4.2 TDI - 8M0093780 - Manual de Instalacao

© MERCURY MARINE. All rights reserved.
Reproduction in whole or in part without permission is

prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K-planes,
Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury
Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore,
Skyhook, SmartCraft, Sport-Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're
Mercury Diesel
Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of
Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick
Corporation.
4.2L TDI DIESEL STERNDRIVE MODELS

INSTALLATION MANUAL
Models Covered
Models Covered Serial Number
4.2L TDI sterndrive Serial numbers were not available at the time of publication
Notice
NOTICE
After completing installation, place these instructions with the product for the owner's use.
NOTICE
Predelivery preparation procedures must be performed before delivering the boat to the product owner.
Notice to Boat Manufacturer or Installer

Throughout this publication, safety alerts labeled WARNING and CAUTION (accompanied by the international hazard symbol
! ) are used to alert you to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe these alerts 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.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Additional alerts provide information that requires special attention:
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
This installation manual is provided by Mercury Marine to assist the boat original equipment manufacturer (OEM) with the
installation of the products described herein. The installation manual assumes that the installers are familiar with the
recommended installation procedures for Mercury Marine products.
NOTE: Refer to the Mercury Diesel Product Applications Manual for application recommendations.
We cannot anticipate or advise the marine trade of all conceivable installations and the potential hazards and results of each.
The OEM is responsible for any installation that does not fulfill the requirements of this manual.
The boat manufacturer is responsible for selecting the appropriate engine and drive package (including the correct gear ratio
and propeller) for a given boat design. Any new or unique hull and power package combination should be water tested before
sale and delivery, to verify that the boat performs as desired and that the engine operates in the appropriate RPM range.
Page i © 2015 Mercury Marine 90-8M0093780 JANUARY 2015

Contact a Mercury Diesel product integration engineer (PIE) for additional assistance. For assistance outside the United States,
contact the local Mercury Diesel office or authorized distributor.
All information, illustrations, and specifications 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.
Page ii
1
Manual Outline
Important Information
1 - Important Information
2 - Boat Construction
3 - Exhaust System
Boat Construction
2
3
4 - Fuel System
Exhaust System
5 - Cooling System
4
6 - Drive System and Engine Mounting
7 - Electrical Systems Fuel System
8 - Remote Controls
9 - Predelivery Preparation and Storage
Cooling System
5
Drive System and Engine Mounting
6
Electrical Systems
7
Remote Controls
8
Predelivery Preparation and
Storage 9
Page iii
Page iv
SECTION - 1 IMPORTANT INFORMATION
SECTION 1 - IMPORTANT INFORMATION 1

Table of Contents
General Information..................................................................................................................................................................... 2
Torque Specifications—Bravo Sterndrive............................................................................................................................. 2
Mercury Products—Accessories.......................................................................................................................................... 2
Remote Controls and Instrumentation for the DTS System................................................................................................. 2
Identification................................................................................................................................................................................ 2
Serial Number and Emission Control Decal......................................................................................................................... 2
Engine Data Label Location................................................................................................................................................. 3
Bravo Sterndrive Serial Number and Identification............................................................................................................... 3
Bravo Transom Serial Number............................................................................................................................................. 4
Multiple Sterndrive Steering Tie Bar Arrangements.................................................................................................................... 4
Internal Tie Bar Only............................................................................................................................................................. 4
Internal and External Tie Bar................................................................................................................................................ 4
External Power Steering....................................................................................................................................................... 5
External Power Steering With Low External Tie Bar............................................................................................................ 5
Corrosion..................................................................................................................................................................................... 5
SeaCore Components and Castings.................................................................................................................................... 5
Stainless Steel Fasteners..................................................................................................................................................... 5
Corrosion Protection............................................................................................................................................................. 5
Anodes and the MerCathode System................................................................................................................................... 5
Mounting the MerCathode.................................................................................................................................................... 7
Reference Electrode Wire of the MerCathode System......................................................................................................... 7
Anti‑Fouling Paint................................................................................................................................................................. 7
Continuity Connections......................................................................................................................................................... 8
90-8M0093780 JANUARY 2015 Page 1 / 8

IMPORTANT INFORMATION SECTION - 1
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
95 2-4-C with PTFE Threads of stainless steel fasteners 92-802859A 1
General Information
Torque Specifications—Bravo Sterndrive
NOTE: Securely tighten all fasteners.
NOTE: The propeller torque stated is a minimum torque value.
Description Nm lb–in. lb–ft

75 – 55
Bravo One propeller nut
Then align tabs with grooves
81 – 60
Bravo Two propeller nut
Then align tabs with grooves
Transom assembly hardware 34 – 25
Block‑off plate bolt 5 45 –
Water inlet fitting bolt 5 45 –
Pivot bolts 34 – 25
Exhaust pipe assembly bolts 34 – 25
Rear engine mounting bolts 47 – 35
Seawater inlet nut 47 – 35
Sterndrive unit fasteners 68 – 50
Mercury Products—Accessories
Mercury gauges, remote controls, steering systems, propellers, and other accessories are available for this product. Refer to
the Diesel Parts and Accessories Guide or the Mercury Precision Parts Accessories Guide for complete listings.
These guides are available from:
Mercury Marine
Attn.: Parts Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
USA
If outside the U.S.A., contact your regional distribution center or local distributor.
Remote Controls and Instrumentation for the DTS System

The Digital Throttle and Shift system (DTS) requires the use of specialized helm components, including a command module
kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.
Identification
Serial Number and Emission Control Decal
Three sets of engine, transom assembly, and sterndrive serial number decal strips are provided with each power package.
One set should be used for each of the following:
• Engine specification decal
• Warranty registration card
Page 2 / 8 90-8M0093780 JANUARY 2015

• Operation, Maintenance, and Warranty Manual identification page.
xxxxxxxxx
x.x
xxxxxxxxx
xx
52250
Engine specification and serial number decal
Engine Data Label Location

The engine data label is located on top of the electrical box that houses the ECMs.
Bravo Sterndrive Serial Number and Identification

The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port
side of the sterndrive.
33533
Bravo sterndrive information on ground plate
The serial number is also stamped as a permanent reference on the sterndrive casting inside the back cover.
33534
Bravo sterndrive serial number stamping
90-8M0093780 JANUARY 2015 Page 3 / 8

Bravo Transom Serial Number

The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.
Bravo transom assembly U-bolt plate

a - Transom assembly serial number
51170
The serial number is also stamped on the gimbal housing. This is used as a permanent reference for Mercury Diesel
authorized repair facilities.
Gimbal housing with serial

number stamping
a - Transom assembly
serial number
25905
Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives it is important to consider which of several possible steering systems should be selected.
NOTICE
Incorrect tie bar installation can damage the drive and steering system. Do not let the tie bar contact other components
during severe turning conditions. Always calculate sufficient turning clearances, observe recommended tie bar
arrangements, and check for proper installation before operating the boat.
Internal Tie Bar Only

At the lower end of the performance spectrum—as with boats not capable of speeds in excess of 97 km/h (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.
Internal and External Tie Bar

As a boat moves into a moderate performance range (97–113 km/h [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 should be installed so as to limit this potential tilt
differential to about 20°.
Page 4 / 8 90-8M0093780 JANUARY 2015

IMPORTANT: Mercury Marine does not recommend the use of an external tie bar with 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.
External Power Steering

When boat speeds move past 113 km/h (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 129 km/h [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). This system does not use an internal tie bar.
Corrosion
SeaCore Components and Castings
SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with
special coatings. Do not replace SeaCore components with non‑SeaCore. Use only the specified SeaCore components and
castings, if equipped, on these power packages.
Stainless Steel Fasteners

SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in saltwater
environments.
Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction,
improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads.
Apply a lubricant, such as 2‑4‑C with PTFE or an equivalent, on the threads of stainless steel fasteners during installation to
avoid galling. Lubricate at least the first 8 mm (0.3 in.) of the threads before installation.

95 2-4-C with PTFE Threads of stainless steel fasteners 92-802859A 1
Corrosion Protection
These power packages have anodes as standard equipment to help protect them from galvanic corrosion under moderate
conditions. However, for severe conditions, we recommended the Mercury Anti‑Corrosion Anode Kit. Refer to the Diesel
Parts and Accessories Guide or the Mercury Accessories Guide for part numbers.
The MerCathode System and sacrificial anodes will provide corrosion protection under normal usage. However, boats
connected to AC shore power require additional protection to prevent destructive low‑voltage galvanic currents from passing
through the shore‑power ground wire. A Mercury galvanic isolator can be installed to block the passage of these currents
while providing a path to ground for dangerous fault (shock) currents. Refer to the Diesel Parts and Accessories Guide or
the Mercury Accessories Guide for part numbers.
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.
Anodes and the MerCathode System

IMPORTANT: Replace the sacrificial anodes if they are eroded 50 percent or more.
The following sacrificial anodes are installed at different locations on the power package, if equipped with a MerCathode
system. These anodes help protect against galvanic corrosion by sacrificing their metal to be slowly eroded instead of the
metal components on the power package.
The MerCathode system is an electrode controller and anode assembly. Test the MerCathode system, if equipped, where the
boat is moored to ensure adequate output using the Mercury reference electrode and test meter. Refer to the appropriate
Mercury Marine service manual.
90-8M0093780 JANUARY 2015 Page 5 / 8

IMPORTANT: Replace the sacrificial anodes if they are eroded 50 percent or more.
a- Gearcase anodic plate

b- Ventilation plate anode
c
c- MerCathode controller (in boat)
d- Trim cylinder anodes
e- Propeller shaft anode
b
e
a 41426
Anodes and MerCathode System Locations

Description Location Figure
Mounted on the underside of the

Gearcase anode plate
lower gearcase.
20336
Ventilation plate anode Mounted on the front of the gearcase.
20338
The MerCathode electrode is

mounted to the underside of the
gimbal housing. The MerCathode
MerCathode system controller controller is mounted on the engine
or on the boat transom. The controller
harness connects to the electrode 20340
harness.
Mounted on each of the trim

Trim cylinder anodes
cylinders.
20342
Propeller shaft anode Located behind the aft propeller.
20344
Page 6 / 8 90-8M0093780 JANUARY 2015

Anodes and MerCathode System Locations

Description Location Figure
Anode kit (if equipped) Mounted to the boat transom.
20341
Mounting the MerCathode

A bracket for mounting the MerCathode unit is located on the back of the 4.2 TDI engine as shown.
MerCathode mounting bracket

a - MerCathode bracket
b - Exhaust elbow
b
a
53957
Reference Electrode Wire of the MerCathode System

NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning
equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.
Do not pressure‑wash the MerCathode assembly. Doing so will damage the coating on the reference electrode wire and
decrease the corrosion protection.
a MerCathode—mounted to the
underside of the gimbal housing
a - MerCathode reference electrode
wire—do not pressure‑wash
b - Anode
b
21563
Anti‑Fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the
limited warranty.
90-8M0093780 JANUARY 2015 Page 7 / 8

Painting Boat Hull or Boat Transom: Anti‑fouling paint may be applied to the boat hull and the boat transom, but you must
observe the following precautions:
IMPORTANT: Do not paint anodes or the MerCathode System reference electrode and anode, as this will render them
ineffective as galvanic corrosion inhibitors.
IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper or tin base paints, if not prohibited by
law, can be used. If using copper or tin based anti‑fouling paints, observe the following:
• Avoid an electrical interconnection between the Mercury Diesel product, anodic blocks, or MerCathode System and the
paint by allowing a minimum of 40 mm (1‑1/2 in.) of unpainted area on the transom of the boat around these items.
a - Painted boat transom

b - Minimum 40 mm (1‑1/2 in.) unpainted area around the
transom assembly
8107
NOTE: The sterndrive and transom assembly can be painted with a good quality marine paint or an anti‑fouling paint that
does not contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, the
MerCathode system, or items specified by the boat manufacturer.
Continuity Connections
Maintain proper sterndrive ground continuity connections.
c a- Ground wire between the gimbal ring and gimbal housing

d
b- Ground wire between the gimbal housing and trim cylinder
c- Steering lever ground wire
d- Ground wire between the gimbal ring and bell housing
b a
41427
Page 8 / 8 90-8M0093780 JANUARY 2015

SECTION - 2 BOAT CONSTRUCTION
SECTION 2 - BOAT CONSTRUCTION

Table of Contents
Boat Construction........................................................................................................................................................................ 2
Engine Bed.................................................................................................................................................................................. 2
2
Engine Compartment.................................................................................................................................................................. 2
Design and Construction...................................................................................................................................................... 2
Ventilation............................................................................................................................................................................. 2
Ventilation Considerations.................................................................................................................................................... 2
Combustion Air Requirements (4.2L Models)....................................................................................................................... 3
Inlet Air Temperature............................................................................................................................................................ 3
Compartment Pressure........................................................................................................................................................ 3
90-8M0093780 JANUARY 2015 Page 1 / 4

BOAT CONSTRUCTION SECTION - 2
Boat Construction
! WARNING
Improper boat design and construction may result in serious injury or death. Adhere to all applicable marine regulations
(United States Coast Guard [USCG], European Union–Recreational Craft Directive [EU‑RCD], etc.) and the standards they
reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards
Organization [ISO], etc.) when designing and constructing the boat and other components, such as the engine
compartment, fuel delivery system, or exhaust system.
! WARNING
Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine
are not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines,
unless provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).
For additional boat construction information or if you have an issue with the application of our product that cannot be
resolved, contact your Mercury Diesel product application engineer. If you do not know who your product application engineer
is or if you need further technical assistance, contact us at (920) 929‑5884.
Engine Bed
The engine bed must position the engine so that a minimum of up and down adjustment still exists on all four mounts after
performing final engine alignment. This is necessary to allow for realigning the engine in the future.
Description Measurement
Distance between starboard and port engine mount 64.0–66.5 cm (25.15–26.13 in.)
Mount adjustment up and down (minimum) 8.65 mm (0.340 in.)
NOTE: Although the engine mounts allow some adjustment, verify the front and rear mount locations in the vessel are parallel
and in the same plane. This may be checked by tying a string from the left front mount location to the right rear mount location
and another from right front to left rear. The strings should touch where they cross.
Engine Compartment
Design and Construction
Exercise care in the design and construction of the engine compartment. Locate seams to direct any rainwater that leaks
through away from the air intake system.
NOTICE
Water that runs onto the air intake may enter the engine and cause serious internal engine damage. Design engine
compartments so water cannot run onto the air intake or flame arrestor.
IMPORTANT: Mercury Marine will not honor any warranty claim for engine damage as a result of water entry.
Ventilation
IMPORTANT: This section does not cover the design of the ventilation system as it pertains to ventilation of fumes from the
engine compartment. The requirements for ventilation of fumes varies considerably from one boat design to the next, as well
as from country to country, and therefore, the boat manufacturers are responsible for ensuring that their applications comply
with the appropriate industry regulations and standards (USCG, EU's RCD, IMO, NMMA, ISO, SAE, ABYC, and so on).
According to boating standards (NMMA, ABYC, etc.) and U.S. Coast Guard regulations, the engine compartment ventilation
system has multiple tasks. Included are the following:
• To supply the engine with combustion air.
• To maintain a low temperature in the engine compartment.
Ventilation Considerations
Diesel engines require a great deal of air. Insufficient air intake may result in increased black smoke and decreased engine
output. Consider the following in your designs:
IMPORTANT: Sufficient ventilation must be considered for the heat generation and required air intake of the turbocharger
system.
Page 2 / 4 90-8M0093780 JANUARY 2015

SECTION - 2 BOAT CONSTRUCTION
• The hydraulic cross‑section of the air inlet must be at least 200 cm2 (31 in2).
• Fresh air should enter the engine compartment as low as possible and the heated air should be discharged from the
highest point.
• The air inlet must be mounted where the intake air is as clean as possible and where the engines' own exhaust gases
cannot be drawn in.
• Water must not be able to flow into the air inlet or outlet.
• If a separate air shaft (or similar inlet) provides engine compartment ventilation or additional ventilation, prevent seawater
and spray from entering it.
• The engine compartment must be ventilated so that the engine compartment temperature can be maintained at the
lowest possible optimum value. Refer to Inlet Air Temperature.
• Plan the air inlet to take into account other devices (for example, an auxiliary heater) located in the engine compartment
that require oxygen for their operation. Refer to Combustion Air Requirements.
Combustion Air Requirements (4.2L Models)

Engine compartments with natural draft ventilation must have vent openings of sufficient size and location to accomplish the
tasks previously outlined.
ABYC H‑32‑89 specification, "Compartment Ventilation (Diesel)" states:
"Ventilating provisions and openings to the machinery space provided for supplying 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 hydraulic cross‑section of the air inlet for combustion air must be at least 1181 cm2 (183 in2).
IMPORTANT: The amount of vent area required, according to boating standards (NMMA, ABYC, and so forth) and U.S.
Coast Guard regulations, for complete (total) engine compartment ventilation must include the engine vent area plus the
engine compartment ventilation requirements.
The combined hydraulic cross‑section of the air inlet for both ventilation and combustion air must be at least 1381 cm2
(214 in2).
Inlet Air Temperature

Excessive engine air inlet temperature reduces engine performance and should not exceed the outside air temperature plus
15° C (27° F) with the engine operating at its rated speed.
Since many factors can influence engine compartment temperature, measure the temperature on all new applications when
designing the ventilation system. Contact your Mercury Diesel product application engineer for the appropriate testing
procedures.
IMPORTANT: If the temperature at the engine air inlet (air filter) exceeds specification, increase the air inlet opening airflow or
engine compartment ventilation until the temperature remains within specification.
Compartment Pressure
Pressure lower than ambient pressure restricts engine performance. The maximum pressure differential between the engine
compartment and outside air pressure is 3.5 kPa (0.5 psi).
Since many factors influence engine compartment pressure, test all new applications when designing the ventilation system.
Contact your Mercury Diesel product application engineer for the appropriate testing procedures.
90-8M0093780 JANUARY 2015 Page 3 / 4

BOAT CONSTRUCTION SECTION - 2
NOTES:
Page 4 / 4 90-8M0093780 JANUARY 2015

SECTION - 3 EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Emission‑Related Installation Instructions................................................................................................................................... 2
Important Information........................................................................................................................................................... 2
Controlling Evaporative Emissions....................................................................................................................................... 2
Emission Control Information Label...................................................................................................................................... 2
Exhaust System.......................................................................................................................................................................... 2
Exhaust Elbow Height (Sterndrive)............................................................................................................................................. 2 3
Measuring Exhaust Elbow Height............................................................................................................................................... 3
Boat Requirements............................................................................................................................................................... 3
Loading Requirements......................................................................................................................................................... 3
Loading the Boat (Boats with a Capacity Plate)................................................................................................................... 3
Example ....................................................................................................................................................................... 4
Loading the Boat (Boats without a Capacity Plate).............................................................................................................. 5
Example ....................................................................................................................................................................... 6
Clear Hose Method............................................................................................................................................................... 7
Clear Hose Measurement Method from Muffler Drain.......................................................................................................... 8
Exhaust Back Pressure............................................................................................................................................................... 9
General Information ............................................................................................................................................................. 9
Calculating Back Pressure ............................................................................................................................................... 10
Exhaust Back Pressure Test ............................................................................................................................................. 10
Tools .......................................................................................................................................................................... 10
Procedure ................................................................................................................................................................... 10
90-8M0093780 JANUARY 2015 Page 1 / 12

EXHAUST SYSTEM SECTION - 3
Emission‑Related Installation Instructions

Important Information
NOTICE
Failure to follow these instructions when installing a certified engine in a vessel violates U.S. federal law (40 CFR
1068.105[b]) and may result in fines or other penalties as described in the U.S. Clean Air Act.
Controlling Evaporative Emissions

Specific installation steps are required to control evaporative emissions. The installer and/or the vessel manufacturer must
meet the requirements of EPA regulation 1045.112 and federal regulation 40 CFR part 1060.
Emission Control Information Label

If you install the engine in a way that makes the engine's emission control information label difficult to read during normal
engine maintenance, you must place a duplicate label on the vessel, as described in 40 CFR 1068.105.
Exhaust System
! WARNING
IMPORTANT: The rubber and PVC components used in the wet exhaust system must have a temperature stability of at least
200 °C (392 °F).
Mercury Diesel SDI and TDI engines are operated with wet exhaust systems. After the exhaust plenum chamber or
turbocharger, the flow of exhaust gas is deflected through the exhaust‑pipe connection where the seawater is injected into the
exhaust gas of the engine. The rubber and PVC components used in this system must have a temperature stability of at least
200 °C (392 °F).
Exhaust Elbow Height (Sterndrive)

Determine if an optional exhaust elbow (with riser) or a water lift muffler kit is required, by taking measurements (a) and (b),
with the boat at rest in the water and a maximum load aboard. Subtract (b) from (a) to find (c). If (c) is less than specified in
chart, an optional exhaust elbow or a water lift muffler kit must be installed.
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)

3.0L and 4.2L models (c) must be 254 mm (10.0 in.) or more
b Typical sterndrive shown

d a - From waterline to top of transom
a b - From highest point on exhaust riser to top of transom
c c - From (a) minus (b)
d - Waterline at rest
15450
Page 2 / 12 90-8M0093780 JANUARY 2015

Measuring Exhaust Elbow Height

Boat Requirements
IMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height measurement. No
prototype hulls or light layup hulls should be considered. Any measurement performed on nonproduction boats, prototype
hulls, or light layup hulls could be inaccurate and could result in product damage.
• All boats that display a CE certification capacity plate must use the maximum capacity as stated on the CE
certification capacity plate to perform the exhaust elbow waterline measurement.
• All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on
the USCG capacity plate to perform the exhaust elbow waterline measurement.
• For boats that do not have a capacity plate, the maximum capacity load is the number of persons that can sit on
designated seating plus cargo excluding cabin space.
• Measurements used for official Mercury MerCruiser audit at the OEM boatbuilder must be performed on current
production boats. No prototype hulls or light layup hulls will be considered for official audit purposes.
• Measurements used for official Mercury MerCruiser audit at the OEM boatbuilder must use the CE certification maximum
load for any boat model that will be sold outside of the United States.
Loading Requirements
1. Fill the fuel tanks, fresh water tanks or holding tanks, ballast tanks, and heater tanks to simulate fully loaded condition.
2. Weights can be used to simulate these load conditions if desired. Place weights in the corresponding area for which the
load is being replaced. Refer to the following conversions.
• 1 U.S. gallon of water = 8.3 lb
• 1 liter of water = 1 kg
• 1 U.S. gallon of gasoline = 6 lb
• 1 liter of gasoline = 0.72 kg
3. For the purpose of MerCruiser waterline height measurements:
• One person is equivalent to 74.84 kg (165 lb)
• Cargo per person is equivalent to 11.34 kg (25 lb)
4. Add weight for any additional boat options: extra battery, battery charger, tower, arch, generator, ballast tanks, ballast
sacks, television, carpet, anchor, stereo/entertainment equipment, washer/dryer, safe, etc.
5. If a swim platform is an option, the swim platform must be installed for the waterline height measurement. Use the
following guide to determine the correct swim platform load:
a. Boats less than 8.84 m (29 ft) long, not including boats that are 8.84 m (29 ft) long, must add the maximum rated
swim platform weight capacity to the swim platform.
b. Boats less than 8.84 m (29 ft) long, not including boats that are 8.84 m (29 ft) long, that do not have a maximum
rated swim platform weight capacity, must add 181.45 kg (400 lb) to the swim platform.
c. Boats 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, must add the maximum rated swim platform weight
capacity to the swim platform.
d. Boats 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, that do not have a maximum rated swim platform
weight capacity, must add 226.80 kg (500 lb) to the swim platform.
Loading the Boat (Boats with a Capacity Plate)

For boats with a capacity plate, use the maximum load for persons and gear as listed on the capacity plate to determine the
number of persons to place onto the boat for exhaust elbow waterline height measurements.
IMPORTANT: Use 20 in. for an average passenger seat width when measuring bench seating. Round up or down at 0.5 to
obtain a whole person. See the examples listed below.
• 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons.
• 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.
1. Take the maximum capacity weight as listed on the capacity plate (XXXX lbs, persons, gear) and subtract the swim
platform load, if applicable.
2. Next divide the weight by 74.84 kg (165 lb) per person. This gives the whole number and remainder of 74.84 kg (165 lb)
persons to load onto the boat.
90-8M0093780 JANUARY 2015 Page 3 / 12

3. Put the remainder of a person in the next available seat. See the boat loading diagram.
24860
24861
CE capacity plate USCG capacity plate

IMPORTANT: If there is not enough seating for the number of people, treat the leftover weight as cargo. Load cargo
weight onto the boat before loading passenger weight.
4. If applicable, load cargo (leftover persons weight) onto the boat. Distribute cargo as described below.
IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage application
from the Optional Cargo Distribution table that best applies to your boat configuration.
Preferred Cargo Distribution

Aft storage Center storage Bow storage
25% 50% 25%
Optional Cargo Distribution

25% 75% None
None 75% 25%
50% None 50%
None 100% None
100% None None
None None 100%
5. Perform the first measurement with the swim platform loaded and the person taking the waterline measurement on the
boat.
6. Load the swim platform if equipped.
7. Measure the exhaust elbow waterline height.
IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.
8. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight is loaded
onto the boat. Repeat until a person weight is loaded into each seat in that row.
9. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded
into each seat.
NOTE: The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity plate.
NOTE: The following example is provided as a reference.
Example
NOTE: This example uses a boat that is less than 8.84 m (29 ft) long, not including a boat that is 8.84 m (29 ft) long that does
not have a maximum rated swim platform weight capacity, and must add 181.45 kg (400 lb) to the swim platform.
NOTE: Use 0.50 lb as the break point to round up or down to obtain a whole pound.
1. Maximum load (persons and gear) from capacity plate – swim platform load = remaining weight to be placed in the boat.
• 1100 lb – 400 lb = 700 lb
2. Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the boat.
• 700 lb ÷ 165 lb = 4.24 persons
3. Total number of persons – number of whole persons = remaining persons.
• 4.24 persons – 4 persons = 0.24 remaining persons
4. Remainder persons ÷ MerCruiser person weight = remainder MerCruiser person weight.
Page 4 / 12 90-8M0093780 JANUARY 2015

• 0.24 × 165 lb = 40 lb
5. Using the totals in this example, load four 165‑lb persons and one 40‑lb person onto boat seating with 400 lb on the swim
platform.
• 400 lb + 165 lb = 565 lb
• 565 lb + 165 lb = 730 lb
• 730 lb + 165 lb = 895 lb
• 895 lb + 165 lb = 1060 lb
• 1060 lb + 40 lb = 1100 lb
d e
b
a
c
f
24862
Boat loading diagram

a - Swim platform load
b - MerCruiser person weight (one)
c - MerCruiser person weight (two)
d - MerCruiser person weight (three)
e - MerCruiser person weight (four)
f - Remainder MerCruiser person weight (five)
Loading the Boat (Boats without a Capacity Plate)

For boats that do not display a capacity plate, the number of persons to be loaded onto the boat for measuring purposes is
the number of persons that can sit on designated seating excluding cabin space. An additional weight of 25 lb per person is to
be added to the boat before loading passenger weight onto the boat.
IMPORTANT: Use 20 in. for an average passenger seat width when measuring bench seating. Round up or down at 0.5 to
obtain a whole person. See the examples below.
• 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons.
• 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.
1. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person weight =
maximum passenger load for measurement.
• Number of persons × 165 lb (MerCruiser person weight) = XXXX lb maximum passenger load.
2. Maximum passenger load from the calculation above – swim platform load if applicable.
3. Divide the weight by 165 lb per person. This gives the number of 165‑lb persons to load onto the boat. Round up to next
whole number. See Example 3.
IMPORTANT: To account for cargo, add a weight of 25 lb per person to the boat before loading passenger weight onto
the boat.
4. Calculate the cargo by multiplying 25 lb by the number of persons that can sit on designated seating excluding cabin
space. See Example.
5. Load the cargo onto the boat. Distribute cargo as described below.
IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage application
from the Optional Cargo Distribution table that best applies to your boat configuration.
90-8M0093780 JANUARY 2015 Page 5 / 12

Preferred Cargo Distribution

25% 50% 25%
Optional Cargo Distribution

25% 75% None
None 75% 25%
50% None 50%
None 100% None
100% None None
None None 100%
6. Perform the first measurement with the swim platform loaded and the person measuring the waterline on the boat.
7. Load the swim platform if equipped.
8. Measure the exhaust elbow waterline height.
9. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight is loaded
onto the boat. Repeat until a person weight is loaded into each seat in that row.
10. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded
into each seat.
Example
NOTE: The following example is provided as a reference.
This example uses a boat that is 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, that does not have a maximum rated
swim platform weight capacity, and must add 226.80 kg (500 lb) to the swim platform.
IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on designated
seating excluding cabin space.
6 9
2
4 7
1
5 8
3
24863
Designated seating diagram
This example uses nine persons as the maximum passenger load.

NOTE: Use 0.50 lb as the break point to round up or down to obtain a whole pound.
1. To determine the maximum cargo load multiply the maximum passenger load by the maximum cargo weight per
passenger.
• 9 passengers × 25 lb = 225 lb
2. To determine the preferred cargo distribution for aft, center, and bow storage:
a. To determine the maximum aft storage cargo weight, multiply the maximum cargo weight by 25%.
3. To determine the maximum center storage cargo weight, multiply the maximum cargo weight by 50%.
a. 225 lb × 50% = 112.50 lb
b. 112.50 lb rounded up = 113 lb
4. To determine the maximum bow storage cargo weight, multiply the maximum cargo weight by 25%.
• 225 lb × 25% = 56.25 lb
• 56.25 lb rounded down = 56 lb
Page 6 / 12 90-8M0093780 JANUARY 2015

5. To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb (MerCruiser
person weight) to get a 1485 lb (total passenger load).
• 9 passengers × 165 lb = 1485 lb
6. Subtract the swim platform load from the total passenger load to get the remaining weight to be placed in the boat.
• 1485 lb – 500 lb = 985 lb
7. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of
passengers to load onto the boat.
• 985 lb ÷ 165 lb = 5.9 passengers
• 5.90 passengers rounded up = 6 passengers
8. Using the totals in this example load 56 lb cargo in the aft storage, 113 lb cargo in the center storage, and 56 lb cargo in
the bow storage onto the boat before adding passenger weight. Then, load six 165 lb passengers, onto the boat with 500
lb on the swim platform.
• 500 lb + 225 lb = 725 lb
• 725 lb + 165 lb = 890 lb
• 890 lb + 165 lb = 1055 lb
• 1055 lb + 165 lb = 1220 lb
• 1220 lb + 165 lb = 1385 lb
• 1385 lb + 165 lb = 1550 lb
• 1550 lb + 165 lb = 1715 lb
g
c i
a e j
b h
f
d
24864
Cargo, swim platform, and passenger weight loading diagram

a - Swim platform load
b - MerCruiser person weight (one)
c - MerCruiser person weight (two)
d - MerCruiser person weight (three)
e - MerCruiser person weight (four)
f - MerCruiser person weight (five)
g - MerCruiser person weight (six)
h - Aft storage
i - Center storage
j - Bow storage
Clear Hose Method

1. Obtain an 8–10 mm (0.312–0.375 in.) inside diameter hose approximately 4.5 m (15 ft) long. Put a metal fitting or a
weight on one end of the hose to keep that end of the hose below the waterline.
2. Put the weighted end of the hose over the side of the boat, keeping it in line with the engine's exhaust elbow.
3. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that this open end section of
the hose is as vertical as possible from the boat's bilge to the top of the exhaust elbow.
4. Coil excess hose in the bilge of the boat, keeping it below the waterline.
5. Lower the open end of the hose and siphon the water until it starts to come out of the hose. Put a finger over the hose
and lift the open end until it is at the top of the exhaust elbow.
6. Slowly take your finger off the end of the hose to let the water level stabilize. The water will seek the level of the water
outside the boat. Keep the hose close to the exhaust elbow and as vertical as possible.
7. Ensure that the boat is level.
90-8M0093780 JANUARY 2015 Page 7 / 12

8. The measurement between the water in the hose and the top of the exhaust elbow is the exhaust elbow height. Compare
the measurement to the specifications.
b c
a
e
50900
Exhaust elbow height: clear hose method

a - Waterline
b - Top of exhaust elbow
c - Clear plastic hose
d - Weight
e - Measurement: waterline to top of exhaust elbow
Clear Hose Measurement Method from Muffler Drain

IMPORTANT: Measure the dimension from the top of the exhaust elbow to the waterline inside of the water lift muffler
(instead of the waterline outside of the boat) on applications so equipped.
IMPORTANT: Operate the engine to fill the muffler with water.
IMPORTANT: If the vessel lists to one side or the other, perform the clear hose measurement on the outboard side of the
engine that sits lowest in the water. The following procedure must be performed with the boat in the water.
1. Attach a clear hose to the muffler petcock drain or drain plug fitting.
2. Start and run the engine until water is discharged through the exhaust outlet.
3. Stop the engine.
4. Open the muffler drain so that the clear hose fills with water when the open end of the hose is lower than the drain point
on the muffler.
5. Route the hose vertically next to the exhaust manifold and elbow. Ensure that the hose is routed from the bilge below the
engine to the top of the exhaust elbow.
6. Coil excess hose in the bilge of the boat, keeping it below the waterline.
7. Lower the open end of the hose and siphon water until all air is purged from the hose. Put a finger over the hose end and
raise the hose end until it is level with the top of the exhaust elbow.
8. Slowly take your finger off of the hose end to let the water level stabilize. The water will seek the level of the water inside
the muffler. Keep the hose close to the exhaust elbow and as vertical as possible.
Page 8 / 12 90-8M0093780 JANUARY 2015

9. The dimension from the top of the water column in the hose to the top of the exhaust elbow represents the elbow height
above the waterline inside of the muffler. The minimum exhaust elbow height specification (above the waterline inside the
muffler—if so equipped) is 38 cm (15 in.). If the installed engine's elbow height does not meet this requirement then
optional exhaust elbows (risers) must be installed to achieve the 38 cm (15 in.) specified dimension.
Typical vertical water lift muffler

a - Clear hose for measuring waterline
b - Minimum exhaust elbow height
with maximum load
b
a
56466
IMPORTANT: Horizontal water lift mufflers are permitted for use only if the bottom of the muffler is below the crankshaft
centerline.
Typical horizontal water lift muffler

a - Clear hose for measuring
waterline
b - Minimum exhaust elbow height
b with maximum load
a
56467
Exhaust Back Pressure

General Information
IMPORTANT: Exhaust back pressure should be checked on all new applications to ensure that it is within specifications. Be
sure to test the engine as a system by testing both exhaust banks simultaneously, rather than individually.
Below is a typical test scenario. Be sure to access the ports in both exhaust elbows (a). Run the access lines to a T‑fitting (b)
and then connect the line from the T‑fitting to the gauge (c) to read pressure on the complete exhaust system.
Exhaust back pressure test (typical)

a - Access ports in exhaust elbows
a b b - T‑fitting connecting access from both elbows
a c - Pressure gauge
c
53982
90-8M0093780 JANUARY 2015 Page 9 / 12

All exhaust systems have some restriction to flow or exhaust back pressure. The power output of an engine is directly related
to the amount of exhaust that can flow out of the exhaust system. On sterndrive (MCM) power packages using
through‑the‑propeller exhaust, the back pressure is related to the displacement of the engine and the path of the exhaust
through the drive.
The measured back pressure at WOT must be no greater than shown.
Engine Model Maximum Exhaust Back Pressure

TDI (4.2L) 750 mbar (75 kPa) (10.9 psi)
A higher output engine will create a greater back pressure using the same size exhaust system as an engine with less output.
The boat's exhaust system should be designed and tested for the highest horsepower engine to be offered in that boat.
If pressure is excessive, changes must be made to the system to reduce the pressure. These changes could include:
• Reduce exhaust system length
• Eliminate sharp bends
• Increase exhaust system diameter
• Reduce muffler restriction
• Ensure that through‑the‑transom or through‑the‑hull fittings are above the waterline and are not restrictive
Calculating Back Pressure

Back pressure for a given pipe size and flow can be calculated to give an estimate as to the size of exhaust tube that is
required for a given engine. Use the chart and formula below.
Use the following formula to calculate the approximate maximum back pressure of the exhaust:
P = L × S x Q² divided by 2545 × D5
Where:
P = Exhaust back pressure (in. Hg)
L = Total equivalent length of pipe (ft)
Q = Exhaust gas flow (CFM)
D = Pipe or tubing inside diameter (in.)
S = Specific weight of exhaust gas (lb/ft³)
S = 39.69/(exhaust temperature + 460º F)
Equivalent length ratios
• Flex sections: 2
• 45º elbows: 15
• 90º elbows: 20
To determine the straight line equivalent length:
L (ft) = (L/D) × D/12
Example: for a 4‑in. 90º elbow
L = 20 × 4/12 = 6.67 ft
Exhaust Back Pressure Test

Tools
Description Part Number
Service tachometer Obtain Locally
Pressure gauge accurate in 7 kPa (1 psi) increments Obtain Locally
Procedure
The boat should be in the water and underway. No special loading of the boat is necessary. The engine must be capable of
reaching the specified WOT RPM as verified using an accurate service tachometer or scan tool.
Page 10 / 12 90-8M0093780 JANUARY 2015

1. Remove the pipe plug from the exhaust elbow or riser.
TDI 4.2L engine

b a - Seawater extraction plug,
a location of optional temperature
sensor
b - Sealing plug for exhaust gas
extraction
c - Exhaust gas flow
53034
NOTE: The exhaust gas temperature can be extremely high in the exhaust system where back pressure is measured.
Make or buy a suitable heat sink to dissipate heat before attaching the test gauge.
2. Assemble a suitable heat sink onto an adapter that fits the pipe plug hole in the exhaust elbow or riser. The plug size
varies on different models.
3. Set the pressure gauge to zero.
4. Attach the test gauge to the heat sink or the exhaust system.
5. While underway, operate engine at 1000, 2000, and WOT RPM. Record back pressure at each setting.
6. Repeat the steps for the remaining engines on multiengine applications.
7. If pressure is excessive, changes must be made to the system to reduce the pressure.
8. Replace the exhaust elbow or riser pipe plug.
90-8M0093780 JANUARY 2015 Page 11 / 12

NOTES:
Page 12 / 12 90-8M0093780 JANUARY 2015

SECTION - 4 FUEL SYSTEM
SECTION 4 - FUEL SYSTEM

Table of Contents
Fuel Delivery System.................................................................................................................................................................. 2
General ................................................................................................................................................................................ 2
Fuel System Overview................................................................................................................................................................ 3
Fuel System Connections........................................................................................................................................................... 3
Prime the Fuel System ........................................................................................................................................................ 6
Diesel Fuel Filters and Fuel Additives......................................................................................................................................... 7
90-8M0093780 JANUARY 2015 Page 1 / 8

FUEL SYSTEM SECTION - 4
Fuel Delivery System

! WARNING
IMPORTANT: The maximum return fuel temperature is 96 ºC (204.8 ºF). The fuel return hoses and fuel tank must be selected
accordingly.
General
The primary concern in designing the fuel system should be 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 from the
tank manufacturer.
Only a few points related to function and safety are listed here. Refer to marine regulations (USCG, EU‑RCD, etc.) and the
standards they reference (ABYC, SAE, ISO) for complete guidelines.
Fuel tank manufacturers typically recommend the following:
• All connections should be on the upper side of the tank.
• The drain plug must permit the removal of water and sediment at the lowest point on the tank.
• The tank breather pipe must have a minimum inside diameter of 13 mm (1/2 in.) and must be fitted with a swan neck to
prevent water from entering the tank.
Mercury Diesel recommends:
• Determine the exact route and length of the fuel lines during the initial installation of the engine to prevent problems
during the final engine installation.
• All fuel lines must be well secured.
• Holes in bulkheads where fuel lines pass through should not have sharp edges, or must be protected with rubber
grommets to prevent abrasion damage to the fuel lines.
• Avoid sharp bends and kinks in fuel lines.
• Fuel system components should be handled with care. Cleanliness is very important when making fuel system
connections. Any dirt or impurities could damage the fuel system or result in decreased engine performance.
• Ensure that the fuel supply line pickup is a minimum of 25 mm (1 in.) from the bottom of the tank to prevent picking up
impurities.
• Ensure that the compartment containing the fuel system is properly ventilated.
• The fuel tank and filler cap must be grounded to the battery. If the boat hull is steel, the filler cap and fuel tank must be
grounded to the hull.
• When installing components, allow sufficient room for future maintenance and repair work.
• Avoid the use of non‑ferrous metals, such as copper, copper alloy, lead, or zinc in the fuel system. These metals can
damage or reduce performance of the engine.
• Mount the fuel return line a minimum of 31 cm (12 in.) from the fuel supply line pickup, and a minimum of 25 mm (1 in.)
from the bottom of the fuel tank.
• A minimum inside diameter of 10 mm (3/8 in.) must be used for all fuel supply and return lines.
IMPORTANT: Never install a shutoff valve in the fuel return line.
• A fuel shutoff valve should be installed in the fuel inlet line to prevent fuel leakage during maintenance, and to provide an
emergency shutoff.
• Connect a flexible fuel supply line to the fuel inlet fitting on the engine to absorb deflection when the engine is operating.
The fuel return line must also have a flexible rubber hose segment to absorb deflection.
• On multi‑engine diesel installations, provide separate fuel supply and fuel return lines for each engine.
• Use larger diameter lines and fittings on installations requiring long line runs or numerous fittings.
• Install fuel lines of the proper length to allow a flexible connection free of loose or coiled line.
• Secure the fuel lines to prevent vibration and chafing.
• After installing the fuel system, check for leaks to minimize the risk of fire.
Page 2 / 8 90-8M0093780 JANUARY 2015

• Ensure that the fuel inlet restriction meets specification.

• Ensure that the fuel return restriction meets specification.
Contact your Mercury Diesel product application engineer for further information.
Fuel System Overview

Fuel system diagram
a - Water in fuel sensor (WIF)
b - Lift pump filter module
c - High–pressure fuel pump
f e d - Fuel temperature sensor
e - Fuel pressure regulator
d f - Fuel rail – starboard side
c g - Fuel pressure sensor
g h - Fuel injector (1 of 8)
i
i - Fuel rail – port side
a 52842
Fuel System Connections

IMPORTANT: When performing installation or other work on the fuel system, ensure that all factory–installed fire sleeving,
which protects rubber fuel hoses and the fuel temperature sensor, are kept in their original position.
Refer to the instruction sheet supplied with the lift pump filter module for assembly, prior to installation.
The on‑engine factory installed fuel hoses each provide a mounting radius of 91 cm (3 ft.) for the off‑engine lift pump filter
module. When selecting a suitable mounting location in the engine bay, consider the following:
• Keep the lift pump filter module and connecting fuel hoses clear of any hot or moving components.
• Support fuel hoses between the lift pump filter module to the engine to prevent vibration and chafing. The hoses must be
supported flexible enough to account for engine movement during operation.
• Consider access to the factory–installed fuel hoses to provide for easy annual inspection.
• Select a mounting location that promotes easy fuel filter access.
• Where possible, install the lift pump filter module within 30.5 cm (1 ft.) from the engine to minimize the risk of trip and
pinch hazard of the fuel lines.
• Fasten the lift pump mounting bracket using a minimum of four fasteners with 8 mm (5/16 in.) thread diameters. Use
suitable fasteners for the installation location.
• If above average fuel inlet restriction is expected, mount the fuel module lower in the engine bay to effectively lower the
inlet restriction.
The following figures show the recommended mounting area for single and dual engine applications.
90-8M0093780 JANUARY 2015 Page 3 / 8

NOTE: Factory pre–installed fuel hoses are located at the front of the engine. The recommended mounting area for the lift
pump filter module is shown below.
Single engine lift pump mounting

area (recommended)
a - Factory installed fuel hose
location
b - Recommended lift pump filter
b module mounting area
52895
Dual engine lift pump mounting

area (recommended)
a - Factory–installed fuel hose
location
b - Recommended lift pump filter
module mounting area
52897
Page 4 / 8 90-8M0093780 JANUARY 2015

1. Find a suitable location to mount the lift pump module that meets the specifications outlined in this document.
2. Fasten the lift pump module with fasteners suitable for the installation location.
53028
Factory installed fuel hoses and fittings
3. Separate the factory fuel fittings.

4. Ensure that all factory–installed fire sleeving, which protects rubber fuel hoses, and the fuel temperature sensor are kept
in their original positions.
IMPORTANT: When tightening multiple fuel fittings, use two wrenches: a wrench to secure the fittings installed directly
into the lift pump module housing, and a torque wrench for the outer fittings, to eliminate damage to the lift pump filter
module housing.
5. Connect the factory–installed supply and return fittings (a) and (b) to the lift pump filter module. Tighten to specification
using two wrenches, one to hold the fitting in the lift pump filter module and a torque wrench to tighten the fitting being
installed.
90-8M0093780 JANUARY 2015 Page 5 / 8

! WARNING
Avoid fire or explosion from leaking fuel. Improper installation of fittings or plugs into the fuel pump or fuel filter base can
crack the casting, causing a fuel leak. Always install fittings and plugs correctly, and do not tighten them with power tools.
b
d
c
a
53053
Lift pump filter module and fuel hoses
Description Nm lb‑in. lb‑ft

Factory–installed fuel supply fitting (engine side) (a) 27 – 20
Factory installed fuel return fitting (engine side) (b) 27 – 20
*Fuel supply hose (tank side) 10mm (3/8 in.) (c) n/a
*Fuel return hose (tank side) 10mm (3/8 in.) (d) n/a
NOTE: Items marked with an asterisk in the above table are not included and must be purchased seperately.
6. Connect the rubber fuel hoses from the fuel tank. Tighten the fittings to specification using two wrenches: one to hold the
fitting in the lift pump module housing and another to tighten the fittings being installed.
Prime the Fuel System

! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
Prime the fuel system prior to initial engine operation.

1. Turn the ignition to the "ON" position and the fuel pump will run for five seconds. Turn the ignition switch to the "OFF"
position and wait five seconds. Repeat this step six times.
2. Start the engine and check for leaks.
IMPORTANT: Measure the inlet and return restrictions at the lift pump filter module to ensure that they do not exceed
specification. Refer to table below.
The inlet and return restrictions are measured at the tank‑side connections of the provided lift pump filter module.
Description TDI 4.2L

Maximum fuel inlet restriction at maximum fuel flow 20 kPa (6.0 in. Hg)
Maximum fuel return restriction at maximum fuel flow 14 kPa (4.1 in. Hg)
Minimum internal inlet fuel line diameter 10 mm ( 3/8 in.)
Page 6 / 8 90-8M0093780 JANUARY 2015


Minimum internal return fuel line diameter 10 mm ( 3/8 in.)
Diesel Fuel Filters and Fuel Additives

IMPORTANT: The use of anti‑siphoning devices and additional filtration components must not cause the inlet restriction to
exceed the ratings in the following table.

Maximum fuel inlet restriction at maximum fuel flow 20 kPa (6.0 in. Hg)
A remote mounted lift pump filter module, which includes a large capacity fine‑mesh water separating fuel filter to protect the
fuel system from contaminants, provided with the engine is:.
Under normal operating conditions, the addition of a pre‑filter is not required. A boat under extreme operating conditions
(excessive dirt/water or other impurities) may require the installation of a 10–25‑micron boat mounted large capacity water
separating pre‑filter.
Mercury Diesel recommends the following fuel‑water separating pre‑filter (if used):
Description Specification
Flow rate 265 L/h (70 gph)
Primary fuel water separator
Filtration 10–25 micron
Description Qty. Part Number

SAE threads 1 35‑850481A1
Racor Model 500® fuel filter (or equivalent)
Metric threads 1 35‑809867
Select a suitable position in the fuel system between the lift pump filter module on the engine and the fuel tank for the primary
pre‑filter. The selected position must be free from vibrations and allow for easy inspection and replacement.
A diesel fuel additive can be used to reduce the chances of algae growth in diesel fuel, particularly in warmer climates.
Contact your Mercury Diesel representative for additional information.
90-8M0093780 JANUARY 2015 Page 7 / 8

NOTES:
Page 8 / 8 90-8M0093780 JANUARY 2015

SECTION - 5 COOLING SYSTEM
SECTION 5 - COOLING SYSTEM

Table of Contents
Cooling System Overview........................................................................................................................................................... 2
Cooling Circuit Diagram ...................................................................................................................................................... 2
Seawater Cooling........................................................................................................................................................................ 3
Seawater Cooling Installation .............................................................................................................................................. 3
Seawater Hoses .................................................................................................................................................................. 3
Seawater Pump ................................................................................................................................................................... 3
Seawater Intake .................................................................................................................................................................. 3
Cold Weather Storage ......................................................................................................................................................... 4
Seacock....................................................................................................................................................................................... 4
Requirements ...................................................................................................................................................................... 4
Installation ........................................................................................................................................................................... 4
Installing the Seawater Strainer.................................................................................................................................................. 5
Requirements ...................................................................................................................................................................... 5
Installation ........................................................................................................................................................................... 5
Water Heater............................................................................................................................................................................... 5 5
Water Heater Installation...................................................................................................................................................... 5
90-8M0093780 JANUARY 2015 Page 1 / 8

COOLING SYSTEM SECTION - 5
Cooling System Overview

This engine has a closed‑cooling circuit and a seawater‑cooling circuit. The internal engine‑cooling circuit is a closed circuit
that contains a mix of antifreeze and distilled water. The seawater circuit is an open circuit in which seawater is pumped
through the main heat exchanger, and exits through the exhaust system.
Seawater is brought in through an intake in the boat's hull, downstream of which is a seacock. A seawater filter removes dirt
and impurities from the seawater circuit.
To prevent the entry of seawater into the exhaust system via the intake side of the seawater circuit, a ventilation unit has to
be fitted only if the engine is installed below the waterline. If the cooling system is below the waterline, then filling of the
exhaust system with water may occur, if the boat remains stationary for some time. This is because the seawater pump is not
100% watertight and causes a siphon effect in the seawater circuit. If this occurs, close the seacock.
Cooling Circuit Diagram

j k l Cooling circuits
a - Seawater
i b - Seawater filter
c - Seawater pump
h m d - Intercooler
e - 70° C thermostat
g f - Engine‑side coolant pump
g - Right cylinder bank
exhaust manifold
n h - Oil cooler
i - Engine ventilation position
o j - Oil pressure switch
k - Temperature sensor
l - Left cylinder bank exhaust
f manifold
p m - Coolant expansion tank
q n - Engine
e o - External engine cooling
circuit
r p - External heating supply
connection
q - External heating return
d s connection
r - Ventilation position
s - Servo/gearbox oil cooler
c t - Seawater cooling circuit
u - Main heat exchanger
a u t 51302
Page 2 / 8 90-8M0093780 JANUARY 2015

Seawater Cooling
Seawater Cooling Installation
Typical seawater-cooling
installation
b a - Waterline
b - Engine
c c - Seawater filter
a d - Seacock
d e - Intake
f - Seawater connection
to the seawater pump
f e 50823
Seawater Hoses
IMPORTANT: Use a wire‑reinforced seawater hose to avoid collapsing the hose when suction is created by the seawater
pump impeller.
Seawater hose connections must be made with wire‑reinforced hose of adequate wall thickness to prevent them from
collapsing from pump suction. Secure the hose connections with hose clamps. Secure the hose to prevent contact with any
moving parts of the engine.
Seawater Pump
Connect the seawater inlet hose to the inlet side of the seawater pump.
50821
Seawater pump inlet
NOTE: An adapter is necessary if installing a 38 mm 1.5 in. hose.

• The intake hose from the seawater filter to the seawater pump must have a diameter of at least 38 mm (1.5 in.).
• The hose should be as short as possible.
• The use of two hose clamps per connection is recommended.
• Use a wire‑reinforced hose with an adequate wall thickness to prevent the seawater hose from collapsing at high engine
speeds.
Seawater Intake
IMPORTANT: Do not install the seawater pickup directly in line with the propeller. The pickup must be installed ahead of the
drive unit by 1.2–1.5 m (4.0‑5.0 ft.), to help eliminate turbulence and allow air to flow into the propeller slipstream. This air flow
causes propeller ventilation and adversely affects boat performance.
• The angled side of the intake screen must face the front.
90-8M0093780 JANUARY 2015 Page 3 / 8

• The installation location of the intake fitting should lie within the shaded area in the following illustration.
a - Intake fitting
b - Preferred installation location of the intake fitting (shaded
area)
b a
50670
• Follow the manufacturer's instructions for installing the seawater pickup and seawater strainer.
Cold Weather Storage

Prior to cold weather storage, the seawater must be drained from the engine via the seawater drain screw, shown below.
a - Closed‑cooling drain screw; do not drain

b - Seawater drain screw
a b 50672
Additional instructions for cold weather operation and storage are included in the owner's manual.
Seacock
Requirements
The seacock (water inlet valve) used must have an internal cross‑sectional area equal to or greater than the seawater inlet
hose to prevent restricting the water flow.
Install the seacock in an area where it will be easily accessible and adequately supported to prevent hose fatigue. A brass
ball or gate valve is required.
Installation
If using other than the Mercury seacock shown following, refer to the manufacturer's instructions provided with the seacock.
1. Install the seacock on the seawater pickup. Tighten it securely.
Page 4 / 8 90-8M0093780 JANUARY 2015

2. Install the 38 mm (1.50 in.) hose connector on the seacock. Tighten it securely.
a - Seacock
b - Seawater pickup
c
(through‑the‑hull fitting)
c - 38 mm (1.50 in.) hose
connector
a
b
22241
Installing the Seawater Strainer

IMPORTANT: Failure to provide adequate cooling water flow to either the engine or the sterndrive will cause damage to
components of the power package. This damage is not covered by the Mercury Marine warranty.
Requirements
The boatbuilder is responsible for ensuring that the seawater strainer meets or exceeds the minimum specifications listed
below.
Specification TDI Seawater Strainer

Minimum inlet hose inside diameter 38 mm (1.5 in.)
Minimum flow rate 150 L/min (40 gal/min)
Maximum flow restriction 125 mm Hg (5 in. Hg)
Installation
When choosing a strainer mounting location, follow these requirements:
• Mount the seawater strainer securely to the boat hull so that the strainer is isolated from potential vibration.
• Never mount the seawater strainer on the engine.
• Avoid pinching or twisting the seawater hoses.
• Route and anchor the seawater hoses away from any hot or moving parts.
Water Heater
• The connection kit should be fitted when the engine is cold.
• Secure all hose connections with clips.
• Connection hoses must have a diameter of at least 16 mm (0.63 in.).
• The supply and return lines must not be interchanged.
• Route coolant hoses as directly as possible, and ensure that they are well insulated.
• Do not allow hoses to become kinked, abraded, or crushed during installation.
• Use only original parts from the retrofit kit.
Water Heater Installation

IMPORTANT: The level of antifreeze in the circuit must be 40%.
1. Carefully unscrew the cap from the housing‑radiator package and depressurize the system.
2. Remove the plug caps from the connections on the engine for the hot‑water supply.
3. Collect any cooling water that may run out.
4. Install the bracket of the auxiliary water pump in the immediate vicinity of the engine.
5. Use silicon spray to fit the rubber mounts (with auxiliary water pump) onto the bracket.
90-8M0093780 JANUARY 2015 Page 5 / 8

6. Remove the two screws that secure the pressure converter and move the converter aside.
50760
Pressure converter
7. Remove the screw that secures the water connector within the valley of the two cylinder banks.
d a- Oil filter
c
b- Water connector
c- Screw
b d- Pressure converter mounting location
50762
8. Remove the plug from the water connector.

9. Attach the hot‑side water‑heater hose to the water connector, and secure it with a hose clamp.
50763 50764
Page 6 / 8 90-8M0093780 JANUARY 2015

10. Route the water heater hose between the oil filter and the draft tube on the left side of the oil filter.
50765
IMPORTANT: If the water connector's O‑ring is damaged, it must be replaced.

11. Reattach the water connector (with attached water heater hose) to the engine block, using the screw previously removed.
12. Reattach the pressure converter with the two screws.
13. Remove the hose clamp from the water connector that is located near the electronic control units. Then remove the plug.
50769
Location of the water connector for the cold-side water-heater hose
14. Attach the cold‑side water‑heater hose to the water connector and secure it with a hose clamp.
90-8M0093780 JANUARY 2015 Page 7 / 8

NOTES:
Page 8 / 8 90-8M0093780 JANUARY 2015

SECTION - 6 DRIVE SYSTEM AND ENGINE MOUNTING
SECTION 6 - DRIVE SYSTEM AND ENGINE

MOUNTING
Table of Contents
Transom Cutout........................................................................................................................................................................... 3
Finding the Crankshaft Vertical Centerline........................................................................................................................... 3
Single Engine ............................................................................................................................................................... 3
Dual Engine .................................................................................................................................................................. 4
Finding Crankshaft Horizontal Centerline (X‑dimension)..................................................................................................... 4
90 Degree Tool Method ............................................................................................................................................... 5
Tape Measure Method ................................................................................................................................................. 5
Cutting Out the Transom...................................................................................................................................................... 6
Checking the Transom Thickness........................................................................................................................................ 8
Bravo Drive Transom Installation................................................................................................................................................ 9
Exhaust Tube....................................................................................................................................................................... 9
Installing Gimbal Housing Assembly.................................................................................................................................... 9
Installing the Inner Transom Plate........................................................................................................................................ 9
Connecting the Speedometer Pickup................................................................................................................................. 11
Installing the Sterndrive Seawater Block‑Off Plate............................................................................................................. 11
Gear Lube Monitor Connection at Gimbal Housing............................................................................................................ 13
Power Trim Pump...................................................................................................................................................................... 15 6
Mounting the Power Trim Pump......................................................................................................................................... 15
Hydraulic Hose Connections—Power Trim Pump ............................................................................................................. 16
Installing the Power‑Assisted Steering System......................................................................................................................... 16
Power‑Assisted Steering Hoses................................................................................................................................................ 20
Hoses with Quick‑Connect Fittings ................................................................................................................................... 20
Engine Installation and Alignment............................................................................................................................................. 21
TDI 4.2L Engine Installation............................................................................................................................................... 21
Engine Mounts.................................................................................................................................................................... 21
Notes on Installation of Engine Mounts ...................................................................................................................... 21
Installation .................................................................................................................................................................. 22
Engine and Transmission Mount Important Information..................................................................................................... 23
Preparing the Transom....................................................................................................................................................... 23
Engine Preparation............................................................................................................................................................. 24
Engine Installation.............................................................................................................................................................. 25
Exhaust System Connections............................................................................................................................................. 28
Alignment............................................................................................................................................................................ 29
Electrical Connections............................................................................................................................................................... 32
Continuity Circuit................................................................................................................................................................ 32
Trim Position Sender Connection....................................................................................................................................... 32
Power Trim Pump Connection............................................................................................................................................ 33
Quick‑Connect MerCathode System Connection .............................................................................................................. 33
Bravo Sterndrive Shift Cable Installation................................................................................................................................... 34
Shift Cable Travel............................................................................................................................................................... 34
Mechanical Throttle and Shift—Shift Cable Installation and Adjustment............................................................................ 34
Digital Throttle and Shift System—Shift Cable Installation................................................................................................. 37
Bravo Sterndrive Installation..................................................................................................................................................... 39
Additional Trim Limit Spacer Kit......................................................................................................................................... 45
Trim Cylinder Installation.................................................................................................................................................... 45
Speedometer Connections ‑ Bravo Models........................................................................................................................ 47
Paddle Wheel Speed Sensor Installation (If Equipped)............................................................................................................ 49
Parts Provided ................................................................................................................................................................... 49
Selecting Location ............................................................................................................................................................. 49
Transom Angle Requirements ........................................................................................................................................... 49
Installing Bracket ............................................................................................................................................................... 50
Routing the Cable .............................................................................................................................................................. 50
Drilling Hole Through Transom (optional) .................................................................................................................. 50
Without Drilling Hole Through Transom (optional) ..................................................................................................... 50
Installing and Removing the Paddle Wheel ....................................................................................................................... 51
90-8M0093780 JANUARY 2015 Page 1 / 52

DRIVE SYSTEM AND ENGINE MOUNTING SECTION - 6
Wiring Connections ........................................................................................................................................................... 51

Template ‑ Paddle Wheel Speed Sensor .......................................................................................................................... 51
Page 2 / 52 90-8M0093780 JANUARY 2015

Lubricants, Sealants, Adhesives

Coupler
Extreme Grease 8M0071842
U-joint O-rings, driveshaft splines
19 Perfect Seal Engine mounting hardware threads and nuts 92-34227Q02
25 Liquid Neoprene Exposed terminals and connections 92- 25711 3
80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
87 High Performance Gear Lubricant Gear lube monitor 92-858064K01

Gimbal housing studs
Steering cylinder bushings
Threads of the upper and lower pivot bolts
Clevis pin
95 2-4-C with PTFE Steering cable end 92-802859A 1
Shift cable stud threads
First 6 mm (1/4 in.) of the bell housing stud threads
O-ring seals
Trim cylinder hardware
114 Power Trim and Steering Fluid Power trim pump 92-858074K01
Special Tools
Tapered Insert Tool 91‑43579
Removes and installs the tapered insert retainer into the water inlet hose.
9197
Transom Cutout
Finding the Crankshaft Vertical Centerline
Single Engine
1. Locate and mark the vertical centerline on the transom, if known. This is also the crankshaft vertical centerline.
2. If unknown, a compass can be used to locate the vertical centerline:
a. Mark identical locations on each side of the boat 30.5 cm (12.0 in.) from the bottom of the hull.
b. Position the fixed end of a compass at the marks and draw arcs on the transom.
90-8M0093780 JANUARY 2015 Page 3 / 52

c. Draw the crankshaft vertical centerline through the intersection points of the two arcs.
b e
a
c b e
d
7687
Single engine installation

a - 30.5 cm (12.0 in.)
b - Identical side marks
c - Compass arc
d - Arc intersection points
e - Crankshaft vertical centerline
Dual Engine
1. Locate and mark the vertical centerline on the transom. Refer to Single Engine procedure.
2. Make a set of marks equal to half the minimum distance between crankshaft vertical centerlines on either side of the
vertical centerline.
Minimum Distance Between Crankshaft Vertical Centerlines (Dual Side‑By‑Side)

Model Measurement
All 4.2L models 85.6 cm (33.7 in.)
IMPORTANT: Crankshaft vertical centerlines must be an equal distance from the boat vertical centerline.
3. Draw the two crankshaft vertical centerlines through the intersection of the marks.
b
c c
b
a 7688
Dual installation
a - Vertical centerline
b - 1/2 minimum distance between crankshaft centerline marks
c - Crankshaft vertical centerlines
Finding Crankshaft Horizontal Centerline (X‑dimension)

X‑dimension can be measured by the 90 Degree Tool Method or by the Tape Measure Method.
Page 4 / 52 90-8M0093780 JANUARY 2015

90 Degree Tool Method

1. Construct the 90 degree tool.
a - 34.5 cm (13‑9/16 in.)

90 b - 1.2 m (4 ft)
a
b 7689
IMPORTANT: The 34.5 cm (13‑9/16 in.) dimension should only be raised or lowered after proper testing.
• To lower drive unit ‑ Subtract from dimension "a."
• To raise drive unit ‑ Add to dimension "a."
2. Place the 90 degree tool along the boat bottom at the vertical centerline.
3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical centerline. This is the crankshaft
horizontal centerline or X‑dimension.
4. Draw a line perpendicular to the vertical centerline at the crankshaft horizontal centerline.
c
b
b
c
a 7691
a 7690
Single engine Dual engine

a - 90 degree tool along boat bottom at vertical centerline
b - Contact point
c - Crankshaft horizontal centerline
Tape Measure Method

1. Determine the X‑dimension from the following chart.
IMPORTANT: This dimension should only be raised or lowered after proper testing.
Transom Angle (degrees) X‑dimension

16 36.4 cm (14‑5/16 in.)
15 36.2 cm (14‑1/4 in.)
14 36.0 cm (14‑3/16 in.)
13 35.9 cm (14‑1/8 in.)
12 35.7 cm (14‑1/16 in.)
11 35.6 cm (14 in.)
10 35.4 cm (13‑15/16 in.)
2. On the vertical crankshaft centerline, measure up from the bottom of the transom to the X‑dimension selected previously.
This is the crankshaft horizontal centerline at the X‑dimension.
90-8M0093780 JANUARY 2015 Page 5 / 52

3. Draw a line perpendicular to the vertical centerline at the crankshaft horizontal centerline.
a
a
c c
b
b
7693
7692
Single engine Dual engine

a - Vertical centerline
b - X‑dimension that corresponds to transom angle
c - Crankshaft horizontal centerline
Cutting Out the Transom

IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is suitable for most boats. The
best mounting location for a particular boat, however, can be determined only by testing.
1. Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from the X‑Dimension.
2. Heavy duty applications: Subtract 25 mm (1 in.) from the X‑Dimension.
3. Above 40 km/h (25 mph): Use the X‑Dimension shown.
4. Above 80 km/h (50 mph): The X‑Dimension can be increased to improve performance in some applications. However,
pulling power for skiing will decrease. During testing, the X‑Dimension should be increased 13 mm (1/2 in.) at a time until
desired performance is achieved, but in no case should it ever be increased by more than:
Maximum Increase In the X‑Dimension

Bravo One and Three 76 mm (3.0 in.)
Bravo Two 25 mm (1.0 in.)
Extreme care should be taken when raising drive unit to ensure that water supply does not become aerated. Use clear water
inlet hose to monitor the incoming water, and monitor the engine temperature gauge to ensure the engine does not overheat.
In applications where cooling water to the engine is supplied by a through‑the‑hull transom fitting, the sterndrive height will not
cause cooling water aeration.
IMPORTANT: Damage to Mercury Diesel products caused by too high of an installed height will not be covered by the
Mercury Marine warranty.
Page 6 / 52 90-8M0093780 JANUARY 2015

1. Cut out transom using the template or the transom drilling fixture kit (purchased separately).
7893 7694
Transom cutout template Transom drilling fixture kit
2. Follow the instructions indicated on the template or provided with the drilling fixture.
3. Ensure that the centerline on either the template or transom drilling fixture align with the lines previously marked on the
transom.
4. Drill two 6 mm (1/4 in.) pilot holes at a 60 degree angle for hole saw guides.
5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole saw cutout is made incorrectly,
the drive unit steering lever may contact the transom, causing limited steering travel.
a - 51 mm (2 in.) hole saw holes (steering lever cutout)
a b b - 60º versus transom angle
7695
6. Cut the transom on the cut line at a 90 degree angle. If the transom cutout is made incorrectly, the gimbal housing or
exhaust system may improperly contact the boat transom causing transom mounting problems.
90-8M0093780 JANUARY 2015 Page 7 / 52

7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water absorption and deterioration
of the transom.
a- Cut line
b- 90º to transom
c- Exhaust pipe area
d- Mounting holes perpendicular to the transom (8)
b
a
d c
7696
Checking the Transom Thickness

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.
Ensure that transom thickness and surface conform to specifications.
Transom Specifications
Thickness Between 51–57 mm (2–2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical centerline
Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.)
Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal
Flatness
dimensions): Inner surface ‑ Flat within 3 mm (1/8 in.); Outer surface ‑ Flat within 2 mm (1/16 in.)
Angle 10–16°
7697
a - Measuring thickness
b - Measuring flatness
c - Suitable mandrel to check for uniform transom thickness
Page 8 / 52 90-8M0093780 JANUARY 2015

Bravo Drive Transom Installation

Exhaust Tube
All diesel models covered by this manual are now factory equipped with an exhaust tube to reduce the exhaust back pressure
when using through‑the‑propeller exhaust.
a - Exhaust tube
22758
Installing Gimbal Housing Assembly

1. Carefully remove transom assembly from shipping carton.
2. Remove and read all tags attached to transom assembly.
a - Shipping hardware
b - Trim cylinder support
a
7713
3. Remove the shipping hardware.

4. Remove the dust cover if boat will be shipped with drive installed.
5. Retain the serial number envelope.
Installing the Inner Transom Plate

1. Insert wires, hoses, and the shift cable through the appropriate openings in the inner transom plate.
2. Position the gimbal housing on the transom and hold it in place.
3. Apply lubricant to the first 8 mm (0.30 in.) of the threads of the gimbal housing studs.

95 2-4-C with PTFE Gimbal housing studs 92-802859A 1
4. Start threading the locknuts onto the studs by hand.
IMPORTANT: Avoid damaging the gimbal housing studs, which prevents proper installation. Pneumatic tools can cause
the locknuts to damage the threads on the gimbal housing studs. Use hand tools to secure the transom plate locknuts.
IMPORTANT: Tighten the transom assembly locknuts using an X‑pattern torque sequence, starting from the middle
locknuts. Tighten in small increments and repeat the pattern several times until you reach the proper torque.
5. Secure the transom assembly with the locknuts.
90-8M0093780 JANUARY 2015 Page 9 / 52

IMPORTANT: Position the steering lever continuity circuit wire as shown to avoid stressing the wire when the steering
lever moves.
c
a
5 7
a
3 2
a 1 4
a
8 6
e
b 56188
a- Locknuts and flat washers (8)

b- Hydraulic hoses and MerCathode wire
c- Steering lever continuity wires
d- Transom plate continuity wires
e- Torque sequence
f- Trim sender and limit wires
6. Using a 5/8 in. deep well socket, tighten the fasteners to the specified torque.

Transom assembly locknuts 34 – 25
Page 10 / 52 90-8M0093780 JANUARY 2015

Connecting the Speedometer Pickup

The supplied pitot kit is 881879A15.
56219
Pitot kit
NOTE: If using a speedometer pickup other than the one supplied, leave the protective cap on the male quick‑connect fitting.
Follow the manufacturer's instructions to install the new speedometer pickup.
1. Remove the protective cap from the male quick‑connect fitting.
2. Connect a 4 mm (5/32 in.) speedometer hose (not provided) from the speedometer to the barb fitting. Secure the hose
with a cable tie.
a
b
c c e
d
7703
Typical
a - Male quick‑connect fitting
b - Female quick‑connect fitting
c - Barbed fitting
d - Hose
e - Cable tie
! CAUTION
A ruptured speedometer hose can introduce water into the bilge, causing boat damage or possible sinking. Position or
install the speedometer hose away from moving parts or pinch points, such as steering system components, engine
coupler, or driveshaft, which could damage the hose.
3. Secure the hose to the transom with the hose clip and screw that are provided in the parts bag. Ensure that the hose
does not contact the steering system components or the engine coupler and driveshaft.
Installing the Sterndrive Seawater Block‑Off Plate

Seawater for engine cooling will be supplied through an alternate (separate) seawater pickup instead of through the
sterndrive. Block the sterndrive seawater passage and cut the water hose that is located between the bell housing and the
gimbal housing. This allows water to continue to circulate through‑the‑sterndrive for cooling.
IMPORTANT: Installation of a water inlet block‑off plate will make it necessary to provide an alternate seawater pickup and
related hardware. Depending upon application and boat configuration a through‑the‑hull or through‑the‑transom seawater
pickup must be used.
90-8M0093780 JANUARY 2015 Page 11 / 52

NOTICE
Obstructions in the water passages will keep cooling water from circulating through‑the‑sterndrive resulting in damage to
the sterndrive. When using a block‑off plate ensure that the water hose between the bell housing and gimbal housing is cut
and removed.
1. Remove the tapered insert from the gimbal housing using the tapered insert tool. Discard the insert.
a b a- Tapered insert location in the gimbal housing

b- Ratchet and extension
c c- Tapered insert
d- Tapered insert tool
17857
Tapered Insert Tool 91‑43579

2. Install the block‑off plate with a new gasket. Secure with screws and lockwashers. Tighten the screws to specification.
53086
Block-off plate installed

Water inlet plate block‑off screws 5 45 –
Page 12 / 52 90-8M0093780 JANUARY 2015

3. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal housing and the bell housing
and detach the water hose from the gimbal housing where the tapered insert was removed.
d a- Trim limit switch wires

a
b- Speedometer hose
c- Gimbal housing
d- Water hose
e- Tapered insert
e
c
b
8489
! WARNING
Improper reassembly of the U‑joint and pinion gear assembly can damage the sterndrive or sink the boat. The U‑joint
bellows must provide a watertight seal to prevent water from entering the boat. Assemble and install the U‑joint and pinion
gear as specified.
NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. The
existing cable tie and clip can be reused if they are moved and repositioned after the hose is cut.
4. Cut completely through the water hose 127 mm (5 in.) from the aft end of the hose where it is fitted into the bell housing
in the area shown. Do not damage the U‑joint bellows.
5. Discard the loose hose piece.
6. Secure the trim limit switch wires and speedometer hose to the remaining section of water hose using the existing cable
tie and clip.
c e a- Cable tie
b- Clip
c- Water inlet hose
d- Speedometer hose
e- Trim limit wire harness
f f- Cutting area
b
d a
8490
7. Install a through‑the‑hull or through‑the‑transom seawater pickup, seawater strainer, and seacock.

8. Connect the seawater inlet hose between the seawater pump and seawater strainer.
9. Secure all hoses with hose clamps.
NOTE: Some locations may require double clamp joints.
Gear Lube Monitor Connection at Gimbal Housing

NOTE: The gear lube monitor, bracket, hose, and miscellaneous mounting hardware are supplied in the engine installation
kit.
90-8M0093780 JANUARY 2015 Page 13 / 52

1. Connect the quick‑release 90° fitting to the hose supplied with the kit.
a- Hose
b- Quick‑release 90° fitting
c- Gimbal housing fitting
d d- Quick‑connect fitting
a c
b
7704
2. Position the quick‑release button on the hose fitting away from the block‑off plate. The release button must not contact
the block‑off plate.
a - Block‑off plate
b - Quick‑release button
c - J‑clip
a
c
52885
3. The gear lube monitor hose must be routed toward the port side of the engine. Secure the hose assembly using the hose
J‑clip.
NOTE: The hose must not come into contact with the steering system components or the engine coupler and driveshaft.
4. Route the hose from the transom to the gear lube bottle and connect the hose via the barb on the bottom of the reservoir.
Ensure that the clamp is installed and secured.
IMPORTANT: Avoid using excessive hose when routing to the gear lube monitor. The hose should be routed directly to
the oil reservoir in as straight a line as possible to avoid low spots (traps) in the system.
5. If necessary, cut the gear lube monitor hose to the correct length at the gear lube monitor.
6. Secure the gear lube monitor hose with cable ties.
7. Connect the two connectors from the gear lube monitor to the bullet connectors on the vessel sensor harness.
Page 14 / 52 90-8M0093780 JANUARY 2015

8. Secure the gear lube monitor hose with the J‑clip onto the transom plate.
a - J‑clip
16791
Power Trim Pump

Mounting the Power Trim Pump
1. Select an appropriate mounting location (floor or transom) for the trim pump that:
• Is within length limits of the BLACK and GRAY hydraulic hoses coming from the gimbal housing assembly.
• Is close to the battery so that the trim pump battery leads can be connected.
• Allows easy access to the trim pump oil fill and vent locations.
• Is in an area where the pump will not be exposed to water.
• Prevents the power steering booster cylinder from coming in contact with the trim pump when the steering wheel is
turned in either direction (right or left).
NOTE: Template 90‑863152 provides mounting hole location for floor or transom mounting.
2. Using the template, mount the trim pump in the desired location.
3. Check the fluid level in the trim pump reservoir and fill if needed.
a. If the oil level is below the "MIN" line, the specified fluid must be added.
b. Remove the fill cap from the reservoir.
NOTE: Fill cap is vented.
a Power trim pump reservoir with the fluid

b level below the "MIN" line
a - Fill cap assembly
b - Fill cap installed
22018
90-8M0093780 JANUARY 2015 Page 15 / 52

c. Add the specified fluid to bring the fluid level to within the "MIN" and "MAX" lines on the reservoir.
a - Reservoir
a b - "MIN" and "MAX" lines
22019

Power Trim and Steering
114 Power trim pump 92-858074K01
Fluid
d. Install the fill cap.
Hydraulic Hose Connections—Power Trim Pump

1. Route the hydraulic trim hoses out of the way for engine installing.
2. Connect the hydraulic hoses to the power trim pump.
3. Ensure that the quick‑connect fittings completely seat when connecting the hoses.
4. Verify that the power trim pump is secured properly and has a fluid level above the "MIN" line.
a
Power trim pump, fluid
c level not shown
a - Positive (+) battery
g lead (not connected)
b - Negative (–) battery
lead (not connected)
c - Vessel sensor harness
connection to the trim
pump
d - BLACK hydraulic hose
(trim up) connected to
the trim pump
f e - GRAY hydraulic hose
(trim down) connected
to the trim pump
b f - Fill and vent cap
d g - Dual mount trim pump
26180
e bracket
Installing the Power‑Assisted Steering System

NOTE: For dual installations, the power steering unit can be mounted on the port or starboard transom assembly. Measure
the exact distance between power package centerlines. Select the tie bar from the Diesel Parts and Accessory Guide.
Refer to Multiple Sterndrive Steering Tie Bar Arrangements and tie bar installation instructions provided in this manual.
Page 16 / 52 90-8M0093780 JANUARY 2015

1. Inspect the bushings for debris. Lubricate the steering cylinder bushings.
26740
Steering cylinder bushings

95 2-4-C with PTFE Steering cylinder bushings 92-802859A 1
2. Remove the protective shipping caps.
3. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.
c
a - Protective shipping caps
a a b - Bushing
c - Upper and lower pivot bolts
b
b
c
a 56246

95 2-4-C with PTFE Threads of the upper and lower pivot bolts 92-802859A 1
4. Position the steering assembly so that the pivot bolts will enter the bushings in the power steering control valve.
5. Install the upper and lower pivot bolts along with the tab washers. Ensure that the tab washer tangs straddle the ridge on
the inner transom plate.
Upper pivot bolt and tab washer shown

b (lower similar)
a - Tab washer tang
b - Ridge
a
7761
6. Turn the pivot bolts all the way in by hand to ensure proper steering assembly alignment.
7. Ensure that the steering assembly pivots freely.
8. Tighten the pivot bolts to the specified torque.

Upper and lower pivot bolt 34 – 25
9. Bend the tab washer tabs against the corresponding flats on the bolt heads.
90-8M0093780 JANUARY 2015 Page 17 / 52

NOTE: If necessary, tighten the pivot bolts slightly enough to align the flats on the bolt head with the tabs on the washer.
b a - Pivot bolt
b - Bent tab
a
b a
8495
! CAUTION
Contents under pressure. Moving the control valve cable guide tube with the hoses disconnected expels fluid from the
ports. Wear eye protection while servicing the system.
10. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tube in the directions shown so
that it will be less difficult to pull it out or push it in during connection.
a a
b
b
8496
a - Port
b - Control valve cable guide tube
11. Connect the clevis to the steering lever. Lubricate the clevis pin. Be sure to spread both ends of the cotter pin.
NOTE: Insert the clevis pin from the top to ensure that the cotter pin hole is as shown in the diagram.
a- Clevis
c b- Steering lever
c- Clevis pin
a b d- Cotter pin
7822
Page 18 / 52 90-8M0093780 JANUARY 2015


95 2-4-C with PTFE Clevis pin 92-802859A 1
IMPORTANT: Most Quicksilver steering cables have a self‑locking coupler nut and do not require an external locking
sleeve or locking plate.
26741
Self-locking coupler nut
NOTICE
Fastening any items to the steering cables or outer casings prevents normal operation. The steering cable and outer casing
must be free to move back and forth. Do not fasten any items to the steering cable and outer casing.
12. Connect the steering cable as follows:
a. Coat the steering cable end with a liberal amount of lubricant.
Steering cable and outer casing

a - Steering cable end
7827

95 2-4-C with PTFE Steering cable end 92-802859A 1
b. Install the steering cable and secure with hardware as shown.
IMPORTANT: Cable guide tube flat surfaces must be positioned vertically or slight feedback in the steering system
could be encountered.
90-8M0093780 JANUARY 2015 Page 19 / 52

c. Using a suitable wrench, hold the flat surfaces on the cable guide tube in the vertical position. Tighten the coupler
nut to the specified torque. Ensure that the flat surfaces are still aligned vertically after torque is applied to the
coupler nut.
d
g
e f
c
a b
d
7830
a- Steering cable
b- Grease fitting
c- Cable coupler nut
d- Cable guide tube
e- Steering cable end
f- Clevis
g- Clevis pin
h- Cotter pin

Steering cable coupler nut 47 – 35
Power‑Assisted Steering Hoses

Hoses with Quick‑Connect Fittings
! WARNING
Stress on hose fittings or kinks in the hoses can damage hydraulic steering components, leading to serious injury or death
due to loss of boat control. Extreme heat can lower the hoses' burst pressure or melt the hose. Route hydraulic hoses to
avoid kinks, heat sources, or stress on the hose fittings.
1. Route the power steering hydraulic hoses to avoid extreme heat, stress on hose fittings, and hose kinks.
IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks.
2. Disconnect the hydraulic line's quick‑connect fittings from each other.
3. Remove the dust cover from the high‑pressure output port on the power steering pump.
4. Install the high‑pressure hose from the steering ram to the high‑pressure port on the power steering pump.
5. Remove the dust cover from the return port on the power steering cooler.
6. Install the return hose from the steering ram to the return port on the power steering cooler.
7. Connect the power‑assisted steering hoses to the control valve. Ensure that the quick‑connect fittings snap into place.
IMPORTANT: Hydraulic hoses must not come in contact with steering system components, engine coupler, U‑joint shaft,
or drive shaft.
8. Secure the hydraulic hoses to avoid contact with hot or moving components.
Page 20 / 52 90-8M0093780 JANUARY 2015

Engine Installation and Alignment

TDI 4.2L Engine Installation
! WARNING
Failure of the lifting eyes will cause the engine to fall suddenly from the hoist, resulting in serious injury, death, or property
damage. Keep the engine level while it is hoisted. Do not tilt the engine more than 12° in any direction during installation.
! CAUTION
Improper lifting during removal or installation of the engine can cause injury or damage to engine components. Use a hoist,
lifting arm, or other approved lifting device. Do not allow the lifting device to hook or compress any engine components.
IMPORTANT: The engine weighs 368 kg (811 lb), including a dry engine with auxiliary units, cooling system, and coupling
flange.
• The four lifting eyes provided on the engine must be used when installing and removing the engine with an engine hoist
and a suitable suspension device.
50759
Locations of four lifting eyes
• Select an installation location that provides access to the engine for installation and removal as well as ease of
maintenance.
Engine Mounts
Notes on Installation of Engine Mounts
• Do not place tension on the engine mounts during installation; otherwise, heavy vibrations and damage can occur.
• Make sure that there is no residual tension in the drivetrain and the engine mounts after installing and aligning the
engine.
90-8M0093780 JANUARY 2015 Page 21 / 52

• Use only the original engine mounts.
b c d
0.20" f
e
g
a
1.53
j i 50784
Engine mount dimensions

a - 123.0 mm (4.84 in.)
b - 16.0 mm (0.63 in.)
c - 30.0 mm (1.18 in.)
d - 183.0 mm (7.20 in.)
e - 140.0 mm (5.51 in.)
f - 13.0 mm (0.51 in.)
g - 75.0 mm (2.95 in.)
h - 37.4 mm (1.47 in.)
i - 20.0 mm (0.79 in.)
j - 13.0 mm (0.51 in.)
Installation
1. Center and tilt the engine to the recommended height with the height adjustment on the engine mount, preferably in the
middle of the height adjustment. The mounting bolts for the engine mounts on the boat hull must be used with washers.
a a- Securing nut
b b- Washer
c- Locking nut
c d- Engine mount with baseplate
50782
2. After aligning the engine, use a 13/16 in. socket to uniformly tighten the securing nuts as deep as possible on the engine
mounts. Leave at least 6.4 mm (1/4 in.) above and below for future adjustment.

Securing nut 105 – 77.4
Page 22 / 52 90-8M0093780 JANUARY 2015

3. Lock the locking nut in place with a suitable tool, such as an open‑end wrench. This will prevent the engine mounts from
twisting to the side when tightening the upper mounting nut.
50700
Engine mount
4. Secure the baseplate to the hull using bolts with a minimum diameter of 10 mm (3/8 in.) and suitable washers.
Engine and Transmission Mount Important Information

• The engine and transmission mounts should not be twisted when secured to the boat or during adjustments. Damage
can occur with subsequent heavy vibration.
• Verify the mounts are properly aligned before securing them to the boat.
• Use only mounts supplied by the original equipment manufacturer.
1. Center the mounts on the transmission and the engine mounting brackets. The preferred height of the mounts is in the
middle of the adjustment range.
2. Secure the adjustment nut with an open‑end wrench to prevent the mount from twisting to the side when tightening the
upper locknut.
3. Secure the mounts to the boat with appropriate hardware.
50700
Preparing the Transom

IMPORTANT: The exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches and the
O‑ring must be properly seated in the groove, or water and exhaust may leak into the boat.
1. Ensure that the exhaust pipe and gimbal housing mating surfaces are clean and free of nicks and scratches.
90-8M0093780 JANUARY 2015 Page 23 / 52

2. Ensure that the O‑ring is properly seated in the groove.
a a - Gimbal housing mating surface

b - O‑ring
6638
3. Install the exhaust pipe assembly as shown, using four bolts and thick lockwashers. Using a 10 mm 12‑point socket,
tighten the exhaust pipe assembly bolts to the specified torque.
Typical installation shown

a - Upper bolts and thick lockwashers (2)
b - Lower bolts and thick lockwashers, not visible (2)
a c - Exhaust pipe
b
52869

Exhaust pipe assembly bolts 34 – 25
4. Position the rear engine mount attaching hardware on the inner transom plate mounts as shown.
a - Locknut
b - Fiber washer
a
22312
Engine Preparation
1. Remove and read all tags attached to the engine.
2. Loosen the fasteners and remove the exhaust pipe and exhaust hose from the pallet.
Page 24 / 52 90-8M0093780 JANUARY 2015

3. Remove the shipping plug from the coupler and lubricate the coupler using the grease fitting.
52519
Grease Fitting

Extreme Grease Coupler 8M0071842
Engine Installation
1. Remove the cover from the top of the engine.
2. Attach an engine hoist and suitable lifting tackle to the four lifting eyes on the engine. These eyes must be used when
installing and removing the engine.
! CAUTION
Improper lifting during removal or installation of the engine can cause injury or damage to engine components. Use a hoist,
lifting arm, or other approved lifting device. Do not allow the lifting device to hook or compress any engine components.
! WARNING
Failure of the lifting eyes will cause the engine to fall suddenly from the hoist, resulting in serious injury, death, or property
damage. Keep the engine level while it is hoisted. Do not tilt the engine more than 12° in any direction during installation.
90-8M0093780 JANUARY 2015 Page 25 / 52

3. Remove the hardware securing the engine mount assembly to the shipping container and remove the engine assembly.
50759
Engine lifting eye locations (typical)
4. Lower the engine assembly into the boat.
NOTICE
Mismatched flywheel housing mounts and inner transom plate mounting hardware will result in improper engine alignment
and possible engine damage. Ensure that the flywheel housing mounts and the inner transom plate mounting hardware,
port and starboard, are the correct parts and match before installing the engine.
Page 26 / 52 90-8M0093780 JANUARY 2015

5. Position the rear engine mounting hardware on the inner transom plate mounts as shown.
a
52871
a - Knurled surface
b - Fiber washer
c - Locknut (hidden)
IMPORTANT: Do not set the engine on the shift cable when lowering the engine into position.
6. Ensure that the fiber washers and locknuts are on the inner transom plate mounts.
7. Align the rear engine mounts with the inner transom plate mounts. Set the engine onto the inner transom plate mounts.
Simultaneously, align the exhaust elbow with the exhaust tube. Do not relieve the tension on the hoist.
IMPORTANT: Install the engine mounting hardware in the sequence shown.
8. Install both rear engine mounting bolts with the hardware as shown.
c a- Rear engine mount

d b- Inner transom plate mount
c- Bolt
d- Washer
e- Spacer
a e f- Fiber washer
f
b 7934
9. Using a 3/4" socket and appropriate extensions, tighten the rear engine mounting bolts to the specified torque.

Rear engine mounting bolts 47 – 35
90-8M0093780 JANUARY 2015 Page 27 / 52

10. Adjust the front mounts until they rest on the boat stringers.
11. Set the engine on the boat stringers.
12. Relieve the tension on the hoist and disconnect the hoist from the engine lift eyes.
Exhaust System Connections

NOTICE
Hot spots in exhaust hoses can damage hoses and cause leaks. Ensure that discharge water from the exhaust elbow flows
without restriction through all hoses and fittings.
IMPORTANT: Exhaust bellows, hoses, and tubes must be secured at each connection with at least two hose clamps.
All exhaust connections, including those at the exhaust elbow, should be secured with two hose clamps. ABYC standards
also specify the use of stainless steel clamps with a minimum 13 mm (1/2 in.) band width. Do not use spring tension clamps.
1. Connect the exhaust hoses and tubes so that they do not restrict the flow of discharge water from the exhaust elbow.
2. Install at least two hose clamps on each exhaust hose and tube connection.
3. Using a 7 mm socket, tighten the exhaust system hose clamps to the specified torque.
a - Exhaust hose clamps (4)
52877

Exhaust system hose clamps 5.1 45 –
Page 28 / 52 90-8M0093780 JANUARY 2015

Alignment
1. Ensure that the dust cover is removed or folded back out of the way.
a - Dust cover
52883
IMPORTANT: Alignment tools from other manufacturers may cause improper alignment and damage to the gimbal
bearing or engine coupler. Use only the Quicksilver alignment tool.
Notice
Improper use of the alignment tool may result in damage to the gimbal bearing or engine coupler. Do not
operate the engine with the alignment tool installed. Do not attempt to force the alignment tool, raise or lower
the engine with the tool inserted in the gimbal bearing or engine coupler, or raise the engine mount bracket
above the top of the engine mount stud.
2. Attempt to insert the solid end of the alignment tool through the gimbal bearing and into the engine coupler splines.
d
b c
a
7936
a- Alignment tool
b- End of alignment tool to insert through the gimbal housing assembly
c- Gimbal bearing
d- Engine coupler
Alignment Tool 8M0070098
90-8M0093780 JANUARY 2015 Page 29 / 52

3. If necessary, firmly strike the sides of the alignment tool with a synthane hammer at 90° increments to help align the
gimbal bearing to the coupler.
Engine alignment tool (typical)

a - Alignment tool
b b - Inserted through the gimbal
a housing assembly
c - 90° increments
c
7937
5. If the alignment tool does not fit, remove it carefully and adjust the engine mounts.
IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in the direction required to align the
engine.
IMPORTANT: The height adjustment, the distance between the adjusting nut and the base jam nut, may not exceed
10 mm (0.39 in.).
a. To adjust the engine up or down, loosen the locknuts on both front mounts. Turn the adjusting nuts as necessary;
then, tighten the locknuts.
a - Adjusting nut
b b - Locknut
c - Base jam nut
52873
b. To move the engine left or right, loosen the locknuts on both front mounts. Move the engine as necessary in the
slotted mount holes.
Page 30 / 52 90-8M0093780 JANUARY 2015

NOTE: The slots on the cast engine mounts provide a small amount of left or right adjustment.
a - Locknut
a b - Cast engine mount slotted hole
52874
7. Repeat the necessary steps until the alignment tool installs easily (slides freely with two fingers) all the way into and out
of the engine crankshaft pilot. Do not check by turning the alignment tool.
8. Fasten the front mount assemblies to the boat stringers using appropriate hardware.
9. Using a 13/16 in. socket, tighten both front mount locking nuts to the specified torque.

Front mount locking nuts 80 – 59
10. Check the alignment with the alignment tool. The tool must enter the coupler splines freely. If not, remove the alignment
tool and readjust the front mounts.
11. Remove the alignment tool.
12. Secure the nut below the engine bracket with a 13/16 in. open‑end wrench and tighten the locknut to the specified torque.
b a - Nut below the engine bracket

b - Locknut and washer
c - Washer and hardware securing mount
c
52875

Locknut 105 – 77.4
13. If operating in a saltwater environment, apply sealant to the threads and nuts of the engine mounting hardware to help
protect against corrosion. This allows for easier loosening in the future if readjustment becomes necessary.

19 Perfect Seal Engine mounting hardware threads and nuts 92-34227Q02
NOTE: If the boat will be shipped without the drive unit installed, it is recommended that the shipping hardware remain on
the transom assembly during shipment.
90-8M0093780 JANUARY 2015 Page 31 / 52

Electrical Connections
Continuity Circuit
1. Connect the continuity circuit wire from the transom assembly to the engine. Tighten the inner transom plate screw
securely.
IMPORTANT: Do not attach any accessory ground (–) wires at the inner transom plate grounding screw.
Typical
a - Flywheel housing screw
b - Continuity circuit wire
c c - Inner transom plate grounding screw
a
b
7782
Trim Position Sender Connection

Connect the trim position sender from the gimbal housing to the vessel sensor harness.
b a - Trim position sender

b - Trim position sender
connector
b
a
24785
Sensor extension harnesses are available in 10, 20 and 30‑ft lengths.
Description Part Number

10 ft extension harness 893371T10
Page 32 / 52 90-8M0093780 JANUARY 2015

Power Trim Pump Connection

Connect the vessel sensor harness to the trim pump.
a Power trim pump

a - Vessel sensor harness
connector
b
b - Trim pump connector
7699
Quick‑Connect MerCathode System Connection

1. Mount the MerCathode controller in an accessible area within reach of the harness, when installed.
2. Connect the MerCathode harness wires to the MerCathode controller assembly—the orange wire to the A terminal, and
the brown wire to the R terminal.
3. Connect the MerCathode harness to the electrode assembly harness.
c d
b
e
52889
a- MerCathode controller
b- MerCathode harness
c- Positive power harness with 5‑amp fuse
d- Ground cable
e- Battery
f- Electrode assembly harness
4. Connect one end of the positive power harness with 5‑amp fuse to the positive (+) terminal of the MerCathode controller,
and connect the other end directly to the positive terminal of the battery.
5. Connect one end of the ground cable to the negative terminal of the MerCathode controller. Secure the ground ring
terminal to the screw on the port side of the transom plate.
90-8M0093780 JANUARY 2015 Page 33 / 52

6. Apply a thin coat of sealant to all wire connections.

25 Liquid Neoprene Exposed terminals and connections 92- 25711 3
Bravo Sterndrive Shift Cable Installation

Shift Cable Travel
We recommend the use of a Mercury remote control and cable. Refer to the Diesel Parts and Accessories Guide or the
Mercury Parts and Accessories Guide for selection. However, if a control other than Mercury is to be used, the control
must provide a shift cable travel (at the shift plate end) of 73–80 mm (2‑7/8 to 3‑1/8 in.) with a 6.8–9 kg (15–20 lb.) load
applied to the cable end guide.
Mechanical Throttle and Shift—Shift Cable Installation and Adjustment

NOTE: The shift cable adjustment tool (91‑12427) allows the shift cables to be installed and adjusted with or without the
sterndrive attached.
1. Install the shift cable onto the remote control. Refer to the appropriate remote control instructions.
IMPORTANT: Do not overtighten the stud. Overtightening the stud can cause shift lever damage.
2. Loosen the stud and move it to the dimension shown. Retighten the stud.
a - Stud
b - 76 mm (3.0 in.)—distance from the center of pivot bolt to the
b center of the stud
a 56360
3. Remove the adjustment tool.
56361
4. Install the sterndrive shift cable.
Page 34 / 52 90-8M0093780 JANUARY 2015

5. Insert the cotter pins from the top. Spread the ends of the cotter pins fully.
b
a
d a 56362
a- Washers (2)
b- Long cotter pin
c- Sterndrive shift cable
d- Short cotter pin
6. Place the adjustment tool over the sterndrive shift cable as shown. Hold the tool in place using a piece of tape over the
barrel retainer.
8001
7. Locate the center of the remote control and control cable play (backlash).
a. Shift the remote control to neutral.
b. Push in on the control cable end with enough pressure to remove play and mark position "a" on the tube.
c. Pull out on the control cable end with enough pressure to remove play and mark "b" on the tube.
d. Measure the difference between marks "a" and "b" and mark position "c" halfway between marks "a" and "b."
a 7815
b
IMPORTANT: Be sure to keep center mark "c" aligned with the edge of the control cable end guide when making
the following adjustment.
8. Adjust the control cable as follows:
a. Temporarily install the control cable end guide into the shift lever, and insert the clevis pin.
b. Adjust the control cable barrel so that the hole in the barrel aligns with the vertical centerline of the stud. Ensure that
the backlash center mark "c" is aligned with the edge of the control cable end guide.
90-8M0093780 JANUARY 2015 Page 35 / 52

Notice
Do not attempt to install or remove the control cable barrel from the stud without first removing the end
guide anchor pin from the shift lever and removing the cable. Attempting to bend the control cable to
install or remove the barrel will place undue stress on the cable end guide and shift lever, and damage to
both could occur.
c. Remove the control cable end guide from the shift lever by removing the clevis pin.
a- Control cable end guide

b- Clevis pin
c- Backlash center
e d- Control cable barrel
e- Stud
d a
c 8003
b
9. Install the control cable.
10. Install the washer and cotter pin to secure the barrel. Spread the ends of the cotter pin fully.
11. Install the clevis pin.
12. Install the cotter pin into the clevis pin. Spread the ends of the cotter pin fully.
a c a- Cotter pin
b b- Washers (both sides of barrel)
c- Clevis pin
d- Cotter pin (partially shown)
d 8004

14. Shift the remote control lever into the full forward position. Place the end of the adjustment tool in the barrel retainer.
a. RH Rotation Bravo One, Two, and Three models: The rear slot in the tool should fit over the shift lever stud.
b. LH Rotation Bravo One and Two: The forward slot in the tool should fit over the shift lever stud.
Page 36 / 52 90-8M0093780 JANUARY 2015

15. If the slot does not fit over the stud, loosen the shift lever stud and slide the stud up or down until the slot in the tool fits
over the stud. When the adjustment is correct, retighten the stud.
c
c
a
a
b b
d e
56365
LH rotation—Bravo One and Two RH rotation—Bravo One, Two, and Three

a - Barrel retainer cotter pin
b - Adjustment tool
c - Shift lever stud
d - Shift lever adjustment tool, forward slot (LH rotation)
e - Shift lever adjustment tool, rear slot (RH rotation)

17. Shift the remote control into reverse and repeat the adjustment process.
a. LH Rotation Bravo One and Two: The rear slot in the tool should fit over the shift lever stud.
b. RH Rotation Bravo One, Two, and Three models: The forward slot in the tool should fit over the shift lever stud.
18. If the slot does not fit over the stud, loosen the shift lever stud and slide the stud up or down until the slot in the tool fits
over the stud. When the adjustment is correct, retighten the stud.
c
c
a
a
b b
d e
56365
LH rotation—Bravo One and Two RH rotation—Bravo One, Two, and Three

a - Barrel retainer cotter pin
b - Adjustment tool
c - Shift lever stud
d - Shift lever adjustment tool, forward slot (LH rotation)
e - Shift lever adjustment tool, rear slot (RH rotation)

20. Ensure that all cotter pins are secure and that the cotter pins are spread to 180°.
21. Lubricate the shift cable pivot points.

80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
Digital Throttle and Shift System—Shift Cable Installation

IMPORTANT: Do not move the shift cable stud on the shift arm.
IMPORTANT: The shift cable barrel is preset and cannot be adjusted.
1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:
90-8M0093780 JANUARY 2015 Page 37 / 52

IMPORTANT: The cable should be routed away from the driveshaft.

Ensure that the cable is not forced into a radius tighter than 20 cm (8.0 in.).
a. The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of
the boat between the exhaust pipe and the engine flywheel housing.
b. The cable should then be routed under the starboard rear engine mount and turn toward the transom.
c. The cable should then go up behind the power steering valve and loop over to the shift actuator on the transom.
NOTE: Following this routing will prevent the engine coupler from damaging the cable.
56472
NOTE: A final check of the adjustments should be made with the boat in the water and the engine running. If this cannot
be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of
the predelivery inspection.
2. Apply lubricant to the threads of the shift cable stud.

95 2-4-C with PTFE Shift cable stud threads 92-802859A 1
3. Attach the intermediate shift cable to the shift actuator on the engine.
4. Tighten the locknut until it makes contact, and then loosen it ½ turn.
NOTE: Extension harnesses are available through the Mercury Precision Parts Accessories Guide.
b a- Shift actuator
c b- Shift cable
c- Locknut
e d- Shift cable stud
e- Shift cable barrel
a f- Washers
f
d
52876
Page 38 / 52 90-8M0093780 JANUARY 2015

5. Insert the cotter pin from the top and spread the ends.
a a - Cotter pin
52878
Bravo Sterndrive Installation

1. If applicable, remove the trim cylinder straps and dust cover from the bell housing studs. Retain the nyloc nuts and flat
washers.
b a - Trim cylinder supports

b - Dust cover
52880
2. Remove the gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE" line.
a - Gear lube monitor cap

b - "OPERATING RANGE" line
a b
5497

High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
90-8M0093780 JANUARY 2015 Page 39 / 52

3. To purge air from the system, push in on the dribble valve stem until gear lube appears.
a - Dribble valve
21440
4. Release the dribble valve.
5. If the gear lube monitor is below the full line, fill the gear lube monitor to the "OPERATING RANGE" (full) line with the
specified fluid. Do not overfill.

High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap.
7. Coat the sterndrive U‑joint O‑rings and driveshaft splines with grease.
a a
21441
a - O‑rings
a - Splines
a
21442

Extreme Grease U-joint O-rings, driveshaft splines 8M0071842
IMPORTANT: The edge of the U‑joint bellows acts as a seal between the bell housing and the driveshaft housing.
Inspect the surface for damage.
Page 40 / 52 90-8M0093780 JANUARY 2015

8. Ensure that the U‑joint bellows are clean and free of debris.
Bell housing of the transom assembly

a - U‑joint bellows edge
b - U‑joint bellows
a b
21456
9. Apply lubricant to the first 6 mm (1/4 in.) of the threads of the bell housing studs.
b a - Bell housing studs (6)

b - Tube of lubricant
a
a
21457

95 2-4-C with PTFE First 6 mm (1/4 in.) of the bell housing stud threads 92-802859A 1
10. Lubricate the O‑ring seals.
a - O‑ring seals
a
25970

95 2-4-C with PTFE O-ring seals 92-802859A 1
90-8M0093780 JANUARY 2015 Page 41 / 52

11. Pull the shift linkage out until the jaws are fully open.
b
a
c
c
21471
5311
a - Shift linkage assembly
b - Jaws open
c - Underside of lower lip
IMPORTANT: As you insert the sterndrive into the entry of the bell housing, check the shift cable to ensure that it enters
the jaws of the shift linkage assembly.
12. Place the remote control in the neutral position.
NOTE: As the bell housing shift cable enters the shift linkage assembly, it pushes the assembly back into the sterndrive
housing and the jaw closes, securing the cable as shown in steps "A," "B," and "C."
C 5312
Page 42 / 52 90-8M0093780 JANUARY 2015

IMPORTANT: If the bell housing shift cable does not line up to properly enter the jaws of the shift linkage assembly, use
your hand to guide the cable into place.
a - Shift linkage assembly

b - Shift cable
a
b
5313
13. Install the sterndrive as follows:

a. Remove the nuts from the trim cylinders and remove the trim cylinders from the anchor pin.
a- Socket
c b- Wrench
a b c- Anchor pin
d- Ground wires
e- Trim cylinders
d
e
21521
b. Position the sterndrive so that the universal joint shaft aligns with the bell housing bore.
a- Universal joint
a b b- Bell housing
c- Shift linkage
d- Shift cable
c d 21518
90-8M0093780 JANUARY 2015 Page 43 / 52

c. Guide the U‑joint shaft through the bearing in the gimbal housing and into the engine coupler. Ensure that the shift
linkage jaws engage the bell housing shift cable assembly.
a - Shift cable
b - Shift linkage jaws
open
c - Shift linkage jaws
engage the shift cable
a b c
21519
d. If necessary, rotate the propeller shaft counterclockwise slightly (using a propeller) to align the U‑joint shaft splines
with the engine coupler splines. Slide the sterndrive all the way into the bell housing.
b d
a c
e
21520
26184
a- Bell housing studs

b- Dribble valve
c- Shift cable
d- Propeller shaft
e- Propeller
IMPORTANT: Avoid damaging the gimbal housing studs, which would prevent proper installation. Pneumatic tools can
cause the locknuts to strip the threads on the studs. Use hand tools to secure the sterndrive.
14. Secure the sterndrive to the bell housing with four flat washers and six locknuts. Do not use flat washers on the ground
plate.
Ground plate with serial number and gear ratio

a - Washers not used here
25908
Page 44 / 52 90-8M0093780 JANUARY 2015

15. Using a 5/8 in. deep well socket, start from the center and tighten the locknuts to the specified torque.
a - Locknut (6), flat washers (4)

b - Torque wrench
a
b
25909

Sterndrive locknuts 68 – 50
Additional Trim Limit Spacer Kit

All trim cylinders have one trim limit spacer kit installed by the vendor before installation. An additional trim limit spacer kit
(91‑15768A3) is not required if the trim and trailer limits will be set using the CDS tool.
1. Install the trim cylinders. See Trim Cylinder Installation.
2. Set the trim and trailer limit during predelivery preparation. Refer to Setting Trailer and Trim Limit in the Predelivery
Preparation and Storage section.
If the trim position sender is set so that the drive will make contact with any part of the vessel or swim platform and the CDS
tool is unavailable to set the trim and trailer limit, then an additional trim limit spacer kit is required. Install the kit before
connecting the trim cylinders to the sterndrive. The trim limit spacer kit keeps the sterndrive from contacting the swim platform
preventing sterndrive or vessel damage.
1. Install the trim limit spacer kit (91‑15768A3).
2. Refer to the instruction sheet contained in the kit.
3. Install the trim cylinders. See Trim Cylinder Installation.
Trim Cylinder Installation

1. Install the front mounting hardware of the trim cylinder as shown.
2. Lubricate the anchor pin threads to prevent the threads from galling.
3. Hand‑thread the locknuts onto the pin. Do not tighten at this time.
90-8M0093780 JANUARY 2015 Page 45 / 52

NOTE: Upon installation of hardware, apply lubricant to all stainless steel components.
b
a
a
b b c d
26192
Front
a - Anchor pin
b - Bushing
c - Flat washer (small ID)
d - Locknut

95 2-4-C with PTFE Trim cylinder hardware 92-802859A 1
IMPORTANT: On all Bravo models, properly position the trim‑in limit insert before installing the trim cylinder anchor pin in
the following steps. Install the trim‑in limit insert in the same position as before removal of the sterndrive. If you are not
sure of the original position, contact the boat manufacturer. Refer to Special Information at the front of this section before
reinstalling the trim‑in limit insert. For a Bravo Three sterndrive, change the position of the insert only after the boat has
been properly tested.
a b
14571
a - Trim‑in limit insert Bravo One and Two (positioned forward)

b - Trim‑in limit insert Bravo Three (positioned aft)
4. Install the mounting hardware of the trim cylinder aft as shown.

5. Lubricate the anchor pin threads to prevent the threads from galling.
6. Hand‑thread locknuts onto the anchor pin.
Page 46 / 52 90-8M0093780 JANUARY 2015

NOTE: Apply lubricant to all installed stainless steel components.
c b c
a
d e
c f
9295
a- Aft anchor pin

b- Larger flat washers (2)
c- Bushings (4)
d- Small ID flat washers (2)
e- Locknuts (2)
f- Plastic caps (2)

95 2-4-C with PTFE Trim cylinder hardware 92-802859A 1
IMPORTANT: Avoid damaging the anchor pin threads, which prevents proper installation. Pneumatic tools can cause the
fasteners to strip the threads on the anchor pin. Use hand tools to secure the trim cylinders.
7. Tighten the locknuts until the washer and locknut contact the shoulder on the anchor pin.
8. Install plastic caps and hand‑tighten only.
b b a
c
21677
a - Socket and tool

b - Wrench tool
c - Plastic cap (4)
Speedometer Connections ‑ Bravo Models

1. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately atop the transom end of the
anti‑ventilation plate.
90-8M0093780 JANUARY 2015 Page 47 / 52

2. Insert speedometer tube fitting into opening on topside of anti‑ventilation plate, in position shown.
a - Tube fitting
b - Opening
a
5319
3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
a - Fitting installed (handle pointing forward)
5320
Page 48 / 52 90-8M0093780 JANUARY 2015

Paddle Wheel Speed Sensor Installation (If Equipped)

Parts Provided
e
d
a i
b
c
i
h
ABCD
f 29269
j
g
a- Spare pin yoke

b- Wire retainer
c- Connector
d- Bracket
e- Paddle wheel
f- Flat washer (2)
g- #10 ‑ 19 mm (3/4 in.) screw (4)
h- Cable cap
i- #6 ‑ 12 mm (1/2 in.) screw (4)
j- Clamp (2)
Selecting Location
Single engine installation ‑ Mount paddle wheel on the transom where the propeller blade is rotating downward. Usually the
right (starboard) side to minimize cavitation. If feasible, mount at least 50 mm (2 in.) beyond the swing radius of the propeller.
Dual engine installation ‑ Mount the paddle wheel between the engines as close to the center line (keel) of the boat as
possible. On slower, heavier displacement boats, however, positioning it farther from the keel is acceptable.
NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes or outlets for live wells or any protrusion that
may cause turbulence or cavitation.
Transom Angle Requirements

Standard 13° to 20° transoms ‑ No special adjustment required.
a b a - 13° transom angle

b - 20° transom angle
29272
Stepped or undercut transom with 3 angles ‑ A small shim of tapered plastic, metal or wood must be fabricated and installed
as shown. Mount the paddle wheel on the step for best performance.
a a - Shim
29276
90-8M0093780 JANUARY 2015 Page 49 / 52

Installing Bracket
1. Cut out the template. At the location selected, tape the template to the transom. Make sure the black dotted line on the
template is aligned with the transom bottom edge, as shown.
NOTE: The mounting template provided is located on the last page of this instruction sheet.
2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on the template. To prevent drilling too
deeply, wrap masking tape around the drill bit 22 mm (7/8 in.) from the point end of drill bit.
NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drilling about 1.5 mm (1/16 in.) deep to
prevent surface cracks.
3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to the two #10 screws provided. Using
the washer provided, attach and tighten the bracket to the hull making sure the bracket is flush with the underside of the
hull.
4. Fill any gap between the housing and the transom with a caulking material, as shown. Using a putty knife, smooth the
surface to ensure proper water flow.
e a- Template
a b- 50 mm (2 in.)
c- #10 screw
d- Flat washer (2)
b e- Caulking
c d 29282
Routing the Cable

Drilling Hole Through Transom (optional)
1. Select a transom location for the hole above the water line that does not interfere with other cables and controls.
2. Drill a 15 mm (5/8 in.) diameter hole.
3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or a comparable marine sealer after
the cable has been routed through.
NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. The hole for the second clamp
should be positioned halfway between the first clamp and the cap covering the transom hole drilled for the cable.
4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm (1/2 in.) deep.
5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads, install the cable clamps and feed the
cable through cable cap.
Without Drilling Hole Through Transom (optional)

Route the cable over the transom or through a drain hole that is above the water line.
a- Splash well drain hole

a b- Cable cap
c- Cable clamp
b d- Paddle wheel assembly
e- Distance between first cable clamp and top of paddle
wheel ‑ 25.4 mm (1.0 in.)
c
e
d
29285
Page 50 / 52 90-8M0093780 JANUARY 2015

Installing and Removing the Paddle Wheel

Installation ‑ Slide the pins into the slots in the bracket and snap the tabs into place.
Removal ‑ squeeze open (unlock) the tabs and pull on the paddle wheel.
a
a - Tabs
b - Pins
b 29288
Wiring Connections
IMPORTANT: Before making wire connections, make sure wires are routed through the transom.
NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs inside the connector. Have
the wiring routed through the transom. Push each wire terminal into its respective location in the connector. Push wire in until
they snap into place. Secure wires into connector with the wire retainer.
DC BA
WHT
DC BA
YEL
BLU
BL K
29289
b b
a
a - Connector
b - Wire retainer
Template ‑ Paddle Wheel Speed Sensor
a a - Drill holes here

b - Align dotted line with the transom bottom edge and fold
under
29291
90-8M0093780 JANUARY 2015 Page 51 / 52

NOTES:
Page 52 / 52 90-8M0093780 JANUARY 2015

SECTION - 7 ELECTRICAL SYSTEMS
SECTION 7 - ELECTRICAL SYSTEMS

Table of Contents
Before You Begin........................................................................................................................................................................ 3
Wiring Guidelines................................................................................................................................................................. 3
Wiring Guidelines for Electrical Boat Accessories ....................................................................................................... 3
Harness Installation Guidelines .................................................................................................................................... 3
Weather Caps....................................................................................................................................................................... 3
Battery and Battery Cables......................................................................................................................................................... 4
Selecting the Battery............................................................................................................................................................ 4
Battery Cable Installation Requirements.............................................................................................................................. 4
Battery Cables...................................................................................................................................................................... 5
Mechanical Throttle and Shift—Battery Precautions for Multiple Engines........................................................................... 5
Connecting the Battery Cables and Control Harness to the Engine..................................................................................... 6
Installing and Connecting the Vessel Adapter Assembly (VAA)................................................................................................. 7
Installing the Vessel Adapter Assembly............................................................................................................................... 7
Vessel Adapter Assembly Connections................................................................................................................................ 7
Vessel Sensor Harness Connections................................................................................................................................... 9
Remote Controls......................................................................................................................................................................... 9
Key Switch................................................................................................................................................................................... 9
Preparation........................................................................................................................................................................... 9
Standard Mounting ‑ With Housing..................................................................................................................................... 10
Optional Mounting ‑ Without Housing................................................................................................................................. 11
Key Switch Extension Harness........................................................................................................................................... 12
Installation .................................................................................................................................................................. 12
Key Switch Wiring Connections.......................................................................................................................................... 12
Start/Stop Panel........................................................................................................................................................................ 12
Preparation ........................................................................................................................................................................ 13
7
Installation ......................................................................................................................................................................... 13
E‑Stop Switch, If Equipped........................................................................................................................................................ 14
Installation ......................................................................................................................................................................... 14
Installation Recommendations: .................................................................................................................................. 14
Lanyard Stop Switch Installation............................................................................................................................................... 14
Digital Throttle and Shift (DTS) Systems................................................................................................................................... 15
Installation Guidelines for DTS System Components......................................................................................................... 15
Data Harness ............................................................................................................................................................. 15
Connectors ................................................................................................................................................................. 15
Data Harness Pulling Procedure........................................................................................................................................ 16
Junction Box (If Equipped)................................................................................................................................................. 16
Connecting 14‑Pin Data Harness–Single Engine............................................................................................................... 17
Single Helm ................................................................................................................................................................ 17
Dual Helm .................................................................................................................................................................. 17
Connecting 14‑Pin Data Harness–Dual Engine.................................................................................................................. 18
Single Helm ................................................................................................................................................................ 18
Dual Helm .................................................................................................................................................................. 18
Installing DTS Command Module and Harness–Single Engine......................................................................................... 18
Harness Installation .................................................................................................................................................... 18
Module Installation ..................................................................................................................................................... 20
Installing DTS Command Module and Harness–Dual Engine............................................................................................ 21
Harness Installation .................................................................................................................................................... 21
Module Installation ..................................................................................................................................................... 22
Wire Color Code Abbreviations................................................................................................................................................. 23
Transom Harness—DTS........................................................................................................................................................... 24
90-8M0093780 JANUARY 2015 Page 1 / 38

ELECTRICAL SYSTEMS SECTION - 7
Typical DTS Control Wiring Diagrams....................................................................................................................................... 26

DTS Panel Control Wiring.................................................................................................................................................. 26
DTS Single‑Console Control Wiring................................................................................................................................... 28
DTS Single‑Console Control Wiring with Dual Helm.......................................................................................................... 30
DTS Dual‑Console Control Wiring...................................................................................................................................... 32
DTS Dual‑Console Control Wiring with Dual Helm............................................................................................................. 34
DTS Zero Effort Control Wiring–Single Engine................................................................................................................... 36
DTS Zero Effort Control Wiring–Dual Engine .................................................................................................................... 37
Page 2 / 38 90-8M0093780 JANUARY 2015

Lubricant, Sealant, Adhesives

25 Liquid Neoprene Battery terminals 92- 25711 3
Special Tools
Data Cable Puller 888462A 1
Attaches to end of DTS data harness to aid in pulling harness through boat.
4618 Prevents damage to DTS data harness.
Before You Begin

Wiring Guidelines
IMPORTANT: Read the following precautions to avoid damage to the electrical system.
• Do not tap accessories into the engine harness.
• Do not puncture wires for testing (probing).
• Do not reverse the battery leads.
• Do not splice wires into the harness.
• Do not attempt diagnostics without the proper, approved service tools.
• Never attempt to connect, network, tie into, switch, sink source voltage or current from the wiring harnesses.
• Never attempt to connect any type of communication or navigation equipment into the wiring harnessing other than at the
designated connection point.
• Always install boat accessory equipment using an appropriate power source connection, such as a fuse panel or junction
box.
• Never attempt to tap directly into any of the electrical wiring harnesses for a source of power.
Wiring Guidelines for Electrical Boat Accessories

IMPORTANT: Do not connect boat accessories to ignition key switch circuits. Use a separate, switched 12‑volt or 24‑volt
source, depending on your application, for wiring boat accessories.
Splicing or connecting accessories to the ignition key switch circuits could cause an open circuit at the fuse or overload
circuits, causing intermittent or complete loss of operation.
Harness Installation Guidelines

• Inspect the routing path to ensure that surfaces are free of any sharp edges or burrs that could cut the harness.
• Fasten and support the harness with clamps or cable ties along the routing path. A clamp or cable tie must be used
within 25.4 cm (10 in.) of any connection and every 45.8 cm (18 in.) along the routing path.
• Ensure that all connections are tight.
• Seal all unused connectors with weather caps.
• Route the harness at least 1 m (3 ft.–3 in.) from any VHF radio and radar equipment.
Weather Caps
Weather caps are to be used whenever there are any unused connectors on a harness. Verify all connections are tight to
prevent moisture or corrosion occurring inside the connections.
90-8M0093780 JANUARY 2015 Page 3 / 38

Typical weather caps are as follows:
a- 10 pin cap
b- 5 pin cap
c- 3 pin cap
d- 2 pin cap
4958
c d
a b
Battery and Battery Cables

Selecting the Battery
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards, and U.S. Coast Guard regulations must be
adhered to when installing a battery. Be sure that the battery cable installation meets the pull test requirements and that the
positive battery terminal is properly insulated in accordance with regulations.
IMPORTANT: It is recommended and required in some locations that the battery be installed in an enclosed case. Refer to
the regulations for your area.
IMPORTANT: Do not use deep cycle batteries for the main engine starting battery.
IMPORTANT: The engine electrical system is negative (–) ground.
Select a battery that meets all of the following specifications:
• 12‑volt marine type.
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system,
leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to
avoid loose connections.
• Tapered post connectors or side terminal connectors. Do not use a battery with wing nut connectors.
• Battery capacity rating of at least:
DTS (Digital Throttle and Shift) or Mechanical Throttle and Shift —Battery Specifications
Minimum SAE Starting Battery Requirements ‑ BCI GRP 24
MCA 1000
CCA 800
Ah 180 (International Rating)
Battery Cable Installation Requirements

IMPORTANT: For DTS products, each engine must be equipped with its own starting battery. If your boat application requires
additional battery loads for boat accessories or marine electronics, install an auxiliary battery or batteries.
• For DTS products, each engine must be equipped with its own starting battery.
• Mechanical throttle and shift multiple‑engine installations (including generator sets) require that a negative cable be
connected between the engines. The cable must be of sufficient size to carry the highest cranking current that could be
encountered. Refer to ABYC standards.
• On applications with crossover (parallel) cranking motor circuits in mechanical throttle and shift multiple‑engine
installations (including generator sets), run a separate negative ground cable between the engines (in addition to the
cable mentioned above). Choose a cable size that will handle the highest load in the cranking circuit (ABYC standard).
• Route the battery cables above normal bilge water levels throughout their length.
• Route the battery cables to avoid contact with metallic fuel system components.
• Route the positive battery cable to avoid contact with any portion of the engine or drivetrain.
• Protect cables that are exposed to possible physical damage by using conduit, raceways, tape, etc.
• Protect cables that pass through bulkheads or other structural members against chafing by using grommets, etc.
• Connect the negative battery cable to the unpainted locations shown in Connecting the Battery Cables and Control
Harness to the Engine to ensure good electrical contact.
Page 4 / 38 90-8M0093780 JANUARY 2015

When connecting the engine battery, hex nuts must be used to secure the battery leads to the battery posts. Tighten the nuts
to the specified torque.

Battery hex nuts 13.5 120 –
IMPORTANT: Battery cable size and length is critical. Refer to the tables in Battery Cables for size requirements.
Spray the battery terminals with a battery connection sealant to help retard corrosion.
On DTS systems, the deep‑cycle battery admonishment decal needs to be placed on or near the battery box for future
service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are
not supplied.
NOTICE - DTS & OptiMax Engines

DO NOT USE DEEP CYCLE BATTERIES!
DTS (Digital Throttle and Shift) applications and
OptiMax engines must use a marine starting
battery with 1000 MCA, 800 CCA, or 180 Ah. rating.
13.5Nm (120 lbs. in.)
DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
Place decal on or near battery box for future service

reference. 5/16” and 3/8” hex nuts supplied for wing
nut replacement. Metric hex nuts not supplied.
3486
Battery Cables
Select proper size positive (+) and negative (‑) battery cables. Using the following chart, battery should be located as close to
engine as possible.
• Add the positive (+) and negative (‑) battery cable lengths together.
• Divide by 2 to obtain the average cable length.
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.
Cable Length Cable Gauge

Less than or equal to 1.1m (3.5 ft.) 25 mm2 (4)
1.1 ‑ 1.8m (3.5 ‑ 6 ft.) 35 mm2 (2)
1.8 ‑ 2.3m (6 ‑ 7.5 ft.) 50mm2 (1)
2.3 ‑ 2.9m (7.5 ‑ 9.5 ft.) 50mm2 (0)
2.9 ‑ 3.7m (9.5 ‑ 12 ft.) 70mm2 (00)
3.7 ‑ 4.6m (12 ‑ 15 ft.) 95mm2 (000)
4.6 ‑ 5.8m (15 ‑ 19 ft.) 120mm2 (0000)
Both positive (+) and negative (‑) cables
Mechanical Throttle and Shift—Battery Precautions for Multiple Engines

Alternators. Connect only one battery to one alternator. Do not connect two batteries to the same alternator unless a battery
isolator is used.
Electronic control module (ECM). The ECM requires a stable voltage supply. During voltage fluctuation, the ECM can
momentarily shut down. When this happens, a cylinder mis‑fire can occur. When the voltage stabilizes, the ECM will
automatically reset, and normal engine operation will resume.
Batteries. Boats with multiengine electronic control system (ECS) power packages require each engine be connected to its
own battery bank. This ensures that the engine's ECM has a stable voltage source.
90-8M0093780 JANUARY 2015 Page 5 / 38

Battery switches. Battery switches should always be positioned so each engine is running off its own battery. Do not operate
the engines with the switches in the "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. Isolators
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. Contact your Mercury Diesel product application engineer for a list of recommended products.
Generators. The same guidelines apply to the generator battery that apply to the engine batteries.
Connecting the Battery Cables and Control Harness to the Engine

1. Remove the bolt from either the two or three o'clock location on the bell housing.
2. Verify that the negative battery cable connection location on the bell housing is clear of paint or any other material that
could cause a poor electrical connection.
3. Secure the negative battery cable to the bell housing with the bolt, and tighten the bolt to the specified torque.

Bell housing bolt 65 – 48
4. Using a 13 mm socket, remove the nut and washer from the starter solenoid and install the positive battery cable. Install
the washer and nut and tighten to the specified torque.
a - Starter solenoid
b - Positive battery cable
a 1
50757

Starter solenoid nut 15 133 –
5. After the battery cables are connected to the engine, apply Liquid Neoprene to the connections to prevent corrosion.

25 Liquid Neoprene Battery terminals 92- 25711 3
6. Allow the Liquid Neoprene to dry. Protect the terminal with the rubber boot, if equipped.
Page 6 / 38 90-8M0093780 JANUARY 2015

7. Attach the vessel adapter extension harness to the central electrical panel and tighten the connector.
56456
Central electrical panel connector
Installing and Connecting the Vessel Adapter Assembly (VAA)

Installing the Vessel Adapter Assembly
Use the included hardware to install the vessel adapter assembly (VAA) in an accessible location. Its overall dimensions are
470 mm (18.5 in.) x 171.5 mm (6.75 in.) x 216 mm (8.5 in.). Be sure to allow enough space for cable connection and at least
another 216 mm (8.5 in.) to allow the access panel on the front to swing open.
The VAA weighs approximately 11 kg (24 lb).
Mount the VAA so the connectors do not face up.
c
a
e d 57567
a- 171.5 mm (6.75 in.)

b- 527.05 mm (20.75 in.)
c- 241.3 mm (9.5 in.)
d- 209.55 mm (8.25 in.)
e- 501.65 mm (19.75 in.)
Vessel Adapter Assembly Connections

Use the following illustration for all appropriate connections:
1. The CAN P, X, and H connectors are tagged. Use only those appropriate for your installation. The others must remain
weather capped.
2. The clean power connector is on the harness that connects to the engine harness.
90-8M0093780 JANUARY 2015 Page 7 / 38

3. The drive application connection is only used on inboard installations. The weather cap must be installed, if the
connection is not being used.
f g i
e h
52643
a- CAN P, X, and H terminator resistors

b- J1939 connector
c- Fuel lift pump
d- Fuse holder
e- Mechanical throttle potentiometer connection
NOTE: Not used on inboard models.
f - Vessel sensor harness connection
g - Drive application harness
NOTE: Use on inboard models only; weather capped on sterndrive models.
h - Helm harness connection (14‑pin data harness)
i - Clean power connection (unswitched battery connection)
j - Engine harness connection (from VAA to engine)
Page 8 / 38 90-8M0093780 JANUARY 2015

Vessel Sensor Harness Connections

The vessel sensor harness comes with tags identifying the individual connections. It is secured to the vessel adapter
assembly (VAA) with an Allen screw.
c
b d e
g
f h
i
a
j
52667
a- VAA connection
b- Paddle wheel connection
c- Tank level connection
d- Steer position connection
e- Trim position connection ‑ not used on inboard applications
f- Shift actuation connection ‑ not used on inboard applications
g- Seawater flow connection ‑ not used
h- Shift anticipate connection ‑ not used
i- Drive lube monitor connection ‑ not used on inboard applications
j- Trim pump connection ‑ not used on inboard applications
Remote Controls
There are many different remote controls available. Refer to the instructions supplied with the controls when installing.
Key Switch
Preparation
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
1. Ensure battery cables are disconnected.
! CAUTION
Avoid injury or product damage. Obstructions, such as braces and wiring, may be unseen when looking at the front of the
dashboard. Before drilling or cutting any holes in the dashboard, check the area behind the dashboard for obstructions. Do
not drill or cut when obstructions are present.
IMPORTANT: To ensure that water does not collect at the key switch and drains from the housing, install the key switch
a minimum of 10° from vertical.
2. Select a location for the key switch on the dashboard that meets the following requirements:
• unobstructed behind the dashboard
• within harness length limits
90-8M0093780 JANUARY 2015 Page 9 / 38

• able to position the switch a minimum of 10° from a vertical position

• adequate clearance between the components to install bezels, if equipped
3. If the dashboard is fiberglass, prevent the dashboard from chipping by applying masking tape to the area that is to be
drilled or cut.
4. If the dashboard is vinyl covered, keep the vinyl from tearing by removing the vinyl from the area to be drilled or cut.
5. The keyswitches can also be mounted in a remote panel, such as in the salon, using optional extension harnesses.
Follow the instructions included with your key switch.
Standard Mounting ‑ With Housing

1. Cut or drill a 54 mm (2‑1/8 in.) diameter hole through the dashboard at the selected location for each key switch.
2. Install the key switch housing assembly onto the key switch assembly.
3. Align the upper notch of the key switch assembly and housing. Following the instructions on the decal, ensure that the
drain hole with the yellow dot points down after installation for proper draining.
Yellow Dot Caution! Yellow Dot

Down Drain Hole Must Face Down Down a - Decal
b - Drain hole
c - Yellow dot
a
c
51994
4. Install the key switch nut. Tighten the nut to the specified torque.

Key switch nut 2.2 20 –
5. Install the cover and the bezel onto the key switch housing.
6. Install the gasket onto the key switch housing.
b a - Gasket
a b - Key switch housing
4403
7. Insert the key switch electrical connector, wiring, and key switch housing through the dash opening.
a a - Key switch housing
4058
NOTE: The ring mounting nut is threaded so that it can be installed to fit a thick or thin dashboard.
8. Install the ring mounting nut, depending on dash thickness, so that the most threads are engaged when it is threaded
onto the key switch housing.
Page 10 / 38 90-8M0093780 JANUARY 2015

b b
a
a 3893 3894
a - Thin dashboard a - Thick dashboard

b - Ring mounting nut orientation for a thin dashboard b - Ring mounting nut orientation for a thick dashboard
9. Position the key switch properly in the dash.

NOTE: The ring mounting nut must be tight so the assembly will not rotate during use.
10. Tighten the ring mounting nut securely.
Optional Mounting ‑ Without Housing

1. Cut a 22.5 mm (7/8 in.) oblong shaped hole that matches the key switch assembly threaded end with the opposing top
and bottom flat surfaces. This hole shape will keep the assembly from rotating during use.
b a - Distance between the flat surfaces ‑ 20 mm (25/32

in.)
b - Diameter of the hole ‑ 22.5 mm (7/8 in.)
a a
4734
2. Install one nut onto the key switch assembly with the flat flange of the nut toward the key end of the switch. Thread the
nut until it allows the key switch to extend through the dashboard with enough threads exposed for the second nut to be
installed.
IMPORTANT: There are two notches in the key switch assembly. The notch with white plastic showing is a drain
opening. To properly drain the key switch, this notch must point down when installed.
3. Install the key switch assembly into the dashboard oblong hole. Ensure that the drain opening notch, with the white
plastic showing, points down after installation for proper draining.
a - Drain opening notch with white plastic showing

a
4693
4. Install the remaining key switch nut. Tighten the nut to the specified torque.

Key switch nut 2.2 20 –
90-8M0093780 JANUARY 2015 Page 11 / 38

Key Switch Extension Harness

In the event that the key switch is not located close to the helm harness, a key switch extension harness can be used. This
harness extends the key switch circuits in various lengths. However, when using a key switch extension harness a start/stop
panel will be required to operate the engine. This is because the key switch extension harness removes the crank circuit from
the key switches.
31095
Installation
1. Connect one end of the key switch extension harness to the appropriate key switch connector on the helm harness.
2. Connect the other end of the key switch extension harness to the appropriate key switch.
Key Switch Wiring Connections

1. Install the ignition key switches. See the installation instructions outlined previously.
2. Connect the key switches to the helm harness as shown.
a- Start/stop switch connector (optional)

RUN b- Lanyard (E‑stop switch)
c- Ignition key switch connector
OFF
b d- Helm harness
26953
Start/Stop Panel
The start/stop panel allows the operator to start and stop the engines with the press of a single button. Each engine is
controlled independently. For the start/stop panel to function, the key switch must be in the on position. The start/stop panel is
optional if key switches are installed within the operator's reach.
28082
Page 12 / 38 90-8M0093780 JANUARY 2015

Preparation
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
1. Ensure that the battery cables are disconnected.
! CAUTION
2. Select a location for the start/stop panel on the dashboard that meets the following requirements:
• The location provides unobstructed access behind the dashboard.
• The location is within harness length limits.
• The location provides enough clearance between the components to install bezels, if equipped.
3. If the dashboard is fiberglass, prevent the dashboard from cracking by applying masking tape to the area that is to be
drilled or cut.
4. If the dashboard is vinyl covered, keep the vinyl from tearing by removing the vinyl from the area to be drilled or cut.
Installation
1. Cut or drill a 54 mm (2‑1/8 in.) diameter hole through the dashboard at the selected location.
2. Insert the start/stop panel electrical connector, wiring, and start/stop panel housing through the dash opening.
Behind the dashboard or panel

a - Port connector
b - Starboard connector
a c - Back of switch housing
b
31096
NOTE: The ring mounting nut is threaded so that it can be installed to fit a thick or thin dashboard.
3. Install the ring mounting nut so that most threads are engaged when threaded onto the key switch housing. The amount
of engaged threads will depend on the thickness of the dash.
4. Position the start/stop panel in the correct orientation on the dash.
NOTE: The ring mounting nut must be tight so the assembly will not rotate during use.
5. Tighten the ring mounting nut securely.
6. Connect the start/stop panel electrical connectors to the respective "START/STOP" connections on the helm harness.
90-8M0093780 JANUARY 2015 Page 13 / 38

E‑Stop Switch, If Equipped

The E‑stop switch offers a redundant emergency shutdown method if the key switch fails. The E‑stop switch is mounted at the
helm, and connects to the helm harness. The switch itself is a normally open, single‑pole, single‑throw rocker switch.
31992
Installation
Installation Recommendations:
Install the E‑stop switch in a place that is easy to access, but where it will not be accidentally activated.
1. Install the E‑stop switch in the dash using the dimensions provided below.
36.83 mm
(1.45 in.)
21.08mm
(0.83 in.)
31994
2. Connect the 2‑pin connector on the E‑stop switch harness labeled "STBD HELM" to the connector on the helm harness
labeled "STBD E‑STOP."
3. Connect the 2‑pin connector on the E‑stop switch harness labeled "PORT" to the connector on the helm harness labeled
"PORT E‑STOP."
Lanyard Stop Switch Installation

1. Select a location for the lanyard stop switch that will allow the lanyard to be pulled free without interference and will be
within wiring harness length limitations.
2. Mark the location for flush or surface mounting.
! CAUTION
3. If the dashboard is fiberglass, apply masking tape to area that is to be drilled to prevent the dashboard from chipping or
cracking.
4. If the dashboard is vinyl covered, remove the vinyl with a razor blade from the area to be drilled to prevent the vinyl from
tearing.
5. Surface Mounting:
a. Drill pilot holes for the self‑tapping screws. The appropriate drill size for aluminum is 4 mm (5/32 in.) and for wood or
fiberglass use drill size 4.5 mm (11/64 in.).
IMPORTANT: Ensure that wires are routed properly to prevent pinching the wires between the back of the switch
and the mounting surface.
Page 14 / 38 90-8M0093780 JANUARY 2015

b. Install the switch assembly using the surface mount adapter. Ensure that the wires are routed properly.
c a - Wire routing
a b - Self‑tapping screw (2)
c - Adapter
a
a
4932
6. Flush Mounting:
a. Using a hole saw, cut a 54 mm (2‑1/8 in.) hole in the desired location.
b. Install the switch assembly, using the mounting clamp behind the dashboard.
NOTE: To aid installation, first secure the screw to the switch using a nut.
c a - Nut to aid installation

a b - Mounting clamp
c - Washer and nut
4933
7. Route the switch wires to prevent possible chafing or flexing during boat operation.
8. Secure the wires with tie straps.
9. Connect the lanyard stop switch wires. Refer to the appropriate wiring diagram in this document.
Digital Throttle and Shift (DTS) Systems

Installation Guidelines for DTS System Components
! WARNING
Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring
failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do
not splice or probe into any wire insulation of the DTS system.
Data Harness
! WARNING
Prevent serious injury or death from a loss of boat control. Pulling on or flexing connectors can loosen terminals and cause
open or intermittent electrical connections, which will interrupt control of throttle and shifting. Do not pull on cable
connectors when pulling cables through the boat. Do not allow cables to flex at connection points. Fasten all electrical
harnesses within 25 cm (10 in.) of any connection.
Connectors
IMPORTANT: Connectors should never have to be forced into the receptacle. Ensure that connectors are free of any
lubricant or dielectric grease before installation. When the connector is properly aligned, it will only take a small amount of
pressure to insert it into the receptacle. Rotate the locking collar to secure the electrical connection.
90-8M0093780 JANUARY 2015 Page 15 / 38

NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do
not connect multiple harnesses together to make up the required length. For installations requiring a data harness length
longer than 12.2 m (40 ft), contact Mercury Marine for more information.
Data Harness Pulling Procedure

IMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads, and spark plugs), high
power VHF coax, or radios. An electrical field generated from these components could cause interference with data
transmission.
IMPORTANT: Do not route data harness near sharp edges, hot surfaces, or moving parts. Fasten cables away from any
sharp edges, fasteners, or objects that could wear into the harness.
IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be 7.6 cm (3 in.) for the final wiring
installation.
1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs that could cut the harness.
2. Install cable pulling tool to data harness.
3. Secure pulling tool with two cable ties.
IMPORTANT: The cable ties must be tight to prevent any slipping during installation.
3836
Data Cable Puller 888462A 1
IMPORTANT: Carefully inspect data harness pins to ensure that all pins are securely fastened to data harness connector end
following installation.
NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.
Junction Box (If Equipped)

• Although the junction box connections are watertight, it is recommended the junction box be mounted in an area that
stays relatively dry.
• Mount in an area where the wiring connection will not get stepped on or disturbed.
• Mount in an area that is accessible for troubleshooting and servicing the system.
• Ensure the DTS command module harness will reach all the connection points.
• Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.
• Seal all unused connections with weather caps.
a- Clamp
b- Weather cap (859318T 2)
b c c- Junction box
d- 25.4 cm (10 in.)
e- DTS command module harness
a d
29220
Page 16 / 38 90-8M0093780 JANUARY 2015

Connecting 14‑Pin Data Harness–Single Engine

Single Helm
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).
52597
a - 14‑pin data harness

b - Clamp or cable tie
Dual Helm
e
52598
a- 14‑pin data harness

b- Helm 2 (upper helm) – auxiliary
c- Helm 1 (lower helm) – primary
d- Dual helm adapter (Y harness)
e- Clamp or cable tie
90-8M0093780 JANUARY 2015 Page 17 / 38

Connecting 14‑Pin Data Harness–Dual Engine

Single Helm
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).
a - 14‑pin data harness

b
52599
Dual Helm
a- Helm 2 (upper helm)

a b- Helm 1 (lower helm)
c- 14‑pin data harness
d- Dual helm adapter (Y harness)
e- Clamp or cable tie
b
c
52601
Installing DTS Command Module and Harness–Single Engine

Harness Installation
• Locate a routing path for the harness connections so that they can reach their installation points.
Page 18 / 38 90-8M0093780 JANUARY 2015

• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.
• Fasten and support the harness with clamps or cable ties along the routing path.
• Make sure that all connections are tight, and seal all unused connectors with weather caps.
52602
a - DTS command module harness

90-8M0093780 JANUARY 2015 Page 19 / 38

NOTE: For dual‑helm application, remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (the helm
closest to the engine), and seal the connectors with weather caps.
a
c
Terminator Terminator
CAN 1 CAN 2
e f
d
g
c
b
52603
Dual-helm application
a - Helm 2 (upper helm)
b - Helm 1 (lower helm)
c - DTS command module harness
d - Clamp or cable tie
e - CAN P (CAN 1) connector
f - CAN X (CAN 2) connector
g - Weather caps
h - Terminator resistors, blue (CAN P and CAN X)
Module Installation
• Although the command module connection is watertight, we recommend mounting it in a dry location.
• Mount the command module in an area where the wiring connection will not get stepped on or disturbed.
• Mount the command module in an area that is accessible for troubleshooting and servicing the system.
• Ensure that the wiring harness connected to the command module will reach all of the connection points.
Page 20 / 38 90-8M0093780 JANUARY 2015

• Mount the command module with the supplied rubber grommets/bushings to minimize vibration.
a - DTS command module
3939
Installing DTS Command Module and Harness–Dual Engine

Harness Installation
• Locate a routing path for the harness connections so that they can reach their installation points.
• Make sure the routing‑path surfaces are free of any sharp edges or burrs that could cut the harness.
• Fasten and support the harness with clamps or cable ties along the routing path.
• Make sure that all connections are tight and seal all unused connectors with weather caps.
c
Single-helm application
Terminator
CAN 1
a - CAN link harness

b - CAN X (CAN 2) Terminator
a
Terminator
resistors ‑ do not remove
c - CAN P (CAN 1) connectors
CAN 2
b d - Clamp or cable tie

Terminator e - DTS command module
harness
CAN 2
Terminator
CAN 1
e
d 52605
90-8M0093780 JANUARY 2015 Page 21 / 38

NOTE: For dual‑helm application, remove the CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm
closest to the engine), and seal connectors with weather caps.
b
c
e
d
a 2
d
1
52606
Dual-helm application
a - Weather caps
b - CAN link harness
c - Helm 2
d - DTS command module harness
e - Termination resistors ‑ do not remove from helm 2
f - Helm 1
Module Installation
• Although the command module connection is watertight, it is recommended that it be mounted in an area that stays
relatively dry.
• Mount in an area where the wiring connection will not get stepped on or disturbed.
• Mount in an area that is accessible for troubleshooting and servicing the system.
Page 22 / 38 90-8M0093780 JANUARY 2015

• Ensure that the wiring harness connected to the command module will reach all of the connection points.
a - DTS command module
4080
Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRA Gray
GRN Green ORN Orange
PNK Pink PPL Purple
RED Red TAN Tan
WHT White YEL Yellow
LT Light DK Dark
90-8M0093780 JANUARY 2015 Page 23 / 38

Transom Harness—DTS
b
A
C
B
BLK-PNK
GRA-BLK
ORN-PNK
a C BLK-PNK
B PNK-DK BLU
R
A GRA-BLK
L
BLK-PNK A
C
GRA-BLK B
R
L WHT-LT BLU
d
A GRA-BLK ORN-WHT 1
B BLK-PNK
C WHT-LT BLU
D PNK-DK BLU e
E ORN-PNK ORN B
F ORN-WHT
G ORN BRN A
H BRN
J BLK
L R
K
L
BLK
BLK 1 f
M
N GRN
P PPL
BLK
R DK BLU
S
1
k
1
1
23810
g
j i h
a- Steering
b- Digital trim
c- Pitot
d- Analog trim
e- MerCathode
f- Analog trim
g- Ground
h- Trim down
i- Relay power
j- Trim up
k- 16‑pin connector
Page 24 / 38 90-8M0093780 JANUARY 2015

NOTES:
90-8M0093780 JANUARY 2015 Page 25 / 38

Typical DTS Control Wiring Diagrams

DTS Panel Control Wiring
c OFF O
d e
N
a
f
b BLK/YEL
BLK
BLK/YEL
BLK
WHITE
BLUE
+ -
i
BLK/ORG j
PUR/YEL
GRN/YEL k
GRN/ORG
GRN/RED
r q o
p n
5104
Page 26 / 38 90-8M0093780 JANUARY 2015

a- Remote control j- GPS connection

b- Remote control connections k- Cable adapter (male to female)
c- Key switch l- Weather caps
d- Start/stop switch (optional) m- Junction box (optional)
e- SmartCraft VesselView (optional) n- DTS command module harness
f- SmartCraft Link gauge (optional) o- Terminator resistors
g- Display harness p- DTS command module
h- Horn q- Accessory power relay (optional)
i- Horn r- Foot throttle (optional)
90-8M0093780 JANUARY 2015 Page 27 / 38

DTS Single‑Console Control Wiring
c d
OFF O
e
N
BLK/YEL
g
BLK
f
BLK/YEL
BLK h
WHITE
BLUE
j + -
BLK/ORG
PUR/YEL k
GRN/YEL l
GRN/ORG
GRN/RED
r m
s o
n
q
p
5103
Page 28 / 38 90-8M0093780 JANUARY 2015

a- Remote control k- GPS connection

b- Remote control connections l- Cable adapter
c- Lanyard stop switch m- Weather caps
d- Key switch n- Junction box (optional)
e- Start/stop switch (optional) o- Terminator resistor
f- SmartCraft VesselView (optional) p- DTS command module harness
g- SmartCraft Link gauge (optional) q- DTS command module
h- Display harness r- Accessory power relay (optional)
i- Horn s- Foot throttle (optional)
j- Horn
90-8M0093780 JANUARY 2015 Page 29 / 38

DTS Single‑Console Control Wiring with Dual Helm
BLK/WHT
BLK/YEL
f
d
BLK/YEL
BLK
e
b h
c
26 6
5
22 5
6
TANK LEVEL 4 4
FUEL 134
124 3
2
3
2
1 1
n
i
m
k j
o l
g
d
BLK/WHT
BLK/YEL
f
BLK/YEL
BLK
OFF
O
N
p
a h
s 26 6 22 6
5 5
TANK LEVEL 4 4
FUEL 134
3 3
124 2 2
1 1
n
i
m
j
t r q 56204
Page 30 / 38 90-8M0093780 JANUARY 2015

a- Helm 1 l- Terminator resistors (helm 2 only)

b- Helm 2 m- DTS command module
c- Clamps (use as required) n- DTS command module harness
d- Remote control o- Data harness
e- Key switch connector not used; seal with weather cap p- Key switch
f- Start/stop switch q- Accessory power relay
NOTE: Required at helm 2; optional at helm 1. r- Terminator resistors not used at helm 1; seal
g- Lanyard stop switch connectors with weather caps
h- VesselView (optional) s - Dual‑helm adapter harness
i- Horn t - Data harness to engine
j- Foot throttle connector
k- Accessory power relay connector (optional, not used at
second helm)
90-8M0093780 JANUARY 2015 Page 31 / 38

DTS Dual‑Console Control Wiring

NOTE: Optional foot throttle is not compatible with multiple‑engine applications.
b d
b
a c
k k
e
h
h
g
+ –
o o
l l
g f
f g
h
h
h
m
j n n i
12112
a- DTS control
b- Key switch
c- Lanyard stop switch
d- VesselView (optional)
e- Air temperature sensor
f- Command module
g- Horn
h- Clamp
i- To starboard engine
j- To port engine
k- Start/stop switch connector (optional)
l- Accessory power relay (optional)
m- CAN 1 link harness
n- CAN Z termination resistor
o- Junction box connector
Page 32 / 38 90-8M0093780 JANUARY 2015

NOTES:
90-8M0093780 JANUARY 2015 Page 33 / 38

DTS Dual‑Console Control Wiring with Dual Helm
c e
g
d d
f
BLK BLK/WHT BLK/WHT BLK

BLK/YEL BLK/YEL BLK/YEL BLK/YEL
b
n
d d
d m d
i i
o j k l k j o
p q p g
c
f
a BLK
BLK/YEL
BLK/WHT
BLK/YEL
BLK/WHT
BLK/YEL
BLK
BLK/YEL
t t r
r
o m o
i j u d d u j i
v s 56367
Page 34 / 38 90-8M0093780 JANUARY 2015

a- Helm 1 (primary) l- CAN link harness

b- Helm 2 (auxiliary) m- Horn
c- Remote control n- DTS command module harness
d- Connector not used; seal with weather cap o- Data harness
e- Start/stop switch (required at helm #2) p- Key switch
f- Lanyard stop switch q- Start/stop switch (optional at helm 1)
g- VesselView (optional) r- Dual helm adapter harness
h- Clamps (use as required) s- Data harness to starboard engine
i- DTS command module t- Accessory power relay
j- Junction box connection (optional) u- Remove terminator resistor and seal with weather cap
k- Terminator resistor (required at helm #2) v- Data harness to port engine
NOTE: The optional foot throttle is not compatible with multiple‑engine applications.
90-8M0093780 JANUARY 2015 Page 35 / 38

DTS Zero Effort Control Wiring–Single Engine

a
b
GRN/WHT
BLU/WHT
OFF O
N
RED
c
BLK/YEL
BLK
BLU/WHT
GRN/WHT
BLK/YEL
RED
BLK
e
WHT
BLU
k
+ -
f d
l
h g
j
i
56205
a- Start/stop switch (optional)

b- VesselView (optional)
c- SmartCraft Link gauge
d- GPS connection
e- Display harness
f- Cable adapter
g- Weather caps
h- Junction box
i- DTS command module
j- Accessory power relay (optional)
k- DTS command module harness
l- Adapter
Page 36 / 38 90-8M0093780 JANUARY 2015

DTS Zero Effort Control Wiring–Dual Engine
i f
BLU/WHT
GRN/WHT
RED
a
k k
GRN/WHT
BLU/WHT
RED
WHT
BLU
j
+
b
b d
d
c
e
e
g g
7725
a- VesselView (optional)
b- Horn
c- Junction box connection (optional)
d- Accessory power relay (optional)
e- DTS command module
f- To starboard engine
g- Terminator resistor
h- CAN link harness
i- To port engine
j- DTS command module harness
k- Connector ‑ Start/stop switch (optional)
90-8M0093780 JANUARY 2015 Page 37 / 38

NOTES:
Page 38 / 38 90-8M0093780 JANUARY 2015

SECTION - 8 REMOTE CONTROLS
SECTION 8 - REMOTE CONTROLS

Table of Contents
Power Trim System..................................................................................................................................................................... 2
Control.................................................................................................................................................................................. 2
Steering Helm and Cable............................................................................................................................................................ 2
Steering Cable Specifications............................................................................................................................................... 3
Mechanical Throttle and Shift—Remote Control and Cables...................................................................................................... 4
Propeller............................................................................................................................................................................... 4
Rotation On Dual Installations ...................................................................................................................................... 4
Direction Of Propeller Rotation .................................................................................................................................... 4
Throttle Bracket Installation.................................................................................................................................................. 4
Troubleshooting Shift Problems........................................................................................................................................... 6
Digital Throttle and Shift—Remote Control Installation............................................................................................................... 8
Locating and Drilling Mounting Area..................................................................................................................................... 8
Installing a DTS Panel Mount Control.................................................................................................................................. 8
Installing DTS Single‑Handle Console Control................................................................................................................... 10
Installing DTS Dual‑Handle Console Control..................................................................................................................... 12
Installing DTS Zero‑Effort Control...................................................................................................................................... 15
DTS Calibration......................................................................................................................................................................... 16
90-8M0093780 JANUARY 2015 Page 1 / 16

REMOTE CONTROLS SECTION - 8
Lubricant, Sealant, Adhesives

95 2-4-C with PTFE Shift cable eye ends and sliding surfaces 92-802859A 1
Special Tools
CDS G3 Diagnostic Interface Tool With
8M0046124
Harness
Provides diagnostic support for the Computer Diagnostic System.
41993
Power Trim System

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 the trim control in accordance with the instructions that accompany it.
Steering Helm and Cable

The 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.
! WARNING
Failure to use a steering cable locking device can cause serious injury or death due to loss of boat control. Use a locking
device, such as a self‑locking coupler or external locking device when installing steering controls.
All current production Quicksilver RideGuide steering cables have a self‑locking coupler nut and do not require an external
locking device. Other cable manufacturers also make cables with a self‑locking coupler nut.
a - Quicksilver RideGuide steering cable self‑locking

coupler nut (identified by groove)
7827
If the steering cable does not have a self‑locking coupler nut, use an external locking device.
c a- Steering cable
b e b- Grease fitting
c- Cotter pin
d- Locking sleeve (if required) (must be ordered separately)
e- Cable coupler nut
a f- Cable guide tube
d f 16814
Page 2 / 16 90-8M0093780 JANUARY 2015

Steering Cable Specifications

! WARNING
Failure to use the correct cables or other steering system components can cause serious injury or death due to loss of boat
control. Use only approved or required components when installing steering systems.
1. Ensure that the steering cable is the correct length, particularly when installed in larger boats.
2. Avoid sharp bends, kinks, or loops when routing the cable.
3. The fully extended end dimension of the power steering cable must be as shown in the following.
IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against the lock) may mean a steering cable has
been installed that has the incorrect dimensions.
c
a
b d
e g
f
C
L
j
k h
l i
7254
a- Coupler nut ‑ 7/8‑14 UNF ‑ 28 thread

b- 298 mm (11‑3/4 in.) minimum
c- Interface point
d- 12.7 mm (1/2 in.) maximum
e- 10.7 mm (27/64 in.) minimum flat
f- 3.1 mm (7/64 in.) minimum radius
g- 15.9 mm (5/8 in.) maximum diameter end fitting
h- 9.5 mm (3/8 in.)
i- 9.8 mm (3/8 in.) diameter through hole (chamfered each side)
j- 34.9 mm (1‑3/8 in.) maximum
k- 15.9 mm (5/8 in.) diameter tube
l- Cable travel:
• Mid‑travel position ‑ 429 mm (16‑7/8 in.)
• Total travel to be 203 mm (8 in.) minimum to 228 mm (9 in.) maximum
• Travel each side of mid‑travel position ‑ 102 mm (4 in.) minimum, 114 mm (4‑1/2 in.) maximum
90-8M0093780 JANUARY 2015 Page 3 / 16

Mechanical Throttle and Shift—Remote Control and Cables

Propeller
Rotation On Dual Installations
The best all‑around performance usually is obtained by installing engines so that propellers turn outboard (looking at the
stern).
Outboard propeller rotation

a - RH rotation
b - LH rotation
b a
16816
Direction Of Propeller Rotation

IMPORTANT: The direction of propeller rotation (RH or LH) for this drive unit is determined by the following method.
1. Determine desired propeller rotation according to a., b., or c.:
a. Bravo One or Two—If the shift cable end guide moves in direction "A" when the control lever is placed in
FORWARD, the remote control is set up for RIGHT HAND (RH) propeller rotation.
b. Bravo One or Two—If the shift cable end guide moves in direction "B" when the control lever is placed in
FORWARD, the remote control is set up for LEFT HAND (LH) propeller rotation.
B 6614
Bravo One / Two
c. Bravo Three—The front propeller on the drive unit is always LH rotation and the rear propeller is always RH
rotation. The shift cable end guide must move in the direction "A" when the control lever is placed in the FORWARD
gear position.
A
8519
Bravo Three
IMPORTANT: When installing shift cables, be sure that the cables are routed in such a way as to avoid sharp bends and
contact with moving parts. Do not fasten any items to the shift cables.
Throttle Bracket Installation

On non‑DTS models, the throttle cable connects to a throttle bracket, located on the bulkhead. A throttle position sensor then
transmits throttle position information to the vessel adapter assembly. Refer to Section 7 – Installing and Connecting the
Vessel Adapter Assembly.
Note the following requirements:
• The electronic throttle must be calibrated immediately after installation.
• The throttle arm assembly must contact the hard metal idle stop whenever the hand control lever is in the idle position.
Page 4 / 16 90-8M0093780 JANUARY 2015

• The control system must provide enough linear stroke at the lever connection to achieve 100% throttle.
• The cable must pull the throttle lever from idle to full throttle.
• The throttle assembly must be remotely mounted from the engine and isolated for direct sources of vibration.
• Mount the throttle bracket in a location that is protected from water spray or contact.
• Install the bracket onto a rigid, flat surface by using three 8 mm (3/8 in.) bolts and the appropriate mounting holes.
• Do not expose the throttle control to temperatures below ‑40 °C (‑40 °F) or higher than 105 °C (221 °F)
• The maximum actuator load may not exceed 1000 Nm (225 lb‑ft) under any condition.
• Secure the wire harness connections so that they are routed away from heat sources and mechanical interference.
• Wire harness lengths must not exceed 91 m (300 ft). Wire size must be 16 AWG minimum.
• The wire harnesses must be supported by cable ties or cable races no more than 300 mm (12 in.) apart and not subject
to excessive tension.
a
c d
e
h
g
f
52675
Throttle bracket
a - Cable retention slots (3)
b - Cable retention bracket
c - Idle validation switch connector (The idle validation switch is located under the throttle arm assembly.)
d - Throttle arm assembly
e - Side mounting holes (3)
f - Throttle position sensor and connector
g - Bottom mounting holes (3)
h - Cable direction
1. Locate a rigid mounting surface for the throttle bracket, preferably near the helm. It must be isolated from vibration
sources and protected from water. It can be mounted using either the three side or three bottom mounting holes.
2. Secure the bracket using three 8 mm (3/8 in.) screws.
90-8M0093780 JANUARY 2015 Page 5 / 16

3. Position the retention groove on the throttle cable into one of the three retention slots in the throttle bracket and install the
supplied jam nut and cable lug onto the throttle cable. Adjust them to position the cable lug to one of the three mounting
holes in the throttle arm assembly so that, in idle, the throttle arm assembly is at rest (its normal position) against the idle
validation switch, and at 100% throttle it positions the throttle arm assembly it its full‑forward position.
c
b
a
d
g
h
52794
a- Throttle cable
b- Jam nut
c- Cable lug
d- Cotter pin
e- Retaining nut
f- Throttle arm assembly
g- Throttle lug retaining bolt
h- Throttle bracket
i- Retention groove (hidden)
4. Secure the cable lug to the throttle arm assembly using the supplied retaining nut and cotter pin as shown.
5. Secure the cables with the cable retention bracket using the two 10‑32 x 0.375 screws provided.
6. Connect the throttle cable to the throttle position connector.
7. Connect the idle validation switch to the connector on the throttle harness.
8. To calibrate the idle validation switch to reduce deadband, (unresponsiveness) turn the keyswitch to ON without starting
the engine. Then quickly move the throttle lever from idle to full throttle and back to idle three times in quick succession.
Troubleshooting Shift Problems

NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or racheting is
encountered when shifting into forward gear.
1. When installing the control box in the side panel of the boat, make sure that the cables have enough clearance to
operate. This is necessary because the cables move up and down when the shift handle is moved. If the control box is
mounted too far back toward any structure, the cables will be interfered with; resulting in very hard shifting.
Page 6 / 16 90-8M0093780 JANUARY 2015

NOTE: The control box housing can be rotated in 30° increments to improve the cable routing.
7873
Proper cable bend
7872
Improper cable bend
2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull, it does not have any
extremely sharp bends in it or it will cause stiff shifting.
3. Before installing the shift cable into the control box, extend and lubricate the stainless rod eye end of the cable. Move
cable back and forth to distribute the lubricant.
a
a - Shift cable stainless rod eye
end
95
7325

95 2-4-C with PTFE Shift cable eye ends and sliding surfaces 92-802859A 1
4. Do not secure the control cables in any manner within 1 m (3 ft.) of the control box.
5. Do not secure the shift cable in any manner within 1.5 m (5 ft.) of the shift plate.
6. Ensure that the engine was not set down on the intermediate shift cable during installation as this will crush the inner
cable tubing and cause improper and/or stiff shifting.
90-8M0093780 JANUARY 2015 Page 7 / 16

7. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate
on the mounting stud.
Digital Throttle and Shift—Remote Control Installation

Locating and Drilling Mounting Area
1. Locate the area of boat where the remote control is to be mounted. Allow sufficient clearance for handle movement and
clearance for the wiring.
2. Select the correct template for the mounting application, supplied with the controls.
3. Place the template over the mounting area; cut and drill as instructed on the template.
IMPORTANT: After cutting the mounting area, make sure that the opening is free of sharp edges.
a - Template
3600
Installing a DTS Panel Mount Control

1. Ensure that the opening is free of sharp edges.
2. Route the wiring for the remote control into the opening.
26744
3. Connect the trim harness and lever harness.

4. Insert the bayonet end into bracket hole. This will prevent the connector from pulling out.
Page 8 / 16 90-8M0093780 JANUARY 2015

IMPORTANT: Allow some slack in the trim harness. The harness will flex and move during control handle movement.
a - Trim harness
b - Lever harness
5086
5. Place the remote control into the opening.
3250
6. Fasten the remote control with three #12 x 1.25 in. screws.
a - Mounting screw (3)
3251
7. Control handle tension adjustment –This screw can be adjusted to increase or decrease the overall effort needed to
move the control handle. This will help prevent the handle from unwanted motion. Turn the screw towards "+" to increase
tension or towards "–" to decrease tension.
90-8M0093780 JANUARY 2015 Page 9 / 16

8. Detent tension adjustment screw –This screw can be adjusted to increase or decrease the effort to move control
handle into or out of detent position. Turn the screw towards "+" to increase tension or towards "–" to decrease tension.
a - Control handle tension adjustment screw

b - Detent tension adjustment screw
b a
3252
9. Install the front and back bezel covers with attaching screws.
a - Front cover
b - Back cover
b
a c - Screw ‑ (2) M4 x 12
3254
Installing DTS Single‑Handle Console Control

3509
3. Connect the trim, lever, and trackpad harnesses.

4. Insert the bayonet end of the lever harness into bracket hole. This will prevent the connector from pulling out.
Page 10 / 16 90-8M0093780 JANUARY 2015

IMPORTANT: Allow slack in the trim harness. The harness will flex and move during control handle movement.
a - Trim harness
b - Lever harness
c - Trackpad harness
b
c
5098
3296
6. Fasten the remote control with four M6 x 40screws.
a - Mounting screw (4) M6 x 40

b - Washer
a c - Nut ‑ nylon insert
b
c 3297
90-8M0093780 JANUARY 2015 Page 11 / 16

! CAUTION
Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11
turns from the initial point of hex head contact with bracket.
7. Control handle tension adjustment screw –This screw can be adjusted to increase or decrease the overall effort to
move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn the screw toward
"+" to increase tension or toward "–" to decrease tension.
8. Detent tension adjustment screw –This screw can be adjusted to increase or decrease the effort to move the control
handle into or out of detent position. Turn the screw toward "+" to increase tension or toward "–" to decrease tension.
a - Detent tension adjustment

b - Control handle tension adjustment
a b
5102
9. Install the side cover with the attaching screws.
a - Attaching screws (4) M4 x 20

b - Side cover (2)
3298
Installing DTS Dual‑Handle Console Control

1. Make sure that the opening is free of sharp edges.
Page 12 / 16 90-8M0093780 JANUARY 2015

2. Route the wiring for the remote control into opening.
3606
3. Insert the bayonet ends into the bracket holes. This will prevent the connectors from pulling out.
IMPORTANT: Allow slack in the trim button harness going to the control handle. This harness will flex and move during
control handle movement.
a- Bayonet ends
b- Trim button harness
c- Blue paint dot
d- Yellow paint dot
e- Starboard engine
f- Port engine
b
c d
e f
a 3305
90-8M0093780 JANUARY 2015 Page 13 / 16

3306
5. Fasten the remote control with four M6 x 40 screws.
a - Mounting screw (4) M6 x 40

a b - Washer
c - Nut ‑ nylon insert
b
c
3307
! CAUTION
Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11
turns from the initial point of hex head contact with bracket.
6. Control handle tension adjustment screw –This screw can be adjusted to increase or decrease the overall effort to
move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+"
to increase tension or towards "–" to decrease tension.
7. Detent tension adjustment screw –This screw can be adjusted to increase or decrease the effort to move the control
handle into or out of detent position. Turn the screw toward "+" to increase tension or toward "–" to decrease tension.
a - Detent tension adjustment

b - Control handle tension adjustment
a b
5102
Page 14 / 16 90-8M0093780 JANUARY 2015

8. Install the side cover with attaching screws.
a - Side cover (2)

b - Attaching screws (4) M4 x 20
3308
Installing DTS Zero‑Effort Control

3. Connect the trim, lever, and adapter harnesses.
b a- Throttle adapter harness

B LU/W HT
G RN/W HT
b- Remote control
c
R ED
c- Trim harness
d- Trackpad ‑ not used
e- Lever 1 harness (blue)
f- Trim adapter harness
d
a
e
B LU/W HT
G RN/WHT
R ED
LEVER 1
f
5181
4. Ensure that the control is positioned so that the forward‑neutral‑reverse (F‑N‑R) decal is in the correct orientation.
a b b c
c a
d d
5182
Forward cant models Aft cant models

a - Reverse
b - Neutral
c - Forward
d - F‑N‑R decal location
90-8M0093780 JANUARY 2015 Page 15 / 16

5. Ensure that the control is positioned so that the forward‑neutral‑reverse (F‑N‑R) decal is in the correct orientation.
a- Throttle lever
b- Trim switch
c- Shift lever
d- F‑N‑R decal
d
d
c
a c
a
b b
4749
NOTICE
Chipped paint can lead to rapid corrosion. Always install a nylon washer between each screw and the control plate.
6. Secure the control to the console using the 8 x 1‑1/4 in. self‑tapping screws and nylon washers.
a a- 8 x 1‑1/4 in. self tapping screw (4)

b- Nylon washer (4)
c- Control quadrant assembly
b d- Console
c
d
5192
DTS Calibration
NOTE: DTS system calibration must be performed following complete system installation. It must also be completed after an
accessory or replacement part is added to the system that requires new configuration codes. A DTS system reset must be
performed prior to calibration, or if an error is made during the calibration setup.
Connect the CDS G3 diagnostic interface tool to the CAN bus circuit and follow the helm configuration setup on the computer
diagnostic screen.
CDS G3 Diagnostic Interface Tool With

8M0046124
Harness
Page 16 / 16 90-8M0093780 JANUARY 2015

SECTION - 9 PREDELIVERY PREPARATION AND STORAGE
SECTION 9 - PREDELIVERY PREPARATION AND

STORAGE
Table of Contents
Predelivery Preparation............................................................................................................................................................... 2
Propeller Selection...................................................................................................................................................................... 2
Engine Operation Testing............................................................................................................................................................ 2
Testing Preparation.............................................................................................................................................................. 2
Boat Out of the Water........................................................................................................................................................... 3
Boat in the Water.................................................................................................................................................................. 3
Testing.................................................................................................................................................................................. 4
Boat‑in‑the‑Water Tests....................................................................................................................................................... 4
Engine Initial Break‑In Procedure ................................................................................................................................ 4
Maximum RPM Test............................................................................................................................................................. 4
After Operating the Engine................................................................................................................................................... 5
Predelivery Inspection Checklist................................................................................................................................................. 5
90-8M0093780 JANUARY 2015 Page 1 / 6

PREDELIVERY PREPARATION AND STORAGE SECTION - 9
Predelivery Preparation
NOTICE
Before starting predelivery, read General Information and Installation Requirements completely.
Take the following final steps to prepare the power package for delivery to the customer after the power package installation
is complete. It is the boat manufacturer's responsibility to perform these procedures or to ensure that the dealer completes
these procedures.
Propeller Selection
IMPORTANT: The installed propeller must allow the engine to operate at the engine rated revolutions per minute (RPM). Use
an accurate service tachometer to verify engine operating RPM.
It is the responsibility of the boat manufacturer and the selling dealer to equip the power package with the correct propellers.
Refer to the Mercury Diesel Parts and Accessories Guide and read Everything You Need To Know About Propellers.
The specified engine rated RPM is listed in the appropriate Performance Curve and Data Sheet (available at
www.mercurymarine.com/engines/diesel/).
Select a propeller that will allow the engine power package to operate at the engine rated RPM 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 engine rated RPM, the propeller must be changed to prevent loss of performance and
possible engine damage. On the other hand, operating an engine above the engine rated RPM will cause higher than normal
wear or damage.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:
1. Warmer weather and greater humidity cause an RPM loss (not as significant on electronic control models).
2. Operating in a higher elevation causes an RPM loss (not as significant on electronic control models).
3. Operating with increased load (additional passengers, pulling skiers, etc.).
For better acceleration, such as is needed for waterskiing, 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.
Refer to Boat in the Water Tests, Maximum RPM Test in this installation manual.
Engine Operation Testing

! WARNING
Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine
are not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines,
unless provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).
! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution
when performing a test that requires the engine running, and remove the propeller to avoid injury.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
Provide a sufficient supply of water to the water inlets during operation.
1. Ensure that the cooling system drain plugs and petcocks are installed and tight.
2. Ensure that the cooling system hoses are installed and clamped securely.
Testing Preparation
! WARNING
Leaving the helm unattended while performing tests with the boat in the water may result in loss of boat control causing
serious injury or death. Ensure someone is at the helm at all times, unless the boat is secured to a dock.
Page 2 / 6 90-8M0093780 JANUARY 2015

NOTE: Refer to the appropriate Mercury Diesel Operation, Maintenance, and Warranty Manual for operating specifications
and fluid capacities.
1. Check the drive belt tension.
2. Check the closed cooling system fluid level.
NOTICE
With the engine running, the crankshaft journals or rod journals may strike and break the dipstick, resulting in damage to
internal engine components. Stop the engine completely before removing or inserting the dipstick.
3. Check the engine oil level.
4. Check the power trim fluid level.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and
overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water
supply.
5. Ensure that a sufficient supply of cooling water is available to the seawater inlets.
Boat Out of the Water

For engine operation tests with the boat out of the water:
! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution
when performing a test that requires the engine running, and remove the propeller to avoid injury.
1. Remove the propeller.

2. Connect an alternate water supply hose to the engine seawater pump inlet.
56928
Seawater pump inlet
3. Open the water source about 1/2 maximum pressure. Do not use full water pressure.
4. Proceed to Testing.
Boat in the Water

The following information is for engine operation tests with the boat in the water:
! WARNING
IMPORTANT: If using a test tank, the water level must be above the water inlet holes on the through‑the‑hull pickup.
1. Ensure that the water level is above the water inlet holes on the through‑the‑hull water inlet.
2. Proceed to Testing.
90-8M0093780 JANUARY 2015 Page 3 / 6

Testing
! WARNING
1. Supply water to the engine either by putting the boat in the water or by using the correct flush attachments.
2. Refer to the Operation, Maintenance, and Warranty Manual for starting information.
3. Start the engine.
4. In throttle‑only mode, operate at a fast idle RPM until the water temperature is normal.
5. Watch all the gauges for normal readings.
6. Set the engine to idle RPM.
7. Inspect the engine compartment for water, oil, fuel, and exhaust leaks.
8. Ensure that the remote control shift cable installation results in correct forward and reverse gear operation.
a. Move the remote control handle to FORWARD, idle speed position.
b. Check that the propeller shaft is turning in the FORWARD direction.
c. Shift the remote control handle to NEUTRAL, idle speed position.
d. Check that the propeller shaft is not turning.
e. Shift the remote control handle to REVERSE, idle speed position.
f. Check that the propeller shaft is turning in the REVERSE direction.
g. If the power package will not shift, check that the shift cables are properly connected.
IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and contact with
moving parts. Do not fasten any items to the shift cables.
9. Turn the key switch to the "OFF" position to stop the engine.
10. If operating with the boat out of the water, discontinue supplying cooling water to the power package.
Boat‑in‑the‑Water Tests
IMPORTANT: Do not perform the following with the boat in a test tank or tied to a dock.
Engine Initial Break-In Procedure

IMPORTANT: Use the following procedure on new diesel engines. This break‑in procedure allows the proper seating of the
pistons and rings, which greatly reduces the likelihood of low‑hour problems.
IMPORTANT: Mercury Diesel recommends that the boat not be accelerated hard until this procedure has been completed.
The initial break‑in procedure is as follows:
1. Start the engine and operate at a fast idle until coolant has reached a minimum operating temperature of 65° C (150° F).
2. Operate the engine in gear for three minutes at each of the following: 1200 RPM, 2400 RPM, and 3000 RPM.
3. Operate the engine in gear for three minutes at each of the following: 1500 RPM, 2800 RPM, and 3400 RPM.
4. Operate the engine in gear for three minutes at each of the following: 1800 RPM, 3000 RPM, and the maximum engine
rated RPM.
Maximum RPM Test

The power package must be equipped with a propeller that will allow the engine to operate at or slightly above the rated–
engine RPM (revolutions per minute) at wide‑open throttle.
To test if propellers with the correct pitch have been installed, operate the boat with a maximum load on board at wide open
throttle (WOT) and check engine RPM. Engine RPM must not be less than the rated RPM. If engine RPM is too high, use
propellers with a higher pitch. If engine RPM is too low, use propellers with a lower pitch.
IMPORTANT: To operate the engine at rated RPM before the 20‑hour break‑in period is complete, follow this procedure:
1. Perform the Engine Initial Break‑in Procedure, if not already completed.
2. Start the engine and operate at idle RPM until it reaches normal operating temperature.
3. Run the boat up on plane.
4. Advance the engine RPM (in 200 RPM increments) until the engine reaches its rated engine RPM, or WOT. If maximum
rated RPM is not possible or the engine operates against the RPM limiter the propeller is not correct.
IMPORTANT: Do not operate at WOT RPM for more than two minutes.
Page 4 / 6 90-8M0093780 JANUARY 2015

After Operating the Engine

1. Disconnect both battery cables from the battery.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the
boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling
system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
IMPORTANT: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the
operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.
2. If the power package will not be used for an extended period of time, or if it will be exposed to freezing temperatures,
drain the water from the seawater cooling system. Refer to Cold Weather (Freezing Temperature), Seasonal Storage,
and Extended Storage in the Owner's Manual.
Predelivery Inspection Checklist

Not Check/ Not Check/
CHECK BEFORE RUNNING ON‑THE‑WATER TEST
Applicable Adjust Applicable Adjust
⃞ ⃞ Drain plug in and petcocks closed ⃞ ⃞ Engine alignment (Inboards only)
⃞ ⃞ Seawater inlet valve open ⃞ ⃞ Starter neutral safety switch operation
⃞ ⃞ Engine mounts tight ⃞ ⃞ Water pump operation
⃞ ⃞ Engine alignment ⃞ ⃞ Instruments operation
⃞ ⃞ Drive unit fasteners torqued ⃞ ⃞ Fuel leaks
⃞ ⃞ Power trim cylinder fasteners tight ⃞ ⃞ Oil leaks
⃞ ⃞ Battery fully charged and secured ⃞ ⃞ Water leaks
⃞ ⃞ All electrical connections tight ⃞ ⃞ Exhaust leaks
⃞ ⃞ Exhaust system hose clamps tight ⃞ ⃞ Ignition timing
⃞ ⃞ All fuel connections tight ⃞ ⃞ Idle________ RPM, within specifications
Correct rotation propeller (installed
⃞ ⃞ ⃞ ⃞ Forward ‑ Neutral ‑ Reverse gear operation
and torqued)
Throttle, shift, and steering system
⃞ ⃞ ⃞ ⃞ Steering operation throughout range
fasteners tightened properly
⃞ ⃞ Crankcase oil level ⃞ ⃞ Acceleration from idle RPM
WOT________ RPM within specifications (in
⃞ ⃞ Power trim oil level ⃞ ⃞
FORWARD gear)
⃞ ⃞ Sterndrive oil level ⃞ ⃞ Power trim operation
⃞ ⃞ Power steering fluid level ⃞ ⃞ Trim tab adjustment
⃞ ⃞ Closed cooling level ⃞ ⃞ Boat handling
⃞ ⃞ Transmission fluid level AFTER ON‑THE‑WATER TEST
⃞ ⃞ Alternator belt tension ⃞ ⃞ Propeller nut torque
⃞ ⃞ Seawater pickup pump belt tension ⃞ ⃞ Fuel, oil, coolant, water, and fluid leaks
⃞ ⃞ Power steering pump belt tension ⃞ ⃞ Oil and fluid levels
Apply Mercury Corrosion Guard to engine
⃞ ⃞ Audio warning system operation ⃞ ⃞
package
C.A.R.B. hang tag and owner's manual in
⃞ ⃞
boat (if registered to a CA resident)
C.A.R.B. decal properly affixed to boat hull
⃞ ⃞
(if registered to a CA resident)
90-8M0093780 JANUARY 2015 Page 5 / 6

NOTES:
Page 6 / 6 90-8M0093780 JANUARY 2015

4.2 TDI - 8M0093780 - Manual de Instalacao

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4.2 TDI - 8M0093780 - Manual de Instalacao

Uploaded by

Copyright:

Available Formats

© MERCURY MARINE. All rights reserved.

Reproduction in whole or in part without permission is

4.2L TDI DIESEL STERNDRIVE MODELS

Notice to Boat Manufacturer or Installer

Additional alerts provide information that requires special attention:

IMPORTANT: Identifies information essential to the successful completion of the task.

Page i © 2015 Mercury Marine 90-8M0093780 JANUARY 2015

SECTION 1 - IMPORTANT INFORMATION 1

90-8M0093780 JANUARY 2015 Page 1 / 8

Lubricants, Sealants, Adhesives

Description Nm lb–in. lb–ft

Remote Controls and Instrumentation for the DTS System

Page 2 / 8 90-8M0093780 JANUARY 2015

• Operation, Maintenance, and Warranty Manual identification page.

Engine specification and serial number decal

Engine Data Label Location

Bravo Sterndrive Serial Number and Identification

Bravo sterndrive information on ground plate

Bravo sterndrive serial number stamping

90-8M0093780 JANUARY 2015 Page 3 / 8

Bravo Transom Serial Number

Bravo transom assembly U-bolt plate

Gimbal housing with serial

Multiple Sterndrive Steering Tie Bar Arrangements

Internal Tie Bar Only

Internal and External Tie Bar

Page 4 / 8 90-8M0093780 JANUARY 2015

External Power Steering

External Power Steering With Low External Tie Bar

Stainless Steel Fasteners

Tube Ref No. Description Where Used Part No.

Anodes and the MerCathode System

90-8M0093780 JANUARY 2015 Page 5 / 8

a- Gearcase anodic plate

Anodes and MerCathode System Locations

Mounted on the underside of the

Ventilation plate anode Mounted on the front of the gearcase.

The MerCathode electrode is

Mounted on each of the trim

Propeller shaft anode Located behind the aft propeller.

Page 6 / 8 90-8M0093780 JANUARY 2015

Anodes and MerCathode System Locations

Anode kit (if equipped) Mounted to the boat transom.

Mounting the MerCathode

MerCathode mounting bracket

Reference Electrode Wire of the MerCathode System

90-8M0093780 JANUARY 2015 Page 7 / 8

a - Painted boat transom

c a- Ground wire between the gimbal ring and gimbal housing

Page 8 / 8 90-8M0093780 JANUARY 2015

SECTION 2 - BOAT CONSTRUCTION

90-8M0093780 JANUARY 2015 Page 1 / 4

Page 2 / 4 90-8M0093780 JANUARY 2015

Combustion Air Requirements (4.2L Models)

Inlet Air Temperature

90-8M0093780 JANUARY 2015 Page 3 / 4

Page 4 / 4 90-8M0093780 JANUARY 2015

SECTION 3 - EXHAUST SYSTEM

90-8M0093780 JANUARY 2015 Page 1 / 12

Emission‑Related Installation Instructions

Controlling Evaporative Emissions

Emission Control Information Label

Exhaust Elbow Height (Sterndrive)

Model (c) = (a) Minus (b)