasoline fire or explosion. DO NOT use a power tool (i.e.
impact wrench) to tighten the fuel inlet fitting.
3. Install fuel inlet fitting in fuel pump or filter base. To prevent cracking the casting or
causing fuel leaks, turn fuel inlet fitting in by hand until finger tight. Tighten the fitting an
additional 1-3/4 to 2-1/4 turns with wrench. DO NOT OVERTIGHTEN.
a
a
78276
Models With Boost Pump Models With Out Boost Pump
a-Fuel Inlet Fitting
A
A
77950
Description
A Loctite 592 Fuel Inlet Fitting Obtain Locally
Page 14 of 77 90-864198020
Where Used Part Number
Inline Fuel Filter
INSTALLATION
IMPORTANT: If the engine is equipped with a boost pump, an inline filter must be
installed between the fuel tank and the boost pump.
Avoid injury or death and power package damage from an electrical shock, fire or
explosion. Always disconnect both battery cables from the battery before servicing
the power package.
1. Disconnect both battery cables from the battery.
2. Install boat fuel line from the tank to the engine.
3. With the engine installed, locate a section of the fuel line in a serviceable location,
4. Remove 76 mm (3 in.) of fuel line in mounting location.
5. Select appropriate size connector for the fuel line and install the connector on the filter.
6. Apply sealant to the male pipe threads on the connectors.
INSTALLATION MANUAL
WARNING
leaving enough room for filter, connections and bracket mounting.
Description
Where Used Part Number
Loctite 565 Male Threads Obtain locally
7. Torque connectors.
Description
Nm lb-in. lb-ft
Connectors 19-27 14-20
8. Insert filter into the mounting clip.
c
a
b
a-Inline Filter
b-Connectors
c-Mounting Clip
78289
90-864198020 Page 15 of 77
INSTALLATION MANUAL
9. Install and torque screw and washer through the mounting clip into the stringer.
Description
Nm lb-in. lb-ft
Screw, Mounting Clip 12.2 9
10. Install and torque hose clamps over hose and insert barbs into hose.
a
b
78289
a-Fuel Line Stringer Clips
b-Fuel Line
Description
Hose Clamps 3.4-6.8 30-60
11. Inspect the fuel line stringer clips to ensure that the recommended length between clips
has not been exceeded. The maximum allowable length is 45.7 mm (18 in.).
Nm lb-in. lb-ft
12. Pressurize the fuel system and check for leaks. Relieve pressure and then check for
leaks again.
SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS
CAUTION
The electric fuel pump and factory installed water separating fuel filter have been
carefully designed to function properly together . Do not install additional fuel filters
and/or water separating fuel filters between fuel tank and engine.
The installation of additional filters may cause:
• Fuel Vapor Locking
• Difficult Warm-Starting
• Piston Detonation Due to Lean Fuel Mixture
• Poor Driveability
Page 16 of 77 90-864198020
Coolant Recovery System Connections
1. Select a mounting location for coolant recovery bottle and mounting bracket that meets
all of the following:
• Within limits of clear plastic tubing.
• Level with or above the heat exchanger fill neck.
• Accessible for observing coolant level and filling.
2. Mount coolant recovery bottle and mounting bracket in desired location, using two
3/4 in. (19 mm) long screws and flat washers.
3. Route plastic tubing to recovery bottle. Ensure that tubing is positioned away from any
moving parts. Cut plastic tubing as required and connect to bottom connection on recovery bottle and secure with tubing clamp provided.
4. Fasten plastic tubing to boat as necessary, with the 2 hose clips and 1/2 in. (13 mm) long
screws provided.
b
a
INSTALLATION MANUAL
c
d
a-Recovery Bottle And Mounting Bracket
b-Screws And Flat Washers
c-Plastic Tubing
d-Tubing Clamp
70547
90-864198020 Page 17 of 77
INSTALLATION MANUAL
Engine Mount Pre-Adjustment
1. Remove hardware holding engine to shipping pallet. Attach a suitable sling to lifting eyes
on engine. Lift engine from pallet with an overhead hoist.
2. Remove L-shaped shipping bracket from both rear (transmission) mounts as shown.
Retorque mount bracket attaching screw to 47 lb-ft (64 Nm).
a
b
74623
Typical
a-L-shaped Bracket
b-Transmission Mount Bracket Attaching Screw
IMPORTANT: Engine mounts must be adjusted, as explained in Steps 3. and 4., to
center mount adjustment and establish a uniform height on all mounts.
3. Check all 4 engine mounts (2 front, 2 rear) to ensure that distance from bottom of mount
to bottom of trunnion is as shown. If not, loosen mount locking nut and turn adjusting nut
in direction required to obtain proper dimension, then retighten locking nut. Be sure to
leave mount positioned so that slot is forward.
4. Loosen clamping bolts and nuts on all 4 engine mount brackets to ensure the following:
• Large diameter of mount trunnion extended.
• Mount base slotted mounting hole forward, if so designed.
• Each mount base is downward. Tighten clamping bolts and nuts slightly to prevent mov-
ing in or out. Mounts must be free to pivot when installing engine.
Page 18 of 77 90-864198020
Engine Preparation
1. Remove and read all tags attached to engine.
2. Remove all hardware that secures engine to shipping container.
3. Connect battery cables to engine. Be sure to observe the following:
a. Ensure that grounding stud and starter solenoid terminal are free of paint or any oth-
er material that could cause a poor electrical connection.
b. After battery cables are connected, apply a thin coat of sealant to the terminals.
INSTALLATION MANUAL
Description
Liquid Neoprene Battery Terminals 92-25711-2
c. Be sure to slide rubber boot over positive (+) terminal after making connection.
IMPORTANT: There is a fuse located at the starter solenoid. DO NOT remove this fuse.
The positive battery cable must be connected to the same stud as the fuse.
Where Used Part Number
c
a
b
77001
a-Positive (+) Battery Cable
b-Starter Solenoid
c-90 Amp Fuse - DO
NOT Remove
4. Drape battery cables over top of engine to prevent interference during installation.
Engine Oil Dipstick Relocation (If Equipped)
Engine crankcase oil dipstick can be located on either starboard or port side of engine to
suit installation requirements. To move dipstick, remove dipstick from current location and
install in opposite side. Place rubber cap over the open dipstick tube.
a-Dipstick
90-864198020 Page 19 of 77
a
a
77954
INSTALLATION MANUAL
Engine Installation and Initial Engine Alignment
Models With 8 Degree Down Angle Transmissions - Velvet Drive or ZF / Hurth
1. Remove the engine cover.
2. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when
suspended.
CAUTION
Center lifting eye on top of thermostat housing is used for engine alignment only.
Do not use to lift entire engine.
b
c
a-Front Lifting Eye
b-Rear Lifting Eye
c-Center Lifting Eye
3. Lift engine into position in boat using an overhead hoist.
a
77912
Page 20 of 77 90-864198020
INSTALLATION MANUAL
4. Position engine on engine bed so that transmission output flange and propeller shaft
coupler are visibly aligned (no gap can be seen between coupling faces when butted
together). Adjust engine height if necessary to obtain proper alignment. DO NOT use
mount adjustments to adjust engine position at this time.
IMPORTANT: Engine bed must position engine so that a minimum of 1/4 in. (6 mm)
up and down adjustment still exists on all 4 mounts after performing initial alignment.
This is necessary to allow for final engine alignment.
c
b
a
74546
a-Propeller Shaft
b-Propeller Shaft Coupler
c-Transmission Output Flange
5. Ensure quick drain oil fitting is more than 1/2 in. (13 mm) above the boat bottom.
IMPORT ANT: If quick drain oil fitting is within 1/2 in. (13 mm) of boat bottom, remove
fitting and install drain plug from parts bag directly into oil pan.
6. Ensure that all 4 mounts are still positioned properly, then fasten mounts t o engine bed
with 3/8 in. (10 mm) diameter lag bolts (of sufficient length) and flat washers. Tighten
lag bolts securely.
7. Disconnect overhead hoist and remove sling.
90-864198020 Page 21 of 77
INSTALLATION MANUAL
Models with V-Drive Transmissions
1. Lift engine into position in boat using an overhead hoist.
2. Install quick drain oil hose plug in oil drain hose.
3. Position engine so that enough propeller shaft protrudes through transmission and output flange for propeller shaft coupler to be attached. Then install coupler and position
engine (no gap can be seen between coupling faces when butted together). Adjust en-
gine height if necessary to obtain proper alignment. DO NOT use mount adjustments
to adjust engine position at this time.
IMPORTANT: Engine bed must position engine so that a minimum of 1/4 in. (6 mm)
up and down adjustment still exists on all 4 mounts after performing final alignment.
This is necessary to allow for final engine alignment.
d
c
a
50608 50608
b
ZF / Hurth 630V (Others Similar)
a-Propeller Shaft
b-Propeller Shaft Coupler
c-Transmission Output Flange
d-No Gap Allowed
4. Ensure quick drain oil fitting is more than 1/2 in. (13 mm) above the boat bottom.
IMPORT ANT: If quick drain oil fitting is within 1/2 in. (13 mm) of boat bottom, remove
fitting and install drain plug from parts bag directly into oil pan.
5. Ensure that all 4 mounts are still positioned properly. Fasten mounts to engine bed with
3/8 in. (10 mm) diameter lag bolts (of sufficient length) and flat washers. Tighten lag bolts
securely.
6. Disconnect overhead hoist and remove sling.
Page 22 of 77 90-864198020
All Models
INSTALLATION MANUAL
1. Push end of oil drain hose out of boat hull through flange.
2. Pull oil drain hose out until it is 6 in. (152 mm) from the propeller.
3. Move alignment clip on the oil drain hose and squeeze to position it on the hose just in-
side of the boat hull against the flange.
4. Connect bilge drain plug to oil drain hose plug using clip.
b
d
c
a
78002
a-Oil Drain Hose
b-Alignment Clip
c-Clip
d-Bilge Drain Plug
IMPORT ANT: If Quick Drain Oil Fitting is within 1/2 in. (13 mm) of boat bottom, remove
fitting and install drain plug from parts bag directly into oil pan.
5. Push oil drain hose through flange into boat hull.
6. Install bilge drain plug in hull.
90-864198020 Page 23 of 77
INSTALLATION MANUAL
Hot Water Heater Installation
IMPORTANT: When connecting a cabin heater or hot water heater:
• Supply hose (from engine to heater) and return hose (from heater to engine)
MUST NOT EXCEED 5/8 in. (16 mm) I.D.
• Make heater connections ONLY at locations shown.
• Refer to manufacturers’ instructions for complete installation information and
procedures.
• Do not reposition engine temperature switch.
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.
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.
CAUTION
CAUTION
than
SUPPLY HOSE CONNECTION
NOTE: Some models may be equipped with additional fittings.
a
Seawater Cooled Models Closed Cooled Models
77816
a
77815
Page 24 of 77 90-864198020
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