QSD 2.0 - 869261

Cummins MerCruiser Diesel
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks
of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
QSD 2.0L DIESEL STERNDRIVE MODELS

INSTALLATION MANUAL
Models Covered
Sterndrive
Models Covered Serial Number
QSD 2.0 Sterndrives 88201000 and above
Notice
NOTICE
After completing installation, place these instructions with the product for the owner's future use.
NOTICE
Predelivery preparation procedures must be performed before delivering the boat to the product
owner.
Notice to Boat Manufacturer and Installer

This publication uses dangers, warnings, cautions, and notices (accompanied by the
international hazard symbol) to alert the manufacturer or installer about special instructions
concerning a particular service or operation that may be hazardous if it is performed
incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product
safety information in product manuals, instructions, and other collateral materials. Observe
them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strictly comply with
these special instructions and use common sense when performing service to prevent
accidents.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! 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.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component
failure.
Page i © 2008 Mercury Marine 90-869261 MAY 2008

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.
NOTE: Refer to the appropriate Cummins MerCruiser Diesel® product applications
manual for application recommendations.
This installation manual has been written and published by Cummins MerCruiser Diesel
(CMD®) to aid the boat manufacturer (OEM) in the installation of the products described
herein.
This manual assumes that OEM personnel are familiar with marine product installation and
are familiar with, if not trained in, the recommended installation procedures of Cummins
MerCruiser Diesel products.
We cannot anticipate all conceivable installations and their possible hazards or results.
Therefore, the OEM is responsible for any installation that does not fulfill the requirements
of this manual.
It is the responsibility of the boat manufacturer to select the appropriate
engine‑transom‑drive package (including the correct gear ratio and propeller) for a given
boat. Cummins MerCruiser Diesel recommends that any new or unique hull–power
package combination be thoroughly water‑tested before sale to verify that the boat
performs as desired and that the engine operates at rated RPM at wide‑open throttle
(WOT).
For assistance contact a Cummins MerCruiser Diesel distribution application engineer.
This manual covers the basic installation instructions for installation of the QSD engine.
For additional instrumentation installation information, please contact your local Cummins
MerCruiser Diesel Distributor Field Service Engineer (DFSE) or your Factory Original
Equipment Manufacturer (OEM) Account Manager.
All information, illustrations, and specifications contained in this manual are based on the
latest product information available at time of publication. Cummins MerCruiser Diesel
reserves the right to make changes at any time without obligation.
Page ii
Manual Outline
1 - Important Information
Important Information
1
2 - Boat Construction
3 - Exhaust System
Boat Construction
2
3
4 - Fuel System
Exhaust System
5 - Cooling System
6 - Drive System and Engine Mounting
7 - Starting and Electrical
8 - Remote Controls
Fuel System
4
9 - Predelivery Preparation and Storage
Cooling System
5
Drive System and Engine Mounting
6
Starting and Electrical
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
Sales and Technical Assistance........................................................................................................................2
Torque Specifications QSD 2.0L Diesel Alpha Sterndrives............................................................................... 2
Torque Specifications—Bravo Sterndrive.........................................................................................................2
Quicksilver Products—Accessories................................................................................................................... 3
SeaCore Components and Castings.................................................................................................................3
Stainless Steel Fasteners.................................................................................................................................. 3
Trim‑in Limit Insert............................................................................................................................................. 3
Identification............................................................................................................................................................ 4
Serial Number Decal.........................................................................................................................................4
Engine Data Plate.............................................................................................................................................4
Dataplate location..............................................................................................................................................5
Alpha Sterndrive Decal Identification................................................................................................................5
Alpha Transom Serial Number..........................................................................................................................6
Bravo Sterndrive Serial Number and Identification...........................................................................................7
Bravo Transom Serial Number..........................................................................................................................8
Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 8
Internal Tie Bar Only.........................................................................................................................................9
Internal and External Tie Bar.............................................................................................................................9
External Power Steering....................................................................................................................................9
External Power Steering With Low External Tie Bar.........................................................................................9
Corrosion Protection................................................................................................................................................ 9
General Information...........................................................................................................................................9
Sacrificial Anodes and the MerCathode System ............................................................................................10
Reference Electrode Wire of the MerCathode System (if Equipped)..............................................................10
Anti‑Fouling Paint............................................................................................................................................11
90-869261 MAY 2008 Page 1 / 12

IMPORTANT INFORMATION SECTION - 1
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
34 Special Lubricant 101 Threads of stainless steel fasteners 92-802865Q02
General Information
Sales and Technical Assistance
Cummins MerCruiser Diesel (CMD) distributor network is trained to assist you with any sales or
technical issues. This includes application engineering and service.
If you have an issue with the application of our product that cannot resolved, contact your CMD
distributor Application Engineer. All requests for assistance should be directed to your local CMD
distributor. The distributor for your area can be found by using the service locator on the Cummins
website (www.Cummins.com) or by contacting 1‑800‑DIESELS (1‑800‑343‑7357). If further
technical assistance is needed, contact us at our email address wavemaster@cummins.com.
Torque Specifications QSD 2.0L Diesel Alpha Sterndrives
NOTE: Torque all fasteners below to their listed specification; securely tighten all other fasteners.
NOTE: The propeller torque stated is the minimum torque value.
Description Nm lb. in. lb. ft.
Trim cylinder shock piston bolt 23.5 17.5
Trim cylinder end cap 61 45
Transom assembly fasteners 34 25
Pivot bolts 34 25
Coupler nut 47 35
Exhaust pipe bolts 27 20
Rear engine mounting bolts 47 35
Engine mount locknuts 80 59
Trunnion clamping bolts 57 42
Flywheel housing bolts 44 33
Sterndrive to bell housing fasteners 68 50
75 55
Alpha propeller nut
Then align tabs with grooves
Hose clamps 3.4‑6.8 30‑60
Battery stud 8‑11 71‑97
Positive battery cable stud nut at starter solenoid 10 88
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
81 – 60
Bravo Two propeller nut
Transom assembly hardware 31 – 23
Page 2 / 12 90-869261 MAY 2008


Block‑off plate bolt 5 45 –
Water inlet fitting bolt 5 45 –
Pivot bolts 34 – 25
Exhaust pipe assembly bolts 31 – 23
Rear engine mounting bolts 51 – 38
Seawater inlet nut 42 – 35
Sterndrive unit fasteners 68 – 50
Quicksilver Products—Accessories
Quicksilver remote controls, steering systems, and other accessories are available for this product.
Refer to the Diesel Parts And Accessories Guide (90-892645005) for complete listing.
This Guide is available from:
Mercury Marine
Attn: Parts Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
USA
Outside of U.S.A., order through distribution center, or distributor.
SeaCore Components and Castings
Cummins MerCruiser Diesel SeaCore power packages are equipped with additional stainless steel
components and certain aluminum castings with special coatings. Do not replace SeaCore
components with non‑SeaCore components. Use only the specified Cummins MerCruiser Diesel
SeaCore components and castings on these power packages.
Stainless Steel Fasteners
SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion
resistance in salt water 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 Special Lubricant 101 or an equivalent, on the threads of stainless steel
fasteners during installation to avoid galling. Lubricate at least the first 8 mm (1/4 in.) of the threads
before installation.

Threads of stainless steel
34 Special Lubricant 101 92-802865Q02
fasteners
Trim‑in Limit Insert

NOTE: Bravo One, Two and Three Models are equipped with a trim‑in limit insert.
It has been brought to our attention that some boats (predominantly deep‑V heavy boats) will roll
up on their side under certain operating conditions. The roll can be either to port or starboard and
may be experienced while moving straight ahead or making a turn. The roll occurs most frequently
at or near maximum speed, with the sterndrive trimmed at or near full trim‑in. Although the boat
will not roll completely over, the roll may be sufficient to unseat the operator or passengers and
thereby create an unsafe situation.
The roll is caused by stern lift created from excessive trim‑in of the sterndrive. Redistributing the
weight sternward can reduce stern‑lift and help to control the condition. The distribution of weight
forward, to port, or starboard may worsen the condition.
90-869261 MAY 2008 Page 3 / 12

The trim‑in limit insert reduces stern lift by preventing the sterndrive from reaching the last few
degrees of full trim‑under. Although this device should reduce the tendency to roll, it may not
eliminate the tendency entirely. The need for this trim‑in limit insert, and its effectiveness, can only
be determined through boat testing and is ultimately the responsibility of the boat manufacturer.
! WARNING
On some boats, increased trim‑in range can cause handling problems at high speeds, resulting
in personal injury or death. We recommend that only qualified personnel adjust the trim‑in limit
inserts and test the boat for handling problems.
The trim‑in limit insert must be positioned as shown for the appropriate Bravo model.
a a
8548 8557
Bravo One and Two (positioned forward) Bravo Three (positioned aft)
a - Trim‑in limit insert
Identification
Serial Number Decal
The serial number decal is located on the engine and indicates the engine's CMD serial number,
transom serial number, drive serial number, and the fill cap color codes for engine fluids.
25986
Serial number decal
Engine Data Plate

A tamper‑resistant engine data plate is affixed to the engine at the time of manufacture by
Cummins MerCruiser Diesel. It contains important exhaust gas emissions information. Please note
that the engine data plate will not affect the fit, function, or performance of the engine and neither
boatbuilders nor dealers may remove the engine data plate or the engine component it is affixed
to before sale. If modifications are necessary or the engine data plate is damaged contact
Cummins MerCruiser Diesel for a replacement.
Page 4 / 12 90-869261 MAY 2008

The owner or operator is not to modify the engine in any manner that would alter the horsepower
or allow exhaust gas emission levels to exceed their predetermined factory specifications.
a b c
d
j
e
f
g
h k
i
25401
QSD engine data plate
a- Engine serial number g- Minimum idle speed
b- Cummins MerCruiser Diesel model h- Engine power rating
information i- Engine weight
c- Emissions certification information j- Emissions data
d- Fuel rate k- Manufacturer model number, IMO
e- Rated operation engine speed type, liters per cylinder
f- Governed engine speed
Dataplate location
The engine dataplate is located on the side of the integrated exhaust manifold and expansion tank
assembly.
25635
QSD 2.0 engine dataplate
Alpha Sterndrive Decal Identification

The Drive Serial No. is located on the port side of the alpha sterndrive.
90-869261 MAY 2008 Page 5 / 12

The Drive Ratio is located on the starboard side of the alpha sterndrive.
a b
25681
Alpha sterndrive
a - Drive gear ratio decal (starboard) b - Serial number decal (port)
Alpha Transom Serial Number

The transom serial number is located on the top of the transom assembly.
25619
Alpha transom assembly serial number
Page 6 / 12 90-869261 MAY 2008

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
90-869261 MAY 2008 Page 7 / 12

Bravo Transom Serial Number

The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.
25904
Bravo transom assembly U‑bolt plate

a - Transom assembly serial Number
The serial number is also stamped on the gimbal housing. This is used as a permanent reference
for Cummins MerCruiser Diesel Authorized Repair Facilities.
25905
Gimbal housing with serial number stamping
a - Transom assembly serial Number
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.
Page 8 / 12 90-869261 MAY 2008

Internal Tie Bar Only

At the lower end of the performance spectrum—(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 from the sterndrive manufacturer.
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 (P/N 90362A3) should be installed so as to
limit this potential tilt differential to about 20 degrees.
IMPORTANT: Cummins MerCruiser Diesel does not recommend the use of an external tie bar
ONLY with no internal tie bar when using the internal power steering system. This can cause
excessive loads on the steering components on the 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 Protection
General Information
Cummins MerCruiser Diesel power packages are equipped with sacrificial anodes to help protect
them from galvanic corrosion under most conditions. Cummins MerCruiser Diesel recommends
installation of the optional MerCathode System (the MerCathode System is standard equipment
for some models) if the vessel is operated under severe conditions or when using a stainless steel
propeller. We offer a Quicksilver Anti‑Corrosion Anode Kit and a MerCathode Monitor, which
provides additional corrosion protection and the ability to check MerCathode System operation.
Refer to the Cummins MerCruiser Diesel Parts And Accessories Guide for part numbers.
For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine
Corrosion Protection Guide.
IMPORTANT: If AC shore power is not isolated from boat ground the MerCathode System (if
equipped) and sacrificial anodes may be unable to handle the increased galvanic corrosion
potential.
Boats that are connected to AC shore power require additional protection to prevent destructive
low voltage galvanic currents from passing through the shore power ground wire. Install a
Quicksilver Galvanic Isolator to block the passage of these currents while still providing a path to
ground. Refer to the Cummins MerCruiser Diesel Parts And Accessories Guide for the part
number.
90-869261 MAY 2008 Page 9 / 12

Sacrificial Anodes and the MerCathode System

A sacrificial anode located in the rear cover of the engine aftercooler assists in protecting the
engine and the seawater cooling system from corrosion.
25583
Engine sacrificial anode
5
1
4 3 6
22037
Sterndrive anode locations
1 - Gearcase anodic plate 4 - Anode block kit on hull, if equipped
2 - Ventilation plate anode 5 - Trim cylinder anodes
3 - MerCathode System, if equipped 6 - Bearing carrier anodes
MerCathode System (if equipped) The MerCathode assembly replaces the anode block. Test
the MerCathode system to ensure adequate output. This test should be performed where the boat
is moored, using a Quicksilver Reference Electrode and Test Meter. See the appropriate service
manual or contact your Authorized Cummins MerCruiser Diesel repair facility for additional
information.
Reference Electrode Wire of the MerCathode System (if Equipped)
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.
Page 10 / 12 90-869261 MAY 2008

Do not pressure‑wash the MerCathode assembly. Doing so will damage the coating on the
reference electrode wire and decrease corrosion protection.
b
21563
MerCathode—mounted to the underside of the gimbal housing

a - MerCathode reference electrode wire
b - Anode
Anti‑Fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint
will not be covered by the limited warranty.
Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat
transom but you must observe the following precautions:
IMPORTANT: Do not paint anodes or MerCathode System reference electrode and anode, as this
will render them ineffective as galvanic corrosion inhibitors.
90-869261 MAY 2008 Page 11 / 12

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 Cummins MerCruiser Diesel Product, Anodic
Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.)
UNPAINTED area on transom of the boat around these items.
8107
a - Painted boat transom b - Minimum 40 mm (1‑1/2 in.)

UNPAINTED area around transom
assembly
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, MerCathode system, and items specified by
the boat manufacturer.
Page 12 / 12 90-869261 MAY 2008

SECTION - 2 BOAT CONSTRUCTION
SECTION 2 - BOAT CONSTRUCTION

Table of Contents
Boat Construction.................................................................................................................................................... 2
Transom Thickness and Surface Plane.................................................................................................................. 2
2
Transom Cutout....................................................................................................................................................... 3
Checking Transom Thickness................................................................................................................................. 3
Engine Bed.............................................................................................................................................................. 3
Engine Compartment............................................................................................................................................... 3
Design and Construction...................................................................................................................................3
Ventilation..........................................................................................................................................................3
Combustion Air Requirements..........................................................................................................................3
Inlet Air Temperature......................................................................................................................................... 4
Compartment Pressure.....................................................................................................................................4
90-869261 MAY 2008 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.
For additional boat construction information, refer to the Cummins MerCruiser Diesel
Applications Manual (90-866350050)
! 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).
If you have an issue with the application of our product that cannot be resolved, contact your CMD
distributor application engineer. Direct all requests for assistance to your local CMD distributor.
Find the distributor for your area by using the service locator on the Cummins website
(www.cmdmarine.com) or by contacting 1‑800‑DIESELS (1‑800‑343‑7357). If you need further
technical assistance, contact us at our email address: wavemaster@cummins.com.
Transom Thickness and Surface Plane

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the
sterndrive unit mounts.
Transom Specifications
Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical center line
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
Flatness as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.) Outer Surface ‑ Flat within
2 mm (1/16 in.)
Angle 10 ‑16 degrees
a e
d d
b
c 7508
a - Transom thickness d - Transom plate coverage ‑ 203 mm

b - Inner surface (8 in.) from center
c - Outer surface e - Transom angle
Page 2 / 4 90-869261 MAY 2008

SECTION - 2 BOAT CONSTRUCTION
Transom Cutout
Refer to Section 6 - Drive System And Engine Mounting.
Checking Transom Thickness

Refer to Section 6 - Drive System And Engine Mounting.
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
Difference between starboard and port engine mount 57.2 cm (22‑1/2 in.)
Mount adjustment up and down (minimum) 6 mm (1/4 in.)
NOTE: Although the engine mounts allow some adjustment, ensure that the front and rear mount
locations in the vessel are parallel and in the same plane. This may be checked by tying a string
from the left front mount location to the right rear mount location and another from right front to
left rear. The strings should touch where they cross.
Engine Compartment
Design and Construction
Exercise care in the design and construction of the engine compartment. Locate seams to direct
any rain water 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: Cummins MerCruiser Diesel 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 application complies 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 Coast Guard regulations, the engine
compartment ventilation system has multiple tasks. Included are the following:
1. To supply the engine with combustion air.
2. To maintain a low temperature in the engine compartment.
Fresh air should enter the engine compartment as low as possible and the heated air should be
discharged from the highest point.
If a separate air shaft (or similar) provides engine compartment ventilation or additional ventilation,
take care to prevent seawater and spray from entering it.
Combustion Air Requirements
Engine compartments with natural draft ventilation must have vent openings of sufficient size and
location to accomplish the tasks previously outlined.
90-869261 MAY 2008 Page 3 / 4

BOAT CONSTRUCTION SECTION - 2
According to 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 following equation should be used to determine the area required PER ENGINE. Refer to
CMD's Marine Performance Curve / Data Sheet for the intake air flow and the rated engine RPM
for each engine.
• Area (in.2) = 0.272 × Intake Air Flow (ft.3/min.) at rated engine RPM.
• Area (cm2) = 3.72 × Intake Air Flow (liter/sec) at rated engine RPM.
IMPORTANT: The amount of vent area required, according to boating standards (NMMA, ABYC,
and so forth) and Coast Guard regulations for complete (total) engine compartment ventilation
must include the engine vent area plus the engine compartment ventilation requirements.
Inlet Air Temperature
Inlet air temperature that is too high lowers the engine performance. Engine compartment air
temperature shall not be greater than outside air temperature plus 17° C (30° F) with the engine
operating at rated engine RPM.
Because many factors influence engine compartment temperature, measure temperatures on all
new applications when designing the ventilation system.
Refer to the Cummins MerCruiser Diesel Applications Manual (90‑866350050) for the
appropriate testing procedures.
IMPORTANT: If the temperature at the engine air inlet (air filter) exceeds specifications, the engine
compartment needs additional engine combustion air openings or an increase in engine
compartment ventilation area 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.
Refer to the Cummins MerCruiser Diesel Applications Manual (90‑866350050) for the
appropriate testing procedures.
Page 4 / 4 90-869261 MAY 2008

SECTION - 3 EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Exhaust System....................................................................................................................................................... 2
QSD 2.0L Exhaust Elbow Height............................................................................................................................ 2
Measuring Procedure.............................................................................................................................................. 2
3
Measuring Methods................................................................................................................................................. 3
Straight Edge Method........................................................................................................................................3
Clear Hose Method...........................................................................................................................................4
90-869261 MAY 2008 Page 1 / 6

EXHAUST SYSTEM SECTION - 3
Exhaust System
! WARNING
QSD 2.0L Exhaust Elbow Height

NOTICE
Improperly designing, installing, or modifying the engine’s exhaust system can introduce
seawater or water from condensation into the combustion chambers, damaging the engine. The
installing dealer or boat builder is responsible for proper installation of the exhaust system as
explained in the installation instructions for the product. Engine damage resulting from water
ingestion is not covered by the product warranty, unless the damage is the result of a defective
part supplied by the engine manufacturer.
1. Verify that the riser provides the required dimension "c" or a distance greater than "c," as
indicated.
Model "c" = "a" minus "b"

All Models "c" Must Be 279 mm (11 in.) or More
b
a
c
25679
a - From waterline to top of transom c - "a" minus "b"

b - From highest point on exhaust riser d - Waterline at rest
to top of transom
Measuring Procedure
The height of the exhaust elbows must be within the dimensions specified to prevent water
intrusion problems. Exhaust elbow risers are factory installed to assist in obtaining the proper
height. Measurement must be taken with the boat in the water. It is important that the boat be
loaded as outlined following to simulate the maximum loading conditions likely to be encountered
in normal operation.
Page 2 / 6 90-869261 MAY 2008

IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer.
Clearly communicate any load distribution conditions that will affect the exhaust system height
and slope compliance to the operator in the owner's manual. For example, include in the manual
the number of people that can be located on the swim platform simultaneously if this could pose
a problem.
1. Fill all fuel, water, gray water, and heater tanks to maximum capacity. Use people or weights
to simulate these loads if desired. See conversions:
• 1 U.S. gallon of water = 8.3 lb.
• 1 liter of water = 1 kg
• 1 U.S. gallon of Grade 2 diesel fuel = 7 lb.
• 1 liter of Grade 2 diesel fuel = 3.2 kg
2. Add the maximum allowable cargo weight to the boat in areas where it will be stowed, including
the refrigerator and lockers. Do not forget the personal watercraft, if applicable.
NOTE: ABYC specifies an average passenger weight of 64 kg (141 lb.) for boat loading
calculations. Use this as a minimum. An average passenger weight of 86 kg (190 lb.) is desirable.
3. Add the average passenger weight of 86 kg (190 lb.) in all locations where each passenger
will sit during normal operation.
4. Measure the exhaust elbow height. See Measuring Methods.
5. Leave fluid and cargo weights where they are, but remove passenger weights from the boat.
Beginning at the bow, reload passenger weight (the equivalent of one person at a time) while
retaking readings. Use all of the available seating areas in the bow first. Continue adding
passenger weight (and taking readings), moving from the bow to the stern, until the maximum
people weight has been added back on board.
IMPORTANT: Be sure to consider swim platform loading and personal watercraft.
6. Repeat Step 5, but this time, start at the stern of the boat and work toward the bow.
7. Measurements under all loading conditions must be within specifications.
8. Check exhaust system measurements. See Measuring Methods - Straight Edge Method or
Clear Hose Method.
Description All Models

Minimum exhaust elbow height from top of elbow to waterline 279 mm (11 in.)
9. If measurements are less than specified, modify the installation to achieve the proper
dimension.
Measuring Methods
Straight Edge Method
1. Place a straight edge across the boat.
2. With the straight edge above the engine and parallel to the water, measure the distance
between the straight edge and the top of the exhaust elbow.
3. With the straight edge above the engine and parallel to the water, measure the distance
between the straight edge and the outside waterline.
IMPORTANT: The difference between these two measurements is the exhaust elbow height
(above the water line).
90-869261 MAY 2008 Page 3 / 6

4. Compare the measurement to the specifications. See Exhaust Elbow Height.
c d
e
25851
Exhaust elbow height: straight edge method
a - Waterline d - Measurement between straight edge
b - Top of exhaust elbow and top of exhaust elbow
c - Straight edge e - Measurement between straight edge
and water line
Clear Hose Method

1. Obtain an 8–10 mm (5/16–3/8 in.) I.D. 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 water line.
2. Put the weighted end of the hose over the port or starboard 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 water line.
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.
Page 4 / 6 90-869261 MAY 2008

8. The measurement between the water in the hose and the top of exhaust elbow is the exhaust
elbow height. Compare the measurement to the specifications. See Exhaust Elbow Height.
c
a
e
25852
Exhaust elbow height: clear hose method
a - Waterline d - Weight
b - Top of exhaust elbow e - Measurement: waterline to top of
c - Clear plastic hose exhaust elbow
90-869261 MAY 2008 Page 5 / 6

NOTES:
Page 6 / 6 90-869261 MAY 2008

SECTION - 4 FUEL SYSTEM
SECTION 4 - FUEL SYSTEM

Table of Contents
Fuel Delivery System............................................................................................................................................... 2
General ...................................................................................................................................................... 2
Fuel Connection Requirements.........................................................................................................................2
Diesel Fuel Filters and Fuel Additives..................................................................................................................... 4
90-869261 MAY 2008 Page 1 / 6

FUEL SYSTEM SECTION - 4
Fuel Delivery System

! WARNING
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, and so on) and the standards they reference (ABYC, SAE, ISO, and so on) for
complete guidelines.
Typical fuel tank manufacturers 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 an inner diameter of at least 13 mm (1/2 in.) and must be
fitted with a swan neck to prevent water from entering the tank.
Cummins MerCruiser Diesel recommends
• The exact route and length of the fuel lines be established at the first installation of the engine
to prevent problems later in connecting them to the engine.
• All fuel lines must be well secured.
• The holes where the lines go through the bulkheads should be carefully rounded off or
protected with rubber grommets. This prevents damage to the lines from abrasion.
• Sharp bends in fuel lines must be avoided. Fuel lines must not be kinked. Refer to the
Cummins MerCruiser Diesel Applications Manual (90‑866350050) for further information.
Fuel Connection Requirements
Refer to marine regulations (USCG, EU‑RCD, and so on) and the standards they reference for
complete guidelines.
NOTE: Not all requirements are listed.
• Ensure that the fuel supply line pickup is at least 25 mm (1 in.) from the bottom of the tank to
prevent picking up impurities.
• Install a fuel return line between the engine and fuel tank.
• Mount the fuel return line at least 31 cm (12 in.) from the fuel supply line pickup and at least
25 mm (1 in.) from the bottom of the fuel tank.
• Use the supplied 8 mm (5/16 in.) fuel inlet fitting attached to the fuel filter housing. Minimum
fuel supply line internal diameter is 8 mm (5/16 in.).
• 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.
• 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.
Page 2 / 6 90-869261 MAY 2008

• Install fuel lines of the proper length that allow a flexible connection free of loose or coiled line.
• Anchor the fuel lines to prevent vibration and chafing.
• Avoid sharp bends in fuel lines.
• Ensure that the fuel inlet restriction meets specification.
• Ensure that the fuel return restriction meets specification.
Description QSD 2.0L

Maximum Fuel Inlet Restriction 147 mm Hg (5.8 in. Hg)
Maximum Fuel Return Restriction 104 mm Hg (4.1 in. Hg)
d c
g
b
a
33447
Fuel flow diagram without optional fuel cooler

a- Fuel inlet on filter e - Fuel injectors
b- Injection pump f - Injector fuel return
c- Fuel rail g - Fuel distribution block
d- Fuel injector lines h - Fuel return to tank
90-869261 MAY 2008 Page 3 / 6

h
d e
b a
34053
Fuel flow diagram with optional fuel cooler
a- Fuel inlet on filter e - Fuel rail
b- Injection pump f - Fuel injectors
c- Fuel cooler (if equipped) g - Injector fuel return
d- Fuel return to tank h - Fuel distribution block
Diesel Fuel Filters and Fuel Additives

IMPORTANT: The engine is provided with an element‑type fuel filter, but to eliminate water and
dirt, a primary fuel water separator is required.
Contamination of diesel fuel and algae growth in the diesel fuel could block the lift pump resulting
in poor performance.
Cummins MerCruiser Diesel requires installing a primary fuel water separator equipped with a
water trap before the lift pump to filter out contaminants in the diesel fuel.
Cummins MerCruiser Diesel requires the following primary fuel water separator or equivalent:
Description Specification
227 liters/hr.
Flow rate
Primary fuel water separator (60 U.S. gal/hr.)
Filtration 10 micron
Description Qty. Part Number
SAE Threads 1 35‑850481A1
Racor Model 500® fuel filter (Or equivalent).
Metric Threads 1 35‑809867
Page 4 / 6 90-869261 MAY 2008

Select a suitable position in the fuel system between the secondary fuel filter on the engine and
the fuel tank for the primary fuel water separator. The position selected 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. Refer to Cummins Service Bulletin 3379001 or your local Cummins MerCruiser
Diesel Authorized Repair Facility for additional information.
90-869261 MAY 2008 Page 5 / 6

NOTES:
Page 6 / 6 90-869261 MAY 2008

SECTION - 5 COOLING SYSTEM
SECTION 5 - COOLING SYSTEM

Table of Contents
QSD 2.0 Alpha Sterndrive Seawater Connections.................................................................................................. 2
QSD 2.0 Bravo Sterndrive Seawater Connections.................................................................................................. 2
Specifications.......................................................................................................................................................... 2
Seawater Pickup Connection.................................................................................................................................. 3
Installation ........................................................................................................................................................ 3
Seacock................................................................................................................................................................... 4
Requirements ................................................................................................................................................... 4
Installation ........................................................................................................................................................ 4
Seawater Hoses...................................................................................................................................................... 4
Requirements ................................................................................................................................................... 4
Installation ........................................................................................................................................................ 4
Installing the Seawater Strainer.............................................................................................................................. 4
Requirements ................................................................................................................................................... 5
Installation ........................................................................................................................................................ 5
5
Water Heater Installation......................................................................................................................................... 6
Hot Water Heater Hose Connections................................................................................................................6
Supply Hose Connection...................................................................................................................................7
Return Hose Connection...................................................................................................................................7
Cooling System Flow Diagrams.............................................................................................................................. 8
Engine Coolant Oil Cooler Equipped Models....................................................................................................8
Seawater Oil Cooler Equipped Models...........................................................................................................12
90-869261 MAY 2008 Page 1 / 16

COOLING SYSTEM SECTION - 5
Lubricant, Sealant, Adhesives

Marine Caulking Seawater inlet mounting surfaces Obtain Locally
7 Loctite 271 Threadlocker Seawater inlet nut 92-809819
QSD 2.0 Alpha Sterndrive Seawater Connections

All QSD 2.0 Alpha Sterndrive models must be equipped with a through‑hull or through‑transom
alternate seawater pickup to ensure sufficient water flow to the engine. In these applications the
transom assembly has been modified by the installation of a seawater passage block‑off plate and
the seawater hose located between the bell housing and the gimbal housing has been cut. This
allows the sterndrive seawater pump to continue cooling the drive. See Section 6 - Drive System
And Engine Mounting.
QSD 2.0 Bravo Sterndrive Seawater Connections

In certain applications, these models may need to be equipped with a through‑the‑hull or
through‑the‑transom alternate seawater pickup to ensure sufficient water flow to the engine. In
these applications the transom assembly needs to be modified with the seawater passage
block‑off plate that comes with the transom assembly. Cutting the seawater hose that is located
between the bell housing and the gimbal housing allows seawater to continue through the drive
for cooling. See Section 6 - Drive System And Engine Mounting.
Read and observe the following to select the proper alternate seawater pickup, seacock size, hose,
and seawater strainer for all applications.
Specifications
IMPORTANT: All seawater supply solutions must be tested to ensure that minimum seawater
flow specifications are met.
Description QSD 2.0 L with Jabsco Seawater Pump

Seawater pickup:
Minimum 150 L/min (40 U.S. gal/min)
through‑the‑hull or through‑the‑transom mounted
Seacock size
Minimum 31.75 mm (1‑1/4 in.)
(internal cross‑sectional area)
Seawater inlet hose inner diameter
Minimum 31.75 mm (1‑1/4 in.)
(adapter provided for hose)
Seawater strainer flow rate Minimum 150 L/min (40 U.S. gal/min)
Seawater inlet restriction Maximum 125 mm Hg (5 in. Hg)
Description QSD 2.0 L with Sherwood Seawater Pump

Seawater pickup:
Minimum 150 L/min (40 U.S. gal/min)
through‑the‑hull or through‑the‑transom mounted
Seacock size
Minimum 38.10 mm (1‑1/2 in.)
(internal cross‑sectional area)
Seawater inlet hose inner diameter
Minimum 38.10 mm (1‑1/2 in.)
(adapter provided for hose)
Seawater strainer flow rate Minimum 150 L/min (40 U.S. gal/min)
Seawater inlet restriction Maximum 125 mm Hg (5 in. Hg)
NOTE: Before installation, check all engine fluid and electrical connection points to ensure that
they are not obstructed by shipping plugs, covers, or any foreign material.
Page 2 / 16 90-869261 MAY 2008

Seawater Pickup Connection

Water pickup connections must be large enough to permit sufficient water flow to the engine
seawater pump for adequate engine cooling. See Cooling System—Specifications.
IMPORTANT: Do not install the water pickup directly in line with the propeller, as the pickup may
create turbulence and allow air to flow into the propeller slipstream. This air flow causes propeller
ventilation and adversely affects boat performance.
The water pickup must supply a positive head of seawater while underway. Install the water pickup
as close to the seawater pump inlet as possible and in an area where an uninterrupted, solid stream
of water will flow past when the boat is underway.
Utilize a wire‑reinforced hose with an adequate wall thickness to prevent the seawater hose from
collapsing at high engine speeds. Secure the hose connections with double hose clamps. Follow
manufacturer instructions for installing the seawater pickup and seawater strainer.
Installation
NOTE: If using a seawater pickup other than the QuickSilver model referenced below, follow the
installation instructions supplied by the manufacturer.
1. Drill a 50 mm (2 in.) hole through the hull in an appropriate location. See Installation
Requirements.
2. Apply marine caulking to the seawater pickup mounting surface that contacts the hull.

Seawater inlet mounting
Marine Caulking Obtain Locally
surfaces
3. Face the slots in the water pickup forward (toward the bow of the boat) and install the water
pickup through the hull.
4. Apply marine caulking as needed inside the boat.
5. Position the washer on the fitting and install the large nut.
6. Apply sealant to the threads of the nut and install on the pickup on the inside of the boat.
e c
b a
f
d e
f
a
21914
a - Seawater pickup (through‑hull fitting) d - Hull of boat

b - Washer e - Marine caulking
c - Large nut f - Slots facing forward

7 Loctite 271 Threadlocker Seawater inlet nut 92-809819
IMPORTANT: Confirm that the intake slots are still facing forward after the seawater pickup nut is
torqued.
7. Tighten the seawater pickup nut to the specified torque.

Seawater inlet nut 42 – 32
90-869261 MAY 2008 Page 3 / 16

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 supported adequately to
prevent hose fatigue. A brass ball or gate valve is required.
Installation
If using other than the Quicksilver seacock shown following, refer to the manufacturer's instructions
provided with the seacock.
1. Install the Quicksilver seacock:
a. Install the seacock on the seawater pickup. Tighten securely.
b. Install the approximately 38 mm (1‑1/2 in.) hose connector on the seacock. Tighten
securely.
a
b
22241
a - Seacock c - 1‑1/2 in. hose connector
b - Seawater pickup (through the hull
fitting)
Seawater Hoses
IMPORTANT: Use a wire‑reinforced seawater hose to avoid collapsing the hose when suction is
created by the seawater pump impeller.
Requirements
The seawater hose connections must be made with wire‑reinforced hose of adequate wall
thickness to prevent it 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.
Installation
See Section 6 - Drive System And Engine Mounting for seawater hose installation procedures.
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
Cummins MerCruiser Diesel warranty.
Page 4 / 16 90-869261 MAY 2008

Requirements
This engine ships with a seawater strainer that meets Cummins MerCruiser Diesel minimum
specifications. If the boat builder chooses to use a different seawater strainer, the boat builder is
responsible for ensuring that the substitute product meets or exceeds Cummins MerCruiser
Diesel's minimum specifications.
Specifications QSD 2.0L Seawater Strainer Early Production QSD 2.0L Seawater Strainer
Minimum Inlet Hose ID 38.10 mm (1‑1/2 in.) 31.75 mm (1‑1/4 in.)
Minimum Outlet Hose ID 38.10 mm (1‑1/2 in.) 31.75 mm (1‑1/4 in.)
Minimum Outlet Hose ID 200 L/min (53 gal/min) 143 L/min (38 gal/min)
Maximum Flow Restriction 125 mm Hg (5 in. Hg) 125 mm Hg (5 in. Hg)
25813
Seawater strainer physical dimensions
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.
To install the seawater strainer, complete the following steps:
1. Position and mount the seawater strainer in the selected location using hardware appropriate
for the boat's construction.
90-869261 MAY 2008 Page 5 / 16

2. Ensure that the arrow marking the outlet connection on the strainer housing is pointing toward
the seawater pump
a 25818
a - Water outlet (marked with arrow on strainer body)

b - Water inlet
3. Attach the inlet and outlet hoses and clamps carefully to avoid cracking or breaking the plastic
seawater strainer housing.
Water Heater Installation

Hot Water Heater Hose Connections
IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be
met including but not limited to the following:
• The supply hose (from engine to heater) and return hose (from heater to engine) must not
exceed 16 mm (5/8 in.) inside diameter.
• Make heater connections only at locations indicated in the following information.
• Refer to manufacturers' instructions for complete installation information and procedures.
• Do not reposition the engine temperature switch; it must remain as installed by the factory.
NOTICE
Prevent engine damage from overheating. In models equipped with closed cooling, low coolant
levels may allow an air pocket to form when the hot water heater or cabin heater is mounted
higher than the fill cap on the heat exchanger. Mount the heater lower than the fill cap of the
heat exchanger and maintain the recommended coolant level.
QSD series diesel engines have bayonet‑style water fittings installed at the factory. These bayonet
fittings have a valve that can be opened or closed with a screwdriver.
26762
Bayonet fitting with valve
Page 6 / 16 90-869261 MAY 2008

Supply Hose Connection
a
25858
Right rear of engine at the back of heat exchanger
a - Hot water supply bayonet fitting with b - Heat exchanger
valve
Return Hose Connection
25877
QSD 2.0L Diesel
a - Hot water return bayonet fitting with b - Coolant expansion tank
valve
90-869261 MAY 2008 Page 7 / 16

Cooling System Flow Diagrams

Engine Coolant Oil Cooler Equipped Models
b
h
g
a
c
d
f
35247
e
Seawater flow for engine coolant oil cooler equipped models
a - Seawater inlet f - Exhaust riser
b - Seawater pump g - Heat exchanger drain valve
c - Aftercooler h - Engine coolant oil cooler
d - Zinc anode i - Heat exchanger
e - Power assisted steering fluid cooler
Page 8 / 16 90-869261 MAY 2008

a b g
h
e
c d
f
i
k j
33568
Coolant Flow with thermostat closed for engine coolant oil cooler equipped models
a - Closed cooling system drain‑valve g - Closed cooling system line vent
b - Engine water circulating pump h - Engine coolant oil cooler
c - Engine block and heads i - Heat exchanger
d - Exhaust manifold j - Thermostat (closed)
e - Expansion tank vent k - Expansion tank drain valve
f - Expansion tank
90-869261 MAY 2008 Page 9 / 16

a g
b
h
e
c d
k
j
33569
Coolant Flow with thermostat open for engine coolant oil cooler equipped models
b - Engine water circulating pump h - Engine coolant oil cooler
d - Exhaust manifold j - Thermostat (open)
f - Expansion tank
Page 10 / 16 90-869261 MAY 2008

e
f
b c g
26126
a
Coolant flow for hot water heater
a- Coolant return inlet e - Water heater tank
b- Coolant overflow tube f - Water heater inlet
c- Coolant fill neck g - Coolant outlet
d- Water heater outlet
90-869261 MAY 2008 Page 11 / 16

Seawater Oil Cooler Equipped Models

b
a
d
e
j
f
26082
Seawater flow for seawater oil cooler equipped models

a - Seawater inlet f - Power assisted steering fluid cooler
b - Seawater pump g - Oil cooler
c - Fuel cooler (if equipped) h - Heat exchanger drain valve
d - Aftercooler i - Heat exchanger
e - Zinc anode j - Exhaust riser
Page 12 / 16 90-869261 MAY 2008

a g
b
h
e
c d
f
i
k j
26083
Coolant Flow with thermostat closed for seawater oil cooler equipped models
a - Closed cooling system drain valve g - Closed cooling system line vent
b - Engine water circulating pump h - Oil cooler
d - Exhaust manifold j - Thermostat (closed)
f - Expansion tank
90-869261 MAY 2008 Page 13 / 16

a
g
b
h
e
c d
k j
26087
Coolant Flow with thermostat open for seawater oil cooler equipped models
b - Engine water circulating pump h - Oil cooler
d - Exhaust manifold j - Thermostat (open)
f - Expansion tank
Page 14 / 16 90-869261 MAY 2008

e
f
b c g
26126
a
Coolant flow for hot water heater
a- Coolant return inlet e - Water heater tank
b- Coolant overflow tube f - Water heater inlet
c- Coolant fill neck g - Coolant outlet
d- Water heater outlet
90-869261 MAY 2008 Page 15 / 16

NOTES:
Page 16 / 16 90-869261 MAY 2008

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

MOUNTING
Table of Contents
Transom Cutout....................................................................................................................................................... 4
Finding the Crankshaft Vertical Center Line...................................................................................................... 4
Single Engine ............................................................................................................................................. 4
Dual Engine ............................................................................................................................................... 4
Finding the Crankshaft Horizontal Center Line (X‑Dimension).........................................................................5
90‑Degree Tool Method....................................................................................................................................5
Tape Measure Method......................................................................................................................................6
Cutting Out The Transom..................................................................................................................................7
Checking The Transom Thickness....................................................................................................................8
Alpha Drive Transom Installation............................................................................................................................ 9
Unpacking the Gimbal Housing Assembly........................................................................................................9
Installing the Alpha Inner Transom Plate........................................................................................................10
Models With Alpha Sterndrive and Alternative Water Pickups........................................................................11
Alpha Models ........................................................................................................................................... 11
Speedometer Connection: Alpha Sterndrive...................................................................................................13
Alpha Gear Lube Monitor Connection At Gimbal Housing..............................................................................14
6
Bravo Drive Transom Installation.......................................................................................................................... 15
Exhaust Tube..................................................................................................................................................15
Installing Gimbal Housing Assembly...............................................................................................................15
Installing the Inner Transom Plate .................................................................................................................. 16
Connecting Speedometer Pickup....................................................................................................................18
Installing Sterndrive Seawater Pickup.............................................................................................................18
Installing the Sterndrive Seawater Block‑Off Plate.......................................................................................... 19
Gear Lube Monitor Connection At Gimbal Housing........................................................................................22
Installing Power‑Assisted Steering System (If Equipped)..................................................................................... 24
Power Trim Pump.................................................................................................................................................. 28
Mounting the Power Trim Pump......................................................................................................................28
Hydraulic Hose Connections—Power Trim Pump .......................................................................................... 29
Engine Installation and Alignment......................................................................................................................... 30
Engine Preparation..........................................................................................................................................30
Engine Mount Alignment Tool.........................................................................................................................31
Engine Preparation..........................................................................................................................................31
Preparing the Transom....................................................................................................................................31
Connecting the Battery Cables to the Engine.................................................................................................33
Engine Installation...........................................................................................................................................34
Alignment........................................................................................................................................................37
Exhaust System Connections.........................................................................................................................40
Electrical Connections........................................................................................................................................... 41
Continuity Circuit.............................................................................................................................................41
Mounting the Vessel Integration Panel (VIP)..................................................................................................41
Engine‑to‑VIP Connections.............................................................................................................................42
Vessel Sensor Harness...................................................................................................................................43
14‑Pin Helm Extension Harness.....................................................................................................................44
Non‑DTS Helm Harness.................................................................................................................................. 44
Vessel Integration Panel (VIP) Connections...................................................................................................45
Trim Position Sender Connection.................................................................................................................... 46
Power Trim Pump Connection........................................................................................................................46
Neutral Safety Switch Connection...................................................................................................................46
Quick‑Connect MerCathode System Connection (If Equipped)......................................................................48
90-869261 MAY 2008 Page 1 / 80

DRIVE SYSTEM AND ENGINE MOUNTING SECTION - 6
Fluid Connections.................................................................................................................................................. 48
Gear Lube Monitor..........................................................................................................................................48
Power‑Assisted Steering Hoses......................................................................................................................49
Hoses With Quick‑Connect Fittings ......................................................................................................... 49
Seacock and Connector..................................................................................................................................50
Seawater Strainer............................................................................................................................................50
Seawater Hoses..............................................................................................................................................51
Fuel Line Connections.....................................................................................................................................51
Alpha Sterndrive Shift Cable Installation............................................................................................................... 53
Remote Controls and Propeller Rotation......................................................................................................... 53
Separate Shift and Throttle Controls...............................................................................................................53
Measuring Shift Cable Travel..........................................................................................................................54
Installation.......................................................................................................................................................54
Alpha Sterndrive Installation.................................................................................................................................. 57
Trim Limit Spacer Kit (if Equipped).................................................................................................................. 62
Alpha Trim Cylinder Installation....................................................................................................................... 63
Speedometer Connection................................................................................................................................64
Bravo Sterndrive Shift Cable Installation............................................................................................................... 64
Shift Cable Travel............................................................................................................................................64
Shift Cable Installation and Adjustment...........................................................................................................64
Bravo Sterndrive Installation................................................................................................................................. 69
Additional Trim Limit Spacer Kit......................................................................................................................76
Speedometer Connections ‑ Bravo Models..................................................................................................... 78
Page 2 / 80 90-869261 MAY 2008

Lubricants, Sealants, Adhesives

19 Perfect Seal Engine mounting hardware threads and nuts 92-34227 1
Battery terminals
25 Liquid Neoprene 92- 25711 3
Exposed terminals and connections
Gimbal housing studs
Power steering bushings
Upper and lower pivot bolts
Clevis pin
Steering cable end
Bell housing studs
80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
Coupler splines
91 Engine Coupler Spline Grease U-joint O-rings 92-802869A 1
Drive shaft splines
Bell housing studs
2-4-C Marine Lubricant with Trim cylinder hardware
95 92-802859A 1
Teflon Trim cylinder
O-ring seals
114 Power Trim and Steering Fluid Power trim pump 92-858074K01
Special Tools
Transom Cutout and Drill Fixture 91‑43693A 2
Cuts and drills the boat transom for sterndrive installation.
9182
Tapered Insert Tool 91‑43579
Removes and installs the tapered insert retainer into the water
inlet hose.
9197
Alignment Tool Assembly 91‑805475A 1
Aligns the engine and the sterndrive during installation.

9183
90-869261 MAY 2008 Page 3 / 80

Shift Slide Stabilizer 91‑865232
Holds the shift slide in the proper position as the sterndrive is

installed onto the bell housing studs.
9184
Transom Cutout
Finding the Crankshaft Vertical Center Line
SINGLE ENGINE
1. Locate and mark the vertical center line on the transom, if known. This is also the crankshaft
vertical center line.
2. If the center line is unknown, use a compass to locate the vertical center line:
a. Mark identical locations on each side of the boat 304.8 mm (12 in.) from the bottom of
the hull.
b. Position the fixed end of a compass at the marks and draw arcs on the transom.
c. Draw the crankshaft vertical center line through the intersection points of the two arcs.
b e
a
c b e
d
7687
Single engine installation

a - 304.8 mm (12 in.) d - Arc intersection points
b - Identical side marks e - Crankshaft vertical center line
c - Compass arc
DUAL ENGINE
1. Locate and mark the vertical center line on the transom. See Single Engine.
2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical center
lines on either side of the vertical center line.
Minimum Distance Between Crankshaft Vertical Center Lines (Dual Side‑By‑Side)

Model Measurement
All Models 838 mm (33 in.)
IMPORTANT: Crankshaft vertical center lines must be an equal distance from boat vertical center
line.
Page 4 / 80 90-869261 MAY 2008

3. Draw the two crankshaft vertical center lines through the intersection of the marks.
b
c c
b
a 7688
Dual installation
a - Vertical center line c - Crankshaft vertical center lines
b - 1/2 minimum distance between
crankshaft center line marks
Finding the Crankshaft Horizontal Center Line (X‑Dimension)

After finding and marking the crankshaft vertical center line, use either the 90-Degree Tool
Method or the Tape Measure Method to locate the crankshaft horizontal center line
(X‑dimension).
IMPORTANT: The following instructions provide a sterndrive mounting location that is suitable for
most boats. However, only testing can determine the best sterndrive mounting location for a
particular vessel design.
• Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from the X‑dimension.
• Heavy duty applications: Subtract 25 mm (1 in.) from the X‑dimension.
• Above 40 km/h (25 mph): Use the X‑dimension shown.
• Above 80 km/h (50 mph): You can improve performance in some applications by increasing
the X‑dimension. However, pulling power for skiing will decrease. Increase the X‑dimension
13 mm (1/2 in.) at a time during testing until the desired performance is achieved.
IMPORTANT: Do not increase the X‑dimension by more than 25 mm (1 in.)
Take extreme care when raising the sterndrive to ensure that you do not aerate the water supply.
Use a clear water inlet hose to monitor incoming water, and monitor the engine temperature gauge
to ensure that the engine does not overheat.
In applications where cooling water to the engine is supplied by a through-the-hull or
through-the-transom fitting, the sterndrive height does not cause cooling water aeration.
IMPORTANT: Cummins MerCruiser Diesel warranty does not cover damage caused by an
incorrect drive installed height.
90‑Degree Tool Method
1. Construct the 90° tool.
90
a
b 7689
a - 345 mm (13‑9/16 in.) b - 1.2 m (4 ft.)
90-869261 MAY 2008 Page 5 / 80

IMPORTANT: The 345 mm (13 ‑ 9/16 in.) dimension should only be raised or lowered after proper
testing.
To lower the sterndrive, subtract from dimension "a."
To raise the sterndrive, add to dimension "a."
2. Place the 90° tool along the boat bottom at the vertical center line.
3. Locate the point at which top of the 90° tool contacts the transom on the vertical center line.
This is the crankshaft horizontal center line or X‑dimension.
4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.
c
a b
c
b
7692 a 7691
Single engine Dual engine

a - 90° tool along boat bottom at vertical c - Crankshaft horizontal center line
center line
b - Contact point
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
X-dimension
(degrees)
16 364 mm (14‑5/16 in)
15 362 mm (14‑1/4 in.)
14 360 mm (14‑3/16 in.)
13 359 mm (14‑1/8 in.)
12 357 mm (14‑1/16 in.)
11 356 mm (14 in.)
10 354 mm (13‑15/16 in.)
2. On the vertical crankshaft center line, measure up from the bottom of the transom to the
X‑dimension selected previously. This is the crankshaft horizontal center line at the
X‑dimension.
Page 6 / 80 90-869261 MAY 2008

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

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

1. Cut out the transom using the Template or the Transom Drilling Fixture Kit (purchased
separately).
7893 7694
Transom cutout template Transom drilling fixture kit
Transom Cutout and Drill Fixture 91‑43693A 2

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° angle for hole saw guides.
90-869261 MAY 2008 Page 7 / 80

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 steering lever may contact the transom causing limited steering
travel.
a
b
7695
a - 51 mm (2 in.) hole saw holes b - 60° versus transom angle

(steering lever cutout)
6. Cut the transom on the cut line at a 90° angle. If the transom cutout is made incorrectly the
gimbal housing or exhaust system may improperly contact the boat transom causing transom
mounting problems.
7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water
absorption and deterioration of the transom.
b
a
d c
7696
a - Cut line c - Exhaust pipe area

b - 90° d - Mounting holes perpendicular to
transom (8)
Checking The Transom Thickness

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the
sterndrive unit mounts.
1. Ensure that transom thickness and surface conform to specifications.
Page 8 / 80 90-869261 MAY 2008

Transom Specifications
Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical center line
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
Flatness as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.) Outer Surface ‑ Flat within
2 mm (1/16 in.)
Angle 10 ‑16 degrees
7697
a - Measuring thickness c - Suitable mandrel to check for uniform

b - Measuring flatness transom thickness
Alpha Drive Transom Installation

Unpacking the Gimbal Housing Assembly
1. Carefully remove transom assembly from shipping carton.
2. Remove and read all tags attached to transom assembly.
7713
a - Dust cover (shipping hardware) b - Trim cylinder support (shipping

hardware)
3. Remove the trim cylinder support bracket if boat will be shipped with drive installed.
4. Remove the dust cover if boat will be shipped with drive installed.
5. Do not remove the shift slide installation tool.
6. Retain the serial number envelope.
90-869261 MAY 2008 Page 9 / 80

7. If the power package is being equipped with a MerCathode system (optional), refer to
the instructions provided with the MerCathode kit and install the MerCathode electrode and
wiring at this time.
Installing the Alpha Inner Transom Plate
1. Insert the wires, hoses, and shift cable through appropriate openings in the inner transom
plate.
2. Position the gimbal housing on the transom and hold in place.
3. Temporarily secure with hardware.
4. Attach continuity wires.
5. Place the transom harness ground ring terminal on top of the continuity circuit wire on transom
bolt.
6. Secure the transom assembly with the hardware as shown. Torque the hardware.

Transom assembly hardware 34 25
IMPORTANT: Tighten the transom assembly fasteners using an X‑pattern torque sequence,
starting from the middle fasteners. Tighten in small increments and repeat the pattern several
times until the proper torque is achieved.
IMPORTANT: The steering lever continuity circuit wire must be positioned as shown to avoid
stressing the wire when the steering lever moves.
a
b
d
a
5 7
3 2
e
1 4
8 6
8585
a - Locknuts and flat washers (8) d - Transom plate continuity wires

b - Bolt e - Torque sequence
c - Steering lever continuity wires
Page 10 / 80 90-869261 MAY 2008

Models With Alpha Sterndrive and Alternative Water Pickups

IMPORTANT: The QSD 2.0L Diesel is shipped with the water block‑off kit installed. These
instructions are included for reference purposes only.
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 gimble housing is cut and removed.
IMPORTANT: Installation of a water block‑off plate makes it necessary to provide an alternate

seawater pickup and related hardware. Use a through‑hull or through‑transom seawater pickup
as is appropriate for the boat design and application.
Use a water inlet block‑off kit if the sterndrive unit water pickup will not be used to supply water to
the engine. When installing the block‑off plate, 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
unit for cooling.
ALPHA MODELS
1. Cut off the water tube close to the cover. Remove and discard the screws and the cover.
b
c
a
b
9260
a - Water tube cover c - Water tube

b - Screws
2. Remove the rubber grommet from the cavity around the tube.
a
b
9283
a - Water tube (Cut in the previous step) b - Rubber grommet
90-869261 MAY 2008 Page 11 / 80

3. Remove and discard the bell housing cable tie and clip that retains the wires and speedometer
hose.
f
d
c
a
b
e 9281
a - Cable tie d - Bell housing assembly

b - Clip e - Speedometer hose
c - Bell housing hose f - Trim limit switch wire harness
4. Cut the bell housing hose close to the bell housing as shown.
9285
a - Bell housing hose b - Cut line
5. Pull on the hose to withdraw the water tube through the gimbal housing opening. Remove the
hose, along with the remaining piece of water tube, from the gimbal housing.
b
a
9286
a - Bell housing hose b - Water tube (cut off previously)
6. Bundle the speedometer hose and trim limit switch wiring harness together and attach to the
piece of hose remaining on bell housing with a cable‑tie.
Page 12 / 80 90-869261 MAY 2008

7. Install the block‑off plate with a new gasket. Torque the block‑off plate screws.
a
d
c
7262
a - Block‑off plate c - Screw
b - Gasket d - Lockwasher

Water inlet block off screw 5 45
8. Install a through‑hull or through‑transom seawater pickup, a seawater strainer, and a seacock.
9. Connect the seawater inlet hose between seawater pump and seawater strainer.
10. Secure all hoses with hose clamps.
Speedometer Connection: Alpha Sterndrive
1. Remove the protective cap from the male quick‑connect fitting on the transom plate.
NOTICE
Removing the plug from the speedometer pickup fitting can introduce water into the bilge. Do
not remove the the plug unless you intend to make a connection to a speedometer pickup.
2. Connect a 4 mm (5/32 in.) tube (not provided) to the tube barb on the female quick‑connect
fitting.
3. Align the guide slots on the male and female quick‑connect fittings.
4. Push together to secure.
a b
b
c
e
26771
Speedometer tube connection
a - Male quick‑connect fitting d - Clamp
b - Female quick‑connect fitting e - Speedometer tube
c - Tube barb
90-869261 MAY 2008 Page 13 / 80

5. Secure the speedometer tube to the transom with screw‑down tube clips.
6. Ensure that the speedometer tube is secured and will not contact any steering components,
the driveshaft, the engine coupler, or any other hot or moving components.
! 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.
7. Confirm that the speedometer tube connector is secure.
Alpha Gear Lube Monitor Connection At Gimbal Housing
NOTE: The gear lube monitor hose is provided in the parts bag with the engine.
1. Connect the quick‑release 90 degree fitting of the gear lube monitor hose to the gimbal
housing.
d
a c
b
7704
a - Hose c - Gimbal housing fitting

b - Quick‑release 90‑degree fitting d - Female quick‑connect fitting
NOTE: The quick‑release button on the quick‑release hose fitting must be positioned away from
the water block‑off plate. The release button must not contact the water fitting or block‑off plate.
2. Route the gear lube hose to the port side of the engine and secure with the J‑clip.
26772
a - Gear lube hose b - J‑clip
Page 14 / 80 90-869261 MAY 2008

3. Position the quick‑release button on the hose fitting away from the water inlet block‑off plate.
The release button must not contact the water fitting.
a
e
b
c
d
f
d
7705
Alpha transom
a - Water inlet block‑off plate d - Quick‑release button
b - Star washer and screw e - Acceptable positions
c - 90‑degree hose fitting f - Not acceptable position
NOTE: The hose must not come into contact with any steering system components, the engine
coupler, or drive shaft.
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‑propeller exhaust.
22758
a - Exhaust tube
Installing Gimbal Housing Assembly

1. Carefully remove transom assembly from shipping carton.
90-869261 MAY 2008 Page 15 / 80

2. Remove and read all tags attached to transom assembly.
7713
a - Shipping hardware b - Trim cylinder support
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 inner transom
plate.
2. Position the gimbal housing on the transom and hold in place.
3. Apply lubricant to the first 8 mm (¼ in.) of the threads of the gimbal housing studs.

34 Special Lubricant 101 Gimbal housing studs 92-802865Q02
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.
Page 16 / 80 90-869261 MAY 2008

IMPORTANT: Position the steering lever continuity circuit wire as shown to avoid stressing wire
when steering lever moves.
c
a
5 7
a a
3 2
b
1 4
e 8 6
21633
a - Locknuts and flat washers (8) d - Transom plate continuity wires
b - Hydraulic hoses and MerCathode e - Torque sequence
wire f - Trim sender and limit wires
c - Steering lever continuity wires
6. Torque the fasteners.

Transom assembly locknuts 34 25
90-869261 MAY 2008 Page 17 / 80

Connecting Speedometer Pickup

NOTE: If using a speedometer pickup other than the one supplied, leave the protective cap on the
male quick‑connect fitting. Follow the manufacturers 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 tie strap.
a
b
c c e
d
7703
Typical
a - Male quick‑connect fitting d - Hose
b - Female quick‑connect fitting e - Tie strap
c - Barbed fitting
! 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 drive shaft.
Installing Sterndrive Seawater Pickup
1. Install the seawater inlet fitting gasket.
2. Install the seawater inlet fitting.
3. Install the J‑clip to route the gear lube monitor hose assembly to the port side.
4. Install the star washers and seawater inlet fitting bolts.
Page 18 / 80 90-869261 MAY 2008

5. Torque the bolts.
d
b
c
20135
Seawater inlet fitting and attaching hardware

a- Seawater inlet fitting gasket (not visible)
b- Standard seawater inlet fitting
c- Bolt and star washer
d- J‑clip

Seawater inlet fitting bolt 5 45
Installing the Sterndrive Seawater Block‑Off Plate

Seawater for engine cooling can be supplied through an alternate (separate) seawater pickup
instead of through the sterndrive. When using a separate seawater pickup, 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.
Notice
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-hull or
through-transom seawater pickup must be used.
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 gimble housing is cut and removed.
90-869261 MAY 2008 Page 19 / 80

1. Remove the tapered insert in the gimbal housing using the tapered insert tool. Discard the
insert.
a b
17857
a - Tapered insert location in the gimbal c - Tapered insert
housing d - Tapered insert tool
b - Ratchet and extension
Tapered Insert Tool 91‑43579

2. Install the block‑off plate with new gasket. Secure with screws and lockwashers. Torque the
screws.
a a
d
c
21683
a - Block‑off plate c - Screw
b - Gasket d - Lockwasher

Water inlet block‑off screw 5 45
Page 20 / 80 90-869261 MAY 2008

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
e
c
b
8489
a - Trim limit switch wires d - Water hose

b - Speedometer hose e - Tapered insert
c - Gimbal housing
! 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 tie strap 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.) in front of 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 tie strap and clip.
c e
b
d a
8490
a - Tie strap d - Speedometer hose

b - Clip e - Trim limit wire harness
c - Water inlet hose f - Cutting area
7. Install a through‑hull or through‑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.
90-869261 MAY 2008 Page 21 / 80

Gear Lube Monitor Connection At Gimbal Housing

NOTE: The gear lube monitor hose is now in the parts bag on the engine.
1. Connect the quick‑release 90° fitting of the gear lube monitor hose to the gimbal housing.
d
a c
b
7704
a - Hose c - Gimbal housing fitting

b - Quick‑release 90° fitting d - Quick‑connect fitting
NOTE: The quick‑release button on the hose fitting must be positioned away from the water inlet
fitting, or block‑off plate, if equipped. The release button must not contact the water fitting, or
block‑off plate, if equipped.
2. Position the quick‑release button on the hose fitting away from the water inlet fitting, or the
block‑off plate, if equipped. The release button must not contact the water fitting, or the
block‑off plate, if equipped.
c b
e
c
22514
Block‑off plate installation shown, similar with water inlet fitting

a - Block‑off plate d - Acceptable positions
b - 90° hose fitting e - Unacceptable position
c - Quick Release button
Page 22 / 80 90-869261 MAY 2008

3. The gear lube monitor gimbal housing hose assembly must be routed toward the port side of
the engine. Secure the hose assembly at the top side of the water inlet fitting, or block‑off
plate, if equipped, using the hose J‑clip.
e b
6635
Bravo transom
a - Water inlet fitting d - J‑clip
b - Bolts and star washers e - Quick‑release button
c - Gear lube monitor hose

Water inlet fitting bolts 5 45
NOTE: The hose must not come into contact with the steering system components or the engine
coupler and drive shaft.
4. Secure the gear lube monitor gimbal housing hose assembly with the J‑clip on the transom
plate.
16791
a - J‑clip
5. Temporarily position the hose out of the way until final connection after engine installation.
90-869261 MAY 2008 Page 23 / 80

Installing Power‑Assisted Steering System (If Equipped)

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 center‑lines. Select the
tie bar from the Diesel Parts And Accessory Guide (90‑892645005). Refer to Multiple Steering
Tie Bar Arrangements and tie bar installation instructions in the Cummins MerCruiser Diesel
Installation Manual provided with the power package before proceeding.
1. Inspect the bushings for debris. Lubricate the power steering bushings.
26740
Steering cylinder bushings

34 Special Lubricant 101 Power steering bushings 92-802865Q02
2. Remove the protective shipping caps.

3. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.
b b
a
c
b
21969
a - Bushing c - Upper and lower pivot bolt

b - Protective shipping caps

34 Special Lubricant 101 Upper and lower pivot bolts 92-802865Q02
4. Position the steering assembly so that the pivot bolts will enter the bushings in the power
steering control valve.
Page 24 / 80 90-869261 MAY 2008

5. Install the upper and lower pivot bolts along with tab washers. Ensure that the tab washer
tangs straddle the ridge on the inner transom plate.
7761
Upper Pivot Bolt and Tab Washer Shown (Lower Similar)

a - Tab washer tang b - Ridge
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. Torque the pivot bolts.

Upper and lower pivot bolt 34 25
9. Bend the tab washer tabs against the corresponding flats on the bolt heads.
NOTE: If necessary, tighten the pivot bolts slightly enough to align the flats on bolt head with the
tabs on the washer.
b
b a
8495
a - Pivot bolt b - Bent tab
10. ! 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.
90-869261 MAY 2008 Page 25 / 80

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 b
7822
a - Clevis c - Clevis pin

b - Steering lever d - Cotter pin

34 Special Lubricant 101 Clevis pin 92-802865Q02
Page 26 / 80 90-869261 MAY 2008

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.
7827
Steering cable and outer casing

34 Special Lubricant 101 Steering cable end 92-802865Q02
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.
90-869261 MAY 2008 Page 27 / 80

c. Using a suitable wrench, hold the flat surfaces on the cable guide tube in the vertical
position. Torque the coupler nut. 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 e- Steering cable end

b- Grease fitting f- Clevis
c- Cable coupler nut g- Clevis pin
d- Cable guide tube h- Cotter pin
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.
Page 28 / 80 90-869261 MAY 2008

NOTE: Fill cap is vented.
a
b
22018
Power trim pump reservoir with the fluid level below the "MIN" line
a - Fill cap assembly b - Fill cap installed
c. Add the specified fluid to bring the fluid level to within the "MIN" and "MAX" lines on the
reservoir.
22019
a - Reservoir b - "MIN" and "MAX" lines

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.
90-869261 MAY 2008 Page 29 / 80

4. Verify that the power trim pump is secured properly and has a fluid level above the "MIN" line.
a
c
b d
26180
e
Power trim pump, fluid level not shown
a- Positive (+) battery lead (not e - GRAY hydraulic hose (trim down)
connected) connected to the trim pump
b- Negative (–) battery lead (not f - Fill and vent cap
connected) g - Dual mount trim pump bracket
c- Vessel sensor harness connection to
the trim pump
d- BLACK hydraulic hose (trim up)
connected to the trim pump
Engine Installation and Alignment

Engine Preparation
1. Remove and read all tags attached to the engine.
2. Loosen fasteners and remove the exhaust pipe and exhaust hose from the pallet.
3. Remove the shipping plug from the coupler and lubricate the splines.
b a
24144
Typical
a - Shipping plug covering the splines b - Engine coupler
Page 30 / 80 90-869261 MAY 2008


91 Engine Coupler Spline Grease Coupler splines 92-802869A 1
Engine Mount Alignment Tool

Use the engine mount alignment tool to identify engine mount installation locations on the hull
stringers. Follow the instructions provided with the tool.
CMD Engine Mount Alignment Tool 8M2012124
Aids in locating engine mounts on hull stringers prior to engine

installation
35290
Engine Preparation
1. Remove and read all tags attached to the engine.
2. Loosen fasteners and remove the exhaust pipe and exhaust hose from the pallet.
3. Remove the shipping plug from the coupler and lubricate the splines.
b a
24144
Typical
a - Shipping plug covering the splines b - Engine coupler

Preparing the Transom

IMPORTANT: 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.
90-869261 MAY 2008 Page 31 / 80

2. Ensure that the O‑ring is properly seated in the groove.
6638
a - Gimbal housing mating surface b - O‑ring
3. Ensure that the exhaust pipe mating surface is clean and free of nicks and scratches.
4. Install the exhaust pipe assembly as shown, using four bolts and thick lockwashers. Torque
the exhaust pipe assembly bolts.
c a
b
24128
a - Upper bolts and thick lockwashers c - Exhaust pipe
(2)
b - Lower bolts and thick lockwashers,
not visible (2)

Exhaust pipe assembly bolts 34 25
Page 32 / 80 90-869261 MAY 2008

5. Position the rear engine mount attaching hardware on the inner transom plate mounts as
shown.
a
22312
Starboard side shown, port side similar

a - Locknut b - Fiber washer
Connecting the Battery Cables to the Engine

See Battery Cables for information on selecting and installing battery cables, if not already
installed.
1. Ensure that the standard negative battery cable connection point and the starter solenoid
terminal are free of paint or any other material that could cause a poor electrical connection.
2. Connect the positive (+) battery cable to the starter solenoid terminal.
IMPORTANT: Overtorquing the positive starter solenoid terminal nut may cause damage to the
starter.

Positive (+) starter solenoid terminal 10 88.5 7.4
3. Connect the negative (–) battery cable to the standard connection point.
c d
25882
QSD 2.0L starter location (fuel filter removed for access)

a - Common engine ground for negative c - Starter solenoid to starter motor wire
(–) battery stud, MerCathode ground, d - Starter positive (+) battery cable stud
and continuity wires
b - Starter solenoid control wire terminal
4. After the battery cables are connected to the engine, apply a thin coat of sealant to the
terminals.

25 Liquid Neoprene Battery terminals 92- 25711 3
5. Slide the rubber protective boot over the positive (+) starter terminal after sealant is dry.
90-869261 MAY 2008 Page 33 / 80

6. Drape battery cables over the top of the engine to prevent them from getting in the way during
installation.
Engine Installation
1. Ensure that the front engine mount adjusting nuts are positioned midway on the studs so that
they can be adjusted up or down as required to align the engine.
2. Lubricate the coupler splines.
23500
a - Grease fitting
b - Coupler splines

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 34 / 80 90-869261 MAY 2008

3. Position the rear engine mount attaching hardware on the inner transom plate mounts as
shown.
a
7960
Starboard side shown, port side similar

a - New design mount (knurled surface)
b - Fiber washer
! 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.
4. Before attaching the engine hoist to the engine lifting eyes, remove the engine cover and set
it aside in a safe location.
5. Attach a suitable sling and lifting arm to the engine lifting eyes. Adjust it so that the engine is
level when suspended.
90-869261 MAY 2008 Page 35 / 80

! 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.
a
b
34009
Engine cover removed

a - Rear engine lifting eye
b - Front engine lifting eye
6. Lift the engine into position in the boat using an overhead hoist.
IMPORTANT: When lowering the engine into position do not set the engine on the shift cable.
7. Ensure that the fiber washers and locknuts are on the inner transom plate mounts.
8. Align the rear engine mounts with the inner transom plate mounts, then 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.
9. Install both rear engine mounting bolts with the hardware as shown.
c
d
a e
f
b 7934
Typical model
a - Rear engine mount d - Washer
b - Inner transom plate mount e - Spacer
c - Bolt f - Fiber washer
10. Tighten the rear engine mounting bolts to specification.
Page 36 / 80 90-869261 MAY 2008


Rear engine mounting bolts 51 – 38
11. Adjust the front engine mounts until they rest on the boat stringers.
12. Set the engine on the boat stringers.
13. Relieve the tension on the hoist.
14. Disconnect the sling from the rear engine lifting eye.
15. Install the engine cover after completing engine and drive installation.
Alignment
1. Ensure that the dust cover is removed or folded back out of the way.
7935
a - Dust cover
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 personal injury or 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.
90-869261 MAY 2008 Page 37 / 80

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 c - Gimbal bearing

b - End of alignment tool to insert d - Engine coupler
through the gimbal housing
assembly
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.
b
a
c
7937
a - Alignment tool c - 90° increments

b - Inserted through the gimbal housing
assembly
Alignment Tool Assembly 91‑805475A 1

5. If the alignment tool does not fit, remove it and 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.
Page 38 / 80 90-869261 MAY 2008

a. To adjust the engine up or down, loosen the locknuts on both front mounts. Turn the
adjusting nuts as necessary. Tighten the locknuts.
23776
Typical front mount

a - Locknut b - Adjusting nut
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.
NOTE: The slots on the engine mount pads provide a small amount of left or right adjustment.
23777
Typical front mount

a - Locknut c - Engine mount pad
b - Slotted mount hole
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 coupler splines. Do not check by turning the
alignment tool.
8. Fasten the front mount assemblies to the boat stringers using appropriate hardware (lag bolts
or thru‑bolts and so on).
9. Torque both front mount locking (jam) nuts.

Front mount locking (jam) nuts 80 59
90-869261 MAY 2008 Page 39 / 80

10. Recheck 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. 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.

Engine mounting hardware
19 Perfect Seal 92-34227 1
threads and nuts
NOTE: If the boat will be shipped without the drive unit installed, we recommend that the shipping
hardware remain on the transom assembly during shipment.
13. Remove the sling from the front lifting 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.
7942
Typical
a - Exhaust riser c - Hose clamps
b - Exhaust tubes
Page 40 / 80 90-869261 MAY 2008

3. Torque the exhaust system hose clamps.
24872
a - Exhaust hose clamps (4)

Exhaust system hose clamps 3.4–6.8 30–60
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.
a
b
7782
Typical
a - Flywheel housing screw c - Inner transom plate grounding screw
b - Continuity circuit wire
Mounting the Vessel Integration Panel (VIP)

The Vessel Integration Panel (VIP) is intended for mounting on the inner transom of the vessel in
the engine compartment.
IMPORTANT: Mount the VIP with the connectors oriented downward, to the port or starboard side,
or laid down. Do not mount the VIP with the connectors facing upward.
1. Mount the Vessel Integration Panel (VIP) in an accessible location.
2. Ensure that the VIP controller is mounted in such a way that
90-869261 MAY 2008 Page 41 / 80

• it is above the waterline at rest and is not near any moving parts.
• it is clear of deck water run‑off and engine compartment water spray.
• the circuit breakers are easily accessible.
• is in an area that is free of excessive heat and minimum 305 mm (12 in.) distance from
all exhaust components.
• it allows a minimum of 229 mm (9 in.) of free space directly below the VIP for wire
harness routing.
• it is not mounted directly or indirectly to the engine and is free from excessive vibration.
24166
a - Mounting bolts (4)
Engine‑to‑VIP Connections
1. Route the harness so that it meets the following conditions:
• Route the harness so that it does not contact any hot or moving parts.
• Ensure that the harness does not rub or get pinched.
• Minimize the harness and harness connections exposure to moisture.
• Mount the harness in the most direct route possible to minimize voltage drop due to wire
resistance.
• Fasten the harness to the boat at least every 460 mm (18 in.) using appropriate
fasteners.
• Follow all ABYC guidelines that govern the installation of signal and DC power wiring in
marine vessels.
Page 42 / 80 90-869261 MAY 2008

2. Connect the extension harness connectors to the engine wiring harness connectors.
a
25889
Engine wiring harness connectors

a - Engine to VIP harness connector b - Power connector
3. Ensure that the harness connectors are securely connected.

4. Connect the engine to VIP harness to the Vessel Integration Panel (VIP). See Vessel
Integration Panel (VIP) Connections.
Vessel Sensor Harness
1. Route the harness out of the way of the engine so that it meets the following conditions.
• The harness does not come into contact with any moving parts.
• The harness does not come into contact with surfaces or components radiating
excessive heat.
• Ensure that the harness does not rub or get pinched.
• Minimize the harness and harness connections from exposure to moisture.
resistance.
• Fasten the harness to the boat at least every 460 mm (18 in.) using appropriate
fasteners.
• Follow all ABYC guidelines that govern the installation of signal and DC power wiring in
marine vessels.
2. Connect the vessel sensor harness to the power trim pump. See Power Trim Pump
Connection.
90-869261 MAY 2008 Page 43 / 80

3. Connect the vessel sensor harness to the trim position sender. See Trim Position Sender
Connection.
b
d
a 26181
Sterndrive vessel sensor harness

a - Vessel sensor harness c - Trim position sender connection
b - Power trim pump connection d - VIP connector
4. Connect the vessel sensor harness to the Vessel Integration Panel (VIP). See Vessel
14‑Pin Helm Extension Harness
When routing any 14‑pin wiring harness back to the engine compartment:
IMPORTANT: Ensure that the harness does not rub or get pinched.
• Ensure that all extension harness connector collars are secure.
• Fasten the harness to the boat at least every 460 mm (18 in.) using appropriate fasteners.
• Minimize the harness and harness connections from exposure to moisture.
• Mount in a location that is free from contact with surfaces or components that are moving or
radiating excessive heat.
resistance.
• Protect the harness from sharp edges when ran through vessel hull support structures.
• Follow all ABYC guidelines that govern the installation of signal and DC power wiring in marine
vessels.
Connect the 14‑pin helm extension harness to the Vessel Integration Panel (VIP). See Vessel
Non‑DTS Helm Harness
Take the following into consideration when mounting and connecting the non‑DTS helm harness:
1. Ensure connectivity capability to all helm mounted devices prior to securing the helm harness
to rigid surfaces.
2. Ensure that it is mounted in a way that will prevent it from being damaged when installing other
helm mounted devices.
3. Mount the harness connections horizontally to minimize water intrusion.
Make the following connections to the helm harness.
1. Connect the key switch to the helm harness.
2. Connect the helm harness to the instrumentation junction box.
3. Connect the trim control and the lanyard wires to their corresponding connections.
Page 44 / 80 90-869261 MAY 2008

4. Ensure that all other necessary connections for the given installation are connected.
NOTE: The non‑DTS helm harness can be connected directly to the VIP if a 14‑pin extension
harness is not required. See Vessel Integration Panel (VIP) Connections.
5. Connect the helm harness to the 14‑pin helm extension harness that is routed to the VIP.
a f
g
c
d e
26325
Non‑DTS helm harness

a- 14‑pin harness connection e - Start/stop panel connection, if
b- CAN terminator resistors equipped
c- Instrumentation junction box f - Lanyard bullet connectors
connection g - Power trim connection
d- Key switch connection
Vessel Integration Panel (VIP) Connections

1. Connect the vessel sensor harness to the VIP (24‑pin connector).
2. Connect the engine extension harness to the VIP (40‑pin connector).
3. Connect the 14‑pin helm harness to the VIP and twist the locking ring into position.
b
a
23778
Vessel Integration Panel (VIP)

a - Vessel sensor harness connector c - 14‑pin helm harness connector
b - Engine extension harness connector
90-869261 MAY 2008 Page 45 / 80

Trim Position Sender Connection

1. Connect the trim position sender from gimbal housing to the engine harness.
b
a
24785
a - Trim position sender b - Trim position sender connector
Power Trim Pump Connection

1. Connect the vessel sensor harness to the trim pump.
7699
Power trim pump

a - Vessel sensor harness connector b - Trim pump connector
Neutral Safety Switch Connection

The neutral safety switch connection prevents the engine from starting while the remote control is
in either the forward or reverse gear.
! WARNING
Improperly installing the remote control can result in serious injury or death. Always remove the
jumper plug from the neutral safety connection on the engine and install it correctly to the remote
control.
Page 46 / 80 90-869261 MAY 2008

1. Disconnect the jumper plug from the neutral safety switch connector located on the engine.
a b
26382
a - Neutral safety switch connector
b - Jumper plug
2. Install a proper connector to the neutral switch wires leading to the remote control.
3. Connect the neutral switch wires from the remote control to the neutral safety switch connector
on the engine.
a b c
26383
a - Neutral safety switch connector
b - Proper connector for wires from the remote control
c - Neutral switch wires leading to the remote control
90-869261 MAY 2008 Page 47 / 80

Quick‑Connect MerCathode System Connection (If Equipped)

1. Connect the wires to the MerCathode controller assembly if they are not already connected.
Connect the male and female quick‑connect terminals.
d
a
c
b
7947
a - Orange lead from anode on transom d - Brown wire from electrode on transom
assembly (through the quick‑connect assembly (through the quick‑connect
fitting) fitting)
b - Red/purple wire to positive (+) battery e - Male and female quick‑connect
terminal terminals
c - Black wire from engine harness, if
equipped, or to negative (–) battery
terminal
2. Apply a thin coat of sealant to all wire connections.

Exposed terminals and
connections
Fluid Connections
Gear Lube Monitor
IMPORTANT: Route hoses to determine the minimum length of hose needed and trim off the
excess to avoid low spots in the system. Avoid kinks and route in a straight path to avoid low spots
(traps) in the system.
1. Locate the quick‑connect fitting of the white gear lube monitor at the rear of the engine.
2. Ensure that the gear lube monitor hose is mounted in the J‑clip on the transom plate.
Page 48 / 80 90-869261 MAY 2008

3. Fasten the quick‑connect fitting between the gimbal housing hose assembly and the gear lube
monitor hose assembly.
c a
b
7800
a - Gear lube monitor hose assembly c - Quick‑connect fitting

from transom
b - Gear lube monitor hose assembly
from gear lube monitor
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.
4. Route the gear lube monitor hose, or hose assemblies, if equipped, with quick‑connect fittings,
to the gear lube monitor.
5. If necessary, cut the gear lube monitor hose to the correct length at the gear lube monitor.
6. Connect and securely clamp the gear lube monitor hose to the gear lube monitor fitting.
a d e
b c
7949
Typical
a - Quick‑connect, if equipped d - Clamp
b - Gear lube monitor hose e - Fitting
c - Gear lube monitor
IMPORTANT: The gear lube monitor hose must not come in contact with the steering system
components, engine coupler, or drive shaft.
7. Secure the gear lube monitor hose with cable ties.
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.
90-869261 MAY 2008 Page 49 / 80

2. Disconnect the hydraulic lines quick‑connect fittings from each other.
19304
a - Hydraulic lines quick‑connect fittings
3. Connect the power‑assisted steering hoses to the control valve. Ensure that the quick‑connect
fittings snap into place.
b
c
7950
a - Rear fitting (pressure hose) c - cable tie

b - Front fitting (return hose)
IMPORTANT: Hydraulic hoses must not come in contact with steering system components, engine
coupler, U‑joint shaft or drive shaft.
4. Secure the hydraulic hoses to avoid contact with hot or moving components.
Seacock and Connector
See Section 5 for information on seawater pickups and the Quicksilver through‑hull seawater
pickup installation, if not already installed.
Seawater Strainer
See Section 5 for information on seawater strainers and their installation if it has not yet been
completed.
Page 50 / 80 90-869261 MAY 2008

Seawater Hoses
IMPORTANT: Before installation, ensure that the shipping dust cap is removed from the seawater
pump inlet. Either an internal or external type of dust cap may be used. Inspect the seawater pump,
seawater strainer and all seawater hoses for any foreign material. Blocked or significantly
restricted seawater flow will cause engine damage.
NOTE: Seawater hoses must be wire‑reinforced to avoid collapsing when suction is created by
the seawater pump impeller.
Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come in contact with
steering system components, the engine coupler, or the drive shaft.
1. Install the seawater hose from the seawater pickup, or seacock (if equipped), to seawater
strainer.
2. Install the seawater hose from the seawater strainer to the seawater pump inlet.
3. Tighten the seawater hose clamps securely.
d
b
a e
25898
Seawater hose standard connections

a - Standard seawater pickup fitting or d - Seawater hose from strainer to
seacock hose connection (if seawater pump
equipped) e - Seawater pump inlet hose connection
b - Seawater hose to seawater strainer
c - Seawater strainer
Fuel Line Connections

For models without the optional fuel cooler:
90-869261 MAY 2008 Page 51 / 80

1. Remove any protective cap or plug from the fuel return fitting and connect the flexible fuel
return hose. Secure with a hose clamp.
c
a
35421
a- Fuel inlet fitting
b- Fuel return fitting
c- Fuel block
d- Fuel filter
3. Tighten the hose clamps to specification.

Hose clamp 5.6 50 –
For models equipped with an optional fuel cooler:
1. Remove any protective cap or plug from the fuel inlet fitting and connect the flexible fuel supply
hose. Secure with a hose clamp.
c b
28100
QSD 2.0L fuel connections
a- Fuel Filter
b- Fuel inlet fitting
c- Fuel return fitting
d- Fuel cooler
3. Tighten the hose clamps to specification.
Page 52 / 80 90-869261 MAY 2008


Hose clamp 5.6 50 –
Alpha Sterndrive Shift Cable Installation

Remote Controls and Propeller Rotation
IMPORTANT: The shift cable must be connected at the remote control for the appropriate rotation
(LH or RH) drive unit, as explained following:
RIGHT‑HAND ROTATION. Install the control cable in the remote control so that the cable end
moves in direction "A" when the shift handle is placed in the FORWARD position.
LEFT‑HAND ROTATION. Install the control cable in the remote control so that the cable end
moves in direction "B" when the shift handle is placed in the FORWARD position.
B 6614
Separate Shift and Throttle Controls

IMPORTANT: If the boat is being equipped with a remote control that has separate shift and throttle
levers, do not use the shift assist assembly that is shipped with the engine. Using the shift assist
assembly with this type of remote control can cause the shift lever to move out of gear
unexpectedly.
Order a spacer kit to connect the remote control shift cable when the shift assist assembly is not
used. Refer to the Diesel Parts and Accessories Guide (90‑892645005) or the Mercury Parts
and Accessories Guide (90‑42000006) for selection.
d 7810
a - Clevis pin c - Spacer

b - Washer d - Cotter pin
90-869261 MAY 2008 Page 53 / 80

NOTE: Do not discard the shift assist assembly. It will be used as a measuring and installation
tool.
Measuring Shift Cable Travel
We recommend the use of a Quicksilver remote control and cable. Refer to the Diesel Parts and
Accessories Guide (90‑892645005) or the Mercury Parts and Accessories Guide
(90‑42000006) for selection.
Shift cable travel at 73 mm to 80 mm (2‑7/8 in. to 3‑1/8 in.)
shift plate Measured with a 6.8‑9 kg (15‑20 lb) load applied to the cable end guide
NOTE: On Alpha sterndrives, shift cable travel can be measured by installing the remote control
shift cable and using the shift assist assembly (provided) to place the proper load on the shift cable.
Place a mark on the tube against the edge of the cable end guide.
d
e
a
b c
7809
a
a - Shift assist assembly d - Remote control shift cable in reverse
b - Remote control shift cable in forward gear position
gear position e - Measurement taken from mark to edge
c - Edge of cable end guide of cable end guide
Installation
1. Remove the shift assist assembly.
Page 54 / 80 90-869261 MAY 2008

2. Remove the shift cable attaching hardware.
b
7812
a - Shift assist b - Shift plate
3. Install the intermediate cable.
7813
4. Secure the brass barrel retainer with the cotter pin.

5. Secure the cable end guide with washers (one on each end of the end guide) and cotter pin.
6. Locate the center of remote control and control cable play (backlash).
IMPORTANT: Keep the center mark "c" aligned with the control cable end guide edge when
making the following adjustment.
a. Shift the remote control to neutral.
b. Push in on the control cable end with enough pressure to remove any slack and mark
position "a" on the tube.
c. Pull out on the control cable end with enough pressure to remove any slack and mark
position "b" on the tube.
90-869261 MAY 2008 Page 55 / 80

d. Measure the distance between marks "a" and "b" and mark position "c" halfway between
marks "a" and "b."
a 7815
b
7. Temporarily install the control cable end guide into the shift lever and insert the anchor pin.
8. Adjust the control cable barrel so that hole in the barrel centers on the vertical center‑line of
stud. Ensure that the center mark is aligned with edge of control cable end guide.
9. Place the remote control and and sterndrive unit in forward gear.
10. Install the remote control shift cable.
11. Place the remote control handle in neutral.
12. Install the shift assist assembly. Ensure that it fits over the clevis pin and barrel stud with no
resistance.
13. Install the fastening hardware. If shift assist assembly attaching points will not align, verify that
the controller is in neutral. Remove the shift cable and reposition the adjustment barrel as
required to allow the shift assembly to be installed with no effort.
a
c
e
b 7818
With shift assist assembly

a - Remote control shift cable d - Large ID washer
b - Shift assist assembly e - Small ID washer and cotter pin
c - Clevis pin (and cotter pin not shown)
Page 56 / 80 90-869261 MAY 2008

d f
e g
a
i
h
b 7841
Without shift assist assembly

a- Remote control shift cable f- Washer
b- Clevis pin g- Spacer
c- Cotter pin (existing) (not shown) h- Washer (existing)
d- Spring (existing) (not shown) i- Cotter pin (existing)
e- Washer (existing)
Alpha Sterndrive Installation

1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts
and flat washers.)
7713
Typical
a - Dust cover b - Trim cylinder support
90-869261 MAY 2008 Page 57 / 80

2. Remove gear lube monitor cap. Fill with lubricant.
a b
5497
a - ‑ Gear lube monitor cap b - "OPERATING RANGE" line

Lubricant
3. Push dribble valve stem in until gear lube appears.
7851
a - Dribble valve stem
4. Once gear lube appears, release dribble valve stem.

5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING
RANGE" (full) line with specified fluid. Do not overfill.

Lubricant
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do
not overtighten the cap.
IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing
drive unit or water may leak into boat.
7. Ensure that rubber gasket and water passage O‑ring are properly positioned in bell housing.
Page 58 / 80 90-869261 MAY 2008

8. Coat bell housing studs with lubricant.
a
c c
7852
a - Rubber gasket c - Studs (6)

b - Water passage O‑ring

2-4-C Marine Lubricant with
95 Bell housing studs 92-802859A 1
Teflon
9. Grease sterndrive U‑joint O‑rings, and drive shaft splines. A grease packet for this procedure
is provided with the sterndrive packaging.
7853
a - U‑joint O‑rings b - Drive shaft splines


91 Engine Coupler Spline Grease Drive shaft splines 92-802869A 1
90-869261 MAY 2008 Page 59 / 80

10. Ensure U‑joint bellows are clean and free of debris.
7854
a - U‑joint bellows
11. Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and
aft. Do this by placing remote control shift lever in: FORWARD gear position for RH drive or
REVERSE gear position for LH drive unit.
c
a
b
7855
a - Shift shaft c - Shift slide

b - Shift shaft coupler d - Slot
IMPORTANT: Shift slide assembly is free to rotate on core wire. Ensure that shift slide remains in
upright position and is properly engaged with shift shaft lever roller while installing drive unit.
12. Engage shift shaft roller into shift shaft lever.
13. Place gasket on bell housing.
Page 60 / 80 90-869261 MAY 2008

14. Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide.
a d
b
c
c 7859
a - Shift shaft lever c - Shift Shaft Slide Stabilizer Tool

b - Roller d - Gasket
Shift Slide Stabilizer 91‑865232

15. Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE
while simultaneously turning propeller shaft COUNTERCLOCKWISE.
7856
a - Drive unit shift shaft
IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dual
engine installations. The LH rotation drive unit can be identified by the decal on the back side of
the upper drive shaft housing, which states: "Alpha One ‑ Counter Rotation"
16. Install sterndrive unit as follows:
a. Position trim cylinder straight back (over top of acceleration plate). Be careful not to
scratch acceleration plate or trim cylinders.
b. Guide U‑joint shaft through gimbal bearing and into engine coupler while simultaneously
guiding shift slide into drive shaft housing. Ensure that shift slide remains upright and
engaged with bell housing shift shaft lever.
c. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align U‑joint
shaft splines with engine coupler splines while sliding sterndrive into bell housing.
90-869261 MAY 2008 Page 61 / 80

IMPORTANT: If drive unit will not slide into bell housing, ensure that the shift shaft and couplers
are positioned properly. Do not force drive unit into position.
b
7857
a - Gasket b - Shift slide
d. Remove Shift Slide Stabilizer Tool and discard.

e. Slide sterndrive all the way into bell housing.
f. Secure sterndrive to bell housings using fasteners as shown. Torque the fasteners.
7858
a - Locknut and flat washers b - Locknut and continuity circuit washer

(no flat washer at this location)

Sterndrive unit fasteners 68 50
17. Return remote control shift lever to the NEUTRAL position.
18. Position the sterndrive unit serial number decal.
Trim Limit Spacer Kit (if Equipped)
All trim cylinders have one trim limit spacer kit installed by a vendor prior to 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. Install the trim cylinder, see Trim Cylinder Installation. 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 for use to set the trim and trailer limit, then an
additional trim limit spacer kit must be installed. Install the kit before connecting the trim cylinders
to the sterndrive. The trim limit spacer kit keeps the sterndrive from raising beyond the gimbal ring
support or from contacting any 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.
Page 62 / 80 90-869261 MAY 2008

Alpha Trim Cylinder Installation

1. Install trim cylinders forward mounting hardware.
2. Coat area in trim cylinder between bushings with lubricant.
3. Replace anchor pin and install bushings and washers.
4. Attach E‑rings and plastic caps to end of anchor pin.
a
c
e
b
d 4827
a - Front anchor pin d - E‑ring (port and starboard) (2)

b - Bushing (port and starboard) (4) e - Plastic caps (port and starboard) (2)
c - Flat washer (port and starboard) (2)

95 Trim cylinder hardware 92-802859A 1
Teflon
5. Install trim cylinders rear mounting hardware.
6. Coat area in trim cylinder between bushings with lubricant.
7. Replace anchor pin and install bushings and washers.
8. Attach E‑rings and plastic caps to end of anchor pin.
b a
d
a c e
b 7844
a - Rear anchor pin d - E‑ring (port and starboard) (2)

b - Bushing (port and starboard) (4) e - Plastic caps (port and starboard) (2)
c - Flat washer (port and starboard) (2)

95 Trim cylinder 92-802859A 1
Teflon
9. Reconnect trim hoses after air bleeding power trim cylinders and hoses following procedures
outlined in Mercury MerCruiser Service Manual 14.
90-869261 MAY 2008 Page 63 / 80

Speedometer Connection
1. Raise the drive to gain access to the area between the gimbal housing and sterndrive
immediately above the transom end of the anti‑ventilation plate.
2. Align the plastic slots on the male and female ends of the speedometer tube fitting and insert.
3. Push down to secure.
4803
a - Male end of speedometer tube fitting b - Female end of speedometer tube

fitting
IMPORTANT: Ensure that the speedometer tube is secure and will not come in contact with any
hot or moving parts.
8029
a - Male end of speedometer tube fitting b - Female end of speedometer tube

fitting
Bravo Sterndrive Shift Cable Installation

Shift Cable Travel
We recommend the use of a Quicksilver remote control and cable. Refer to the Diesel Parts And
Accessories Guide (90‑892645005) or the Mercury Parts and Accessories Guide
(90‑42000006) for selection. However, if a control other than Quicksilver is to be used, the control
must provide a shift cable travel (at the shift plate end) of 73 mm (2‑7/8 in.) to 80 mm (3‑1/8 in.)
with a 6.8–9 kg (15–20 lb.) load applied to the cable end guide.
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.
Page 64 / 80 90-869261 MAY 2008

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 7998
a - Stud b - 76 mm (3 in.)—distance from the

center of pivot bolt to the center of the
stud
3. Remove the adjustment tool.
7999
4. Install the sterndrive shift cable.

5. Insert the cotter pins from the top. Spread the ends of the cotter pins fully.
d
b 8000
a - Sterndrive shift cable c - Long cotter pin

b - Washers (2) d - Short cotter pin
90-869261 MAY 2008 Page 65 / 80

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" half‑way
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 edge of
the control cable end guide.
! CAUTION
Do not attempt to install or remove control cable barrel from stud without first removing end guide
anchor pin from shift lever and removing cable. Attempting to bend control cable to install or
remove barrel will place undue stress on cable end guide and shift lever and damage to both
could occur.
Page 66 / 80 90-869261 MAY 2008

c. Remove the control cable end guide from the shift lever by removing the clevis pin.
d a
c 8003
b
a - Control cable end guide d - Control cable barrel
b - Clevis pin e - Stud
c - Backlash center
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
b
d 8004
a - Cotter pin c - Clevis pin

b - Washers (both sides of barrel) d - Cotter pin (partially shown)

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 Model: 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.
90-869261 MAY 2008 Page 67 / 80

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 adjustment is correct, retighten the stud.
c
c
b
b
a
a
d 8005
e 8006
RH Rotation—Bravo One, Two, Three LH Rotation—Bravo One and Two
a - Adjustment tool d - Shift lever adjustment tool, rear slot
b - Barrel retainer cotter pin e - Shift lever adjustment tool, forward slot
c - Shift lever stud

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 Model: 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
b
b
a
a
d 8005
e 8006
LH Rotation—Bravo One and Two RH Rotation—Bravo One, Two, Three
a - Adjustment tool d - Shift lever adjustment tool, rear slot
b - Barrel retainer cotter pin e - Shift lever adjustment tool, forward slot
c - Shift lever stud

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

Page 68 / 80 90-869261 MAY 2008

Bravo Sterndrive Installation

1. If applicable, remove the trim cylinder support and dust cover from the bell housing studs.
Retain the elastic stop nuts and flat washers.
8993
Typical
a - Dust cover b - Trim cylinder support
2. Remove gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE" mark.
a b
5497
a - Gear lube monitor cap b - "OPERATING RANGE" line

Lubricant
90-869261 MAY 2008 Page 69 / 80

3. To purge air from the system, push in on the dribble valve stem until gear lube appears.
21440
a - Dribble valve
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 specified fluid. Do not overfill.

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 sterndrive U‑joint O‑rings and drive shaft splines with grease.
a a
21441
a - O‑rings
a
21442
a - Splines

Page 70 / 80 90-869261 MAY 2008


91 Engine Coupler Spline Grease Drive shaft splines 92-802869A 1
IMPORTANT: The edge of the U‑joint bellows acts as a seal between the bell housing and the
drive shaft housing. Inspect the surface for damaged.
8. Ensure that the U‑joint bellows are clean and free of debris.
a b
21456
Bell housing of the transom assembly
a - U‑joint bellows edge b - U‑joint bellows
9. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the bell housing studs.
a
a
21457
a - Bell housing studs (6) b - Tube of lubricant

34 Special Lubricant 101 Bell housing studs 92-802865Q02
90-869261 MAY 2008 Page 71 / 80

10. Lubricate the O‑ring seals.
a
25970
a - O‑ring seals

95 O-ring seals 92-802859A 1
Teflon
11. Pull the shift linkage out until it stops opening the jaws.
a
a
c
c
5311
21471
a - Shift linkage assembly c - Underside of lower lip
b - Jaws open
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.
Page 72 / 80 90-869261 MAY 2008

NOTE: As 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
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
b
5313
a - Shift linkage assembly b - Shift cable
13. Install the sterndrive as follows:
90-869261 MAY 2008 Page 73 / 80

a. Remove the nuts from the trim cylinders and remove the trim cylinders from the anchor
pin.
a c
b
d
e
21521
a - Socket d - Ground wires
b - Wrench e - Trim cylinders
c - Anchor pin
b. Position the sterndrive so that the universal joint shaft aligns with the bell housing bore.
a b
c d 21518
a - Universal joint c - Shift linkage
b - Bell housing d - Shift cable
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 b c
21519
a - Shift cable c - Shift linkage jaws engage the shift
b - Shift linkage jaws open cable
Page 74 / 80 90-869261 MAY 2008

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.
a c
26184
21520
a - Bell housing studs d - Propeller shaft
b - Dribble valve e - Propeller
c - Shift cable
IMPORTANT: Avoid damaging the gimbal housing studs, which 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.
25908
Ground plate with serial number and gear ratio
a - Washers not used here
90-869261 MAY 2008 Page 75 / 80

15. Start from the center and torque the locknuts.
a
b
25909
a - Locknut (6) flat washers (4) b - Torque wrench

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.
2. Set the trim and trailer limit during predelivery preparation. Refer to Setting Trailer and Trim
Limit in the Predelivery Preparation and Storage section.
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.
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.
Page 76 / 80 90-869261 MAY 2008

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

Teflon
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 b - Trim‑in limit insert Bravo Three
Two (positioned forward) (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.
90-869261 MAY 2008 Page 77 / 80

NOTE: Apply lubricant to all installed stainless steel components.
c b c
a
d e
c f
9295
a - Aft anchor pin d - Small ID flat washers (2)

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

Teflon
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 c - Plastic cap (4)
b - Wrench tool
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.
Page 78 / 80 90-869261 MAY 2008

2. Insert speedometer tube fitting into opening on topside of anti‑ventilation plate, in position
shown.
5319
a - Tube fitting b - Opening
3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
5320
a - Fitting installed (handle pointing forward)
90-869261 MAY 2008 Page 79 / 80

NOTES:
Page 80 / 80 90-869261 MAY 2008

SECTION - 7 STARTING AND ELECTRICAL
SECTION 7 - STARTING AND ELECTRICAL

Table of Contents
Electrical System Precautions................................................................................................................................. 2
Battery Specifications.............................................................................................................................................. 2
Selecting the Battery.........................................................................................................................................2
Battery Precautions for Multiple Engines..........................................................................................................2
Selecting the Battery Cables.............................................................................................................................3
Battery Cable Installation Requirements...........................................................................................................3
Instrumentation........................................................................................................................................................ 4
General Information...........................................................................................................................................4
Wiring Diagrams...................................................................................................................................................... 5
MerCathode System.......................................................................................................................................... 5
90-869261 MAY 2008 Page 1 / 6

STARTING AND ELECTRICAL SECTION - 7
Electrical System Precautions

The following precautions apply to all engines:
IMPORTANT: Refer to the following precautions when working on or around the electrical harness,
or when adding other electrical accessories, 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.
Battery Specifications
Selecting the Battery
IMPORTANT: Adhere to industry standards (BIA, ABYC, etc.), federal standards, and Coast
Guard regulations when installing a battery. Ensure that battery cable installation meets the pull
test requirements and that the positive battery terminal is properly insulated in accordance with
regulations.
IMPORTANT: We recommend, and some states require, installing the battery in an enclosed case.
Refer to regulations for your area.
IMPORTANT: The engine electrical system is negative (–) ground.
Select a battery that meets all of the following specifications:
• 12‑volt marine type.
• Tapered post connectors or side terminal connectors. Do not use a battery with wing nut
connectors.
• Battery capacity rating of at least:
Engine Minimum Required Cranking Battery Size

QSD 2.0L 750 cca, 950 mca, or 180 Ah
Battery Precautions for Multiple Engines

Alternators. Alternators charge a single battery bank that supplies electrical power to the
individual engine that the alternator is mounted on. Connect only one battery to one alternator.
CMD recommends against connecting two batteries to the same alternator unless a battery isolator
is used.
Electronic Control Module (ECM). The ECM requires a stable voltage source. During multiple
engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine's
battery. The voltage may go below the ECM's minimum required voltage. Also, the alternator on
the other engine may now start charging. This could cause a voltage spike in the engine's electrical
system.
In either case, the ECM could shut off. When the voltage returns to the range that the ECM
requires, the ECM will reset itself. The engine will now run normally. This ECM shut down usually
happens so fast that the engine just appears to have an ignition miss.
Batteries. Boats with multi‑engine Electronic Control System (ECS) power packages require each
engine be connected to its own battery bank. This ensures that the engine's Electronic Control
Module (ECM) has a stable voltage source.
Battery Switches. Battery switches should always be positioned so each engine is running off its
own battery. Do not operate engines with 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.
Page 2 / 6 90-869261 MAY 2008

NOTE: Sure Power Industries Inc., Model 32023A, meets this design specification.
• The boat may have two engines connected to a single Model 32023A battery isolator.
• The Model 32023A battery isolator is connected to two banks of batteries.
• Each bank contains two batteries with the cranking battery for one engine in each bank.
• The second battery in each bank is connected in parallel to the cranking battery.
• The Model 32023A battery isolator is designed for two battery banks, two charging sources,
and 120 amps (maximum alternator output).
• When the engines are running, either engine's alternator could be charging either bank of
batteries through the Model 32023A battery isolator.
Any other manufacturer's battery isolator that is the same type as the Sure Power Inc., Model
32023A can be used.
Generators. The generator's battery should be considered in the same manner as another
engine's battery.
Selecting the Battery Cables
Select battery cables that meet the following specifications:
• Battery cables must comply with SAE J1127 or comparable standards.
• Battery cable terminals must be soldered to the cable ends to ensure good electrical contact,
using electrical grade (resin flux) solder only. Some form of mechanical connection (such as
swage or crimp) is also recommended, and is required if the length of the solder connection
is less than 1‑1/2 times the diameter of the stranded area of the cable (ABYC standard).
• Battery should be located as close to the engine as possible.
• Select the proper gauge cable. The length in the following charts are for one way from the
battery to the engine. Use the longest length cable (positive or negative) when making a
selection from the appropriate chart.
In-Line Diesel Engines

Number of Battery Cables for Positive and
Battery Cable Length Minimum Cable Gauge
Negative
0.9 m (up to 3 ft.) 30 mm2 (2)
0.9–1.1 m (3–3¾ ft.) 50 mm2 (1)
1.1–1.4 m (3¾–4¾ ft.) 50 mm2 (0) One cable of specified gauge required for
positive and two required for negative.
1.4–1.8 m (4¾–6 ft.) 70 mm2 (00)
1.8–2.3 m (6–7½ ft.) 90 mm2 (000)
2.3–2.9 m (7½–9½ ft.) 100 mm2 (0000)
2.9–3.7 m (9½–12 ft.) 70 mm2 (00)
Two cables of specified gauge required for
3.7–4.6 m (12–15 ft.) 90 mm2 (000) positive and two required for negative.
4.6–5.8 m (15–19 ft.) 100 mm2 (0000)
Battery Cable Installation Requirements

• 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 multiple engine installations
(including generator sets), run a separate negative ground cable between the engines (in
addition to the cable mentioned above). Size the cable to 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.
90-869261 MAY 2008 Page 3 / 6

• Route the positive battery cable to avoid contact with any portion of the engine or drive train.
• Protect cables that are exposed to 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 To The Engine to ensure good electrical contact.
Instrumentation
General Information
The QSD engines are designed to work with SmartCraft Instrumentation and Wiring Harnesses.
Refer to the Diesel Parts and Accessories Guide (90‑892645005) or Mercury Parts and
Accessories Guide (90‑42000006) for complete listings.
The SmartCraft data is carried in the 14‑pin system without the use of a special data harness.
The six basic gauges that must be used with the engine are:
1. Tachometer
2. Oil pressure
3. Engine coolant temperature
4. Voltmeter
5. Trim gauge
SmartCraft instrumentation and instrument wiring connectors are labeled for ease of installation.
SmartCraft wiring harnesses connect directly to the 14‑pin boat harness.
Refer to the appropriate manuals that accompany your instrumentation package.
Page 4 / 6 90-869261 MAY 2008

Wiring Diagrams
MerCathode System
a
c
8526
a- Controller
b- 20‑amp fuse
c- Electrode
d- BLACK wire ‑ with engine harness or separate, model dependant
90-869261 MAY 2008 Page 5 / 6

NOTES:
Page 6 / 6 90-869261 MAY 2008

SECTION - 8 REMOTE CONTROLS
SECTION 8 - REMOTE CONTROLS

Table of Contents
Power Trim System................................................................................................................................................. 2
Control...............................................................................................................................................................2
Pump Location..................................................................................................................................................2
Steering Helm and Cable........................................................................................................................................ 2
Steering Cable Specifications...........................................................................................................................3
Throttle and Shift—Remote Control and Cables..................................................................................................... 4
Propeller............................................................................................................................................................5
Rotation On Dual Installations ................................................................................................................... 5
Direction Of Propeller Rotation .................................................................................................................. 5
Troubleshooting Shift Problems........................................................................................................................5
Throttle Cable Installation and Adjustment........................................................................................................ 8
90-869261 MAY 2008 Page 1 / 10

REMOTE CONTROLS SECTION - 8

95 2-4-C Marine Lubricant with Teflon Shift cable end 92-802859A 1
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.
Pump Location
Select an appropriate mounting location for the trim pump that meets the following requirements:
• Is within the 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 trim pump oil fill and vent locations.
• Is where the pump will not be exposed to water.
• Prevents the power steering booster cylinder from touching the trim pump when the steering
wheel is turned right or left.
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.
7827
a - Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove)
Page 2 / 10 90-869261 MAY 2008

If the steering cable does not have a self‑locking coupler nut, use an external locking device.
b e
a f
d 16814
a - Steering cable d - Locking sleeve (if required. Must be

b - Grease fitting ordered separately)
c - Cotter pin e - Cable coupler nut
f - Cable guide tube
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.
90-869261 MAY 2008 Page 3 / 10

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
Throttle and Shift—Remote Control and Cables

To ensure proper shift and throttle operation, we recommend using a Quicksilver remote control
and cables. Refer to the Diesel Parts and Accessories Guide (90‑892645005) or the Mercury
Parts and Accessories Guide (90‑42000006) for selection. However, if a control other than
Quicksilver is to be used, the control must provide the following:
Cable Travel (at Shift Plate End with 6.8-9 kg

Description
[15-20 lb.] Load Applied)
Shift Cable 73 mm to 80 mm (2‑7/8 in. to 3‑1/8 in.)
Page 4 / 10 90-869261 MAY 2008

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).
b a
16816
Outboard propeller rotation

a - RH rotation b - LH rotation
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.
Troubleshooting Shift Problems
NOTE: The following information assists an installer in troubleshooting hard shifting or chucking/
racheting when shifting into FORWARD gear.
90-869261 MAY 2008 Page 5 / 10

1. When installing the control box in the side panel of the boat, ensure 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 fiberglass
structure, the cables will be interfered with; this will cause very hard shifting.
NOTE: The control box housing can be rotated in 30° increments to improve 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 as this will cause stiff shifting.
IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends on
too‑short cables result in kinks and too‑long cables require unnecessary bends or loops. Both
conditions place extra stress on the cables.
IMPORTANT: Shift cable and throttle cable lubrication points use 2‑4‑C with Teflon.
Page 6 / 10 90-869261 MAY 2008

3. Before installing the shift cable into the control box, extend the stainless rod eye end of the
cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.
7874
d
a - Remote control end c - Adjusting barrel
b - Engine end d - Lubricating point

95 Shift cable end 92-802859A 1
Teflon
NOTE: Allow for clearance of the cables directly behind the panel mount remote control. The 4000
GEN II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.)
thickness. The cable radius at any one point must be greater than 305 mm (12 in.).
4000 GEN II Series Panel Mount Remote Control
Mounting surface maximum thickness 25 mm (1 in.)
Minimum cable bend radius at any point 305 mm (12 in.)
4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 cm
(3 ft.) of the control box.
5. Ensure that the cable is not permanently kinked.
6. Ensure that there is proper clearance for cable movement when the control box is installed in
the side panel. The cables must have room to move up and down when the control handle is
shifted into either forward or reverse.
7. 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 or stiff shifting.
8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft.) of
the shift plate.
9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within
1.5 m (5 ft.) of the shift plate.
10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. The barrel and
cable end must be free to rotate on the mounting stud.
NOTE: Lubricate attaching points with engine oil.

90-869261 MAY 2008 Page 7 / 10

11. The sterndrive shift cable must be routed as shown following to allow sufficient length for the
connection to the shift plate.
a
15357
Typical drive unit shift cable routing

a - Cable routed over top of exhaust pipe
NOTE: A final check of the adjustments should be made with the boat in the water and 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 pre‑delivery inspection
12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.
Refer to the Shift Effort Tool (90‑865523) Instruction Sheet for more information.
Throttle Cable Installation and Adjustment
IMPORTANT: When installing throttle cables, route the cables to avoid sharp bends and to avoid
contact with moving parts. Do not attach any items to the throttle cables.
1. Place the remote control lever in the neutral and idle position.
2. Place the engine throttle lever in the idle position.
3. Install the end guide of the throttle cable anchor stud in the third hole from the end of the
throttle lever. Hand‑tighten the locknut only.
b
a
27184
Engine throttle lever (idle)
a - Throttle cable c - Throttle lever locknut
b - Throttle cable mounting holes d - Throttle lever in idle position.
Page 8 / 10 90-869261 MAY 2008

4. Install the throttle cable barrel anchor bolt in the fourth hole from the left on the top row of the
anchor bracket. Hand‑tighten the locknut only.
d
c
b
a
27202
Throttle cable anchor bracket
a - Throttle cable anchor bolt c - Throttle barrel adjustment threads
b - Mounting holes d - Throttle cable
IMPORTANT: Adjust the throttle cable so that the throttle position sensor (TPS) does not contact
the sensor's internal mechanical stop at wide open throttle (WOT). Repeated operation of the TPS
at the limits of its range of travel could result in TPS failure.
5. If using the CDS tool to adjust the throttle cable:
NOTE: Use of the CDS tool to monitor TPS output is the preferred method of throttle cable
adjustment.
a. Move the throttle lever forward until the CDS tool indicates that the TPS is at wide open
throttle (WOT).
b. Adjust the throttle cable so that the throttle lever can travel past the WOT position but
stops short of the TPS's internal mechanical stop.
6. If the CDS tool is unavailable, then adjust the throttle cable as follows:
a. Set the throttle lever at its idle position.
27205
Engine throttle linkage (idle)
a - Throttle lever cable locknut b - Throttle lever in idle position
b. Move the throttle lever toward its WOT position.
90-869261 MAY 2008 Page 9 / 10

c. Using the center of the throttle lever cable locknut as a reference, measure the distance
the throttle lever travels (throttle range of motion) as it moves from idle toward WOT.
c
a
27229
Throttle adjustment measurements
a - Throttle lever cable locknut ‑ idle c - Throttle lever cable locknut ‑ WOT
position position
b - Throttle range of motion
d. The throttle lever's range of motion (Measurement - b) between idle and WOT should
measure between 70 mm (2 3/4 in.) and 79 mm (3 1/8 in.).
e. Adjust the throttle cable so that the throttle's range of motion measures within the
specified 70 mm (2 3/4 in.) and 79 mm (3 1/8 in.).
7. Tighten the locknuts until they contact the washers, then loosen 1/2 turn.
8. Place the remote control lever in the neutral and idle position. Adjust the throttle cable barrel
if the throttle position sensor does not return to the idle position.
9. Place the remote control lever in the forward gear, WOT position.
10. Confirm that the throttle lever range of motion remains within specification.
11. Operate the remote control to ensure proper shift and throttle operation.
Page 10 / 10 90-869261 MAY 2008

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

STORAGE
Table of Contents
Predelivery Preparation........................................................................................................................................... 2
Engine Oil................................................................................................................................................................ 2
Checking...........................................................................................................................................................2
Filling.................................................................................................................................................................3
Engine Coolant........................................................................................................................................................ 5
Checking...........................................................................................................................................................5
Filling.................................................................................................................................................................6
Power‑Assisted Steering Fluid................................................................................................................................ 6
Checking...........................................................................................................................................................6
Filling.................................................................................................................................................................7
Battery Connections................................................................................................................................................ 7
Trim Pump Connections....................................................................................................................................7
Battery Cable Connection.................................................................................................................................8
Power Trim Fluid..................................................................................................................................................... 8
Checking...........................................................................................................................................................8
Filling.................................................................................................................................................................9
Setting Trailer and Trim Limit................................................................................................................................ 10
Setting Trailer Limit with CDS.........................................................................................................................10
Setting Trim Limit with CDS............................................................................................................................10
Sterndrive Gear Lube............................................................................................................................................ 11
Checking.........................................................................................................................................................11
Filling...............................................................................................................................................................11
Propellers.............................................................................................................................................................. 12
Propeller Selection..........................................................................................................................................12
Alpha Sterndrive Propeller Installation ...........................................................................................................13
Alpha Models ........................................................................................................................................... 13
Bravo Diesel Sterndrive Propeller Installation.................................................................................................14
Bravo One Propeller Installation......................................................................................................................14 9
Bravo Two Propeller Installation...................................................................................................................... 16
Engine Operation Testing...................................................................................................................................... 17
Boat in the Water.............................................................................................................................................17
Boat out of the Water......................................................................................................................................18
Testing.............................................................................................................................................................20
Boat‑in‑the‑Water Tests..................................................................................................................................22
Engine Initial Break‑In Procedure ............................................................................................................ 22
Maximum RPM Test........................................................................................................................................23
After Operating the Engine..............................................................................................................................23
Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage............................................. 24
Cold Weather (Freezing Temperature) Storage..............................................................................................25
Preparing Your Power Package for Seasonal or Extended Storage...............................................................25
Draining the Seawater System........................................................................................................................25
Seasonal Storage Instructions........................................................................................................................27
Extended Storage Instructions........................................................................................................................28
Predelivery Inspection Checklist........................................................................................................................... 29
90-869261 MAY 2008 Page 1 / 30

PREDELIVERY PREPARATION AND STORAGE SECTION - 9

19 Perfect Seal Drain plug or fitting threads 92-34227 1
25 Liquid Neoprene Exposed terminals and connections 92- 25711 3
Dexron III Automatic Transmission

28 Power-assisted steering system Obtain Locally
Fluid
Propeller shaft splines
Steering cable and clevis
87 High Performance Gear Lube Gear lube monitor 92-858064K01
94 Anti-Corrosion Grease Propeller shaft splines 92-802867Q 1
95 2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A 1

Power-assisted steering pump
114 Power Trim and Steering Fluid 92-858074K01
Power trim pump
Special Tools
Flushing Attachment 44357Q 2
Attaches to the water intakes; provides a fresh water

connection when flushing the cooling system or operating the
engine.
9192
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 have the dealer to complete these procedures.
Engine Oil
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.
Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing
your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and
contain and dispose of fluids as required.
Checking
IMPORTANT: Engine crankcase oil must be checked at intervals specified in Maintenance
Schedules. It is normal for an engine to use a certain amount of oil in the process of lubricating
and cooling the engine. The amount of oil consumed depends greatly upon engine speed, with
consumption being highest at wide open throttle and decreasing substantially as engine speed is
reduced.
Page 2 / 30 90-869261 MAY 2008

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.
1. To check the engine oil level during operation, stop the engine and allow five minutes for the
oil to drain into the pan.
2. Remove the dipstick. Wipe clean and reinstall into the dipstick tube.
27986
QSD 2.0L engine oil service
a - Engine cover with access panel c - Engine oil dipstick
removed
b - Engine oil fill cap
3. Remove the dipstick and observe the oil level. The oil level must be between the marks on
the dipstick. If necessary, add oil. See Filling.
a b c
14624
Engine oil dipstick markings

a - Dipstick c - Full mark and maximum operation
b - Minimum operating level level
4. Install engine oil dipstick

Filling
IMPORTANT: Do not overfill the engine with oil.
90-869261 MAY 2008 Page 3 / 30

1. Remove the oil fill cap.
27986
QSD 2.0L engine oil service
a - Engine cover with access panel removed
b - Engine oil fill cap
c - Engine oil dipstick
2. Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick.
a b
33988
a - Coolant oil cooler
b - Seawater oil cooler
Engine Coolant Oil Cooler

QSD 2.0 System Capacity Fluid Type Part Number
Engine oil (with filter) 5.85 L (6.20 US qt) 15W40 4‑cycle Diesel Engine Oil 92‑877695K1
Engine Seawater Oil Cooler

QSD 2.0 System Capacity Fluid Type Part Number
Engine oil (with filter) 6.00 L (6.30 US qt) 15W40 4‑cycle Diesel Engine Oil 92‑877695K1
IMPORTANT: When refilling the engine with oil always use the dipstick to confirm the oil level.
3. Install the oil fill cap.
Page 4 / 30 90-869261 MAY 2008

Engine Coolant
! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in
serious injury from burns. Allow the engine to cool down before removing the coolant pressure
cap.
Checking
IMPORTANT: Check the engine coolant before starting the engine.
1. Allow the engine to cool.
2. Remove the pressure cap from the coolant expansion tank.
3. The coolant level in the coolant expansion tank should be within 25 mm (1 in.) of the top of
the fill neck.
b
c
a
25356
Location of engine coolant cap (engine cover removed)
a - Pressure cap c - Bottom of fill neck
b - Coolant expansion tank
4. If the coolant level is low:

a. Inspect the coolant recovery system for leaks.
b. Inspect the gasket in the pressure cap for damage and replace if necessary.
14142
a - Gasket
c. The pressure cap maintains pressure on the cooling system and may not be holding
pressure properly. To have the cap tested, contact your Cummins MerCruiser Diesel
Authorized Repair Facility.
90-869261 MAY 2008 Page 5 / 30

d. Add the specified coolant as necessary. See Filling.

IMPORTANT: When installing the pressure cap, be sure to tighten it securely to prevent coolant
loss.
5. Add the specified coolant as necessary. See Filling .
loss.
6. If the coolant level is correct, install the pressure cap and tighten securely.
7. Recheck the coolant level after the first WOT boat test and add coolant, if necessary.
Filling
1. Allow the engine to cool.
2. Remove the pressure cap from the coolant expansion tank.
3. If the coolant is low in the coolant expansion tank, add the specified coolant as necessary to
bring the level to within 25 mm (1 in.) of the bottom of the fill neck.
b
c
a
25356
Engine coolant fill location (engine cover removed)
a - Pressure cap c - Bottom of fill neck
b - Coolant expansion tank
Description Where Used Part Number

92‑813054A2
Marine Engine Coolant
Europe Only
Fleetguard Compleat with Closed cooling system
Fleetguard Part Number: CC2825
DCA4
Obtain Locally
loss.
4. Install the pressure cap. Tighten securely.
Power‑Assisted Steering Fluid

IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic
transmission fluid (ATF) in the power‑assisted steering system.
IMPORTANT: Running the pump dry will damage the pump. Always check steering fluid levels
before operating the boat.
Checking
1. Center the sterndrive and stop the engine.
2. Remove the fill cap and dipstick from the fluid reservoir and observe the level.
Page 6 / 30 90-869261 MAY 2008

a. The proper fluid level with the engine cold should be between the full cold mark and the
end of the dipstick.
b. With the engine at normal operating temperature should be between the full hot and full
cold marks.
b
c
13064
Typical
a - Fill cap and dipstick c - Full cold mark
b - Full hot mark d - Fluid reservoir
Filling
1. Remove the fill cap and dipstick and observe the fluid level.
2. Add the specified fluid to bring the fluid level up to the proper level.

114 Power Trim and Steering Fluid Power-assisted steering pump 92-858074K01

Dexron III Automatic Power-assisted steering
28 Obtain Locally
Transmission Fluid system
3. Install the fill cap and dipstick.
Battery Connections
Trim Pump Connections
In order to install Cummins MerCruiser Diesel's (CMD) Trim Pump in the manner recommended
by the American Boat and Yacht Council (ABYC), some installations require the use of an
accessory cable assembly.
In an effort to best support all boat builders, CMD has developed three methods to facilitate
compliance with ABYC recommendations. These come in the form of one standard production
and two accessory kits:
1. Installations with batteries (or battery banks) rated less than or equal to 800 cold
cranking amps (CCA) and without a battery switch: The trim pump may be installed using
the current standard production assemblies (per instructions) without the purchase of
additional kits or accessories. Either of the kits below may be installed and remain in
compliance with ABYC recommendations.
90-869261 MAY 2008 Page 7 / 30

2. Installations with batteries (or battery banks) rated more than 800 CCA or with a battery
switch: The red power supply wire (for the trim pump) must be connected to the switched
side of the battery switch and either:
a. provided with circuit protection within 7 inches of the point of connection with the power
source or
b. provided with circuit protection within 40 inches of the point of connection with the power
source and sheathed the entire length of wire from the point of connection at the power
source to the circuit protection device.
1. Connect power trim pump BLACK (–) battery cable to negative (–) battery terminal and
appropriate trim pump RED (+) battery cable to positive (+) battery terminal or battery switch.
2. Ensure that all battery terminal connections are tight. Then spray terminals with a battery
connection sealant to help delay corrosion.

Battery stud 8‑11 71‑97

connections
Battery Cable Connection

IMPORTANT: The sterndrive must be installed before connecting the battery. See Sterndrive
Installation.
IMPORTANT: Engine electrical system is negative (–) ground.
1. Ensure that the power trim pump, the MerCathode controller, and the accessory wiring (if
equipped) are properly connected to the battery terminals.
2. Connect the battery cables to the battery by first connecting the positive (+) battery cable
(usually red) to the positive (+) battery terminal. Tighten the clamp securely.
3. Connect the negative (–) battery cable (usually black) to the negative (–) battery terminal.
Tighten the clamp securely.
4. Ensure that all of the battery terminal connections are tight. Spray the terminals with a battery
connection sealant to help retard corrosion.
5. Apply sealant to the exposed terminals and electrical connections.

connections
Power Trim Fluid

Checking
IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only.
1. Place the sterndrive in full down (in) position.
Page 8 / 30 90-869261 MAY 2008

2. Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the
reservoir.
a b
7876
3. Fill as necessary with the specified fluid. See Filling.

Filling
1. If the fluid level is below the "MIN" line, the specified fluid must be added.
2. Remove the fill cap from the reservoir.
NOTE: The fill cap is vented.
a b
7701
Power trim pump reservoir shows the fluid level is below "MIN" line
a - Fill cap assembly b - Fill cap installed
90-869261 MAY 2008 Page 9 / 30

3. Add the specified fluid to bring the fluid level to within the "MIN" and "MAX" lines on the
reservoir.
a b
7876

4. Install the fill cap.
Setting Trailer and Trim Limit

swim platform and the CDS tool is unavailable for use to set the trim and trailer limit, then an
additional trim limit spacer kit must be installed. Refer to Trim Limit Spacer Kit (if Equipped) in the
Drive System and Engine Mounting section.
Setting Trailer Limit with CDS
The trailer limit function is designed to limit the maximum trailer up position, preventing damage
to swim platforms or other equipment.
NOTE: The trim position sender will automatically be adjusted by setting the trim and trailer limits
1. Connect the CDS to the SmartCraft junction box located at the vessel helm.
2. Turn the ignition key to the "ON" position.
3. Select "Make" Cummins MerCruiser Diesel.
4. Select the appropriate System Integration Module (SIM) model in the CDS engine select
screen.
5. Select the correct engine location.
6. Open the Tool Box icon in the CDS.
7. Open the Active Diagnostics icon.
8. Scroll down the Active Diagnostics window and highlight "Trailer Limit."
9. Follow the CDS on screen instructions and run the the test.
Setting Trim Limit with CDS
The trim limit configures the system integration module (SIM) to control the maximum up trim limit.
The trim limit function is only supported if the SIM has input for the three wire trim sensor.
NOTE: The trim position sender will automatically be adjusted by setting the trim and trailer limits
1. Connect the CDS to the SmartCraft junction box located at the vessel helm.
2. Turn the ignition key to the "RUN" position.
3. Select "Make" Cummins MerCruiser Diesel.
Page 10 / 30 90-869261 MAY 2008

4. Select the appropriate System Integration Module (SIM) model in the CDS engine select
screen.
5. Open the Tool Box icon in the CDS.
6. Open the Active Diagnostics icon.
7. Scroll down the Active Diagnostics window and highlight "Trim Limit."
8. Follow the CDS on screen instructions and run the the test.
Sterndrive Gear Lube

NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.
Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing
your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and
contain and dispose of fluids as required.
Checking
NOTE: The gear lube level will fluctuate during operation. Check the gear lube level with the engine
cold, before starting.
1. Check the gear lube monitor to determine the gear lube level. Keep the gear lube level within
the recommended operating range. See Filling.
19948
Gear lube level shown is at the correct operating range

a - "ADD" mark b - "OPERATING RANGE" mark
Filling
IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the
gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of
lubrication. Contact your Cummins MerCruiser Diesel Authorized Repair Facility.
1. Remove the gear lube monitor cap.
90-869261 MAY 2008 Page 11 / 30

2. Fill the gear lube monitor with the specified gear lube so that the gear lube level is in the
operating range. Do not overfill.
c
b
19947
Gear lube monitor

a - Gear lube level at the "ADD" mark c - Gear lube monitor cap
b - Gear lube level at the "OPERATING
RANGE" mark

87 High Performance Gear Lube Gear lube monitor 92-858064K01
3. Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not
overtighten.
19962
a - Gear lube monitor cap
Propellers
Propeller Selection
IMPORTANT: The installed propeller must allow the engine to operate at the engine's rated RPM.
Use an accurate service tachometer to verify engine RPM.
The boat manufacturer and the selling dealer are responsible for equipping the power package
with the correct propeller. Refer to the Cummins MerCruiser Diesel Parts And Accessories
Guide (90‑892645005) and read Everything You Need To Know About Propellers. The specified
engine rated RPM is listed in the Cummins Curves And Data Sheet (www.Cummins.com).
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 occurs below the engine's rated RPM the propeller must be changed to
prevent loss of performance and possible engine damage. Operating an engine above the engine
rated RPM will increase engine wear and may cause significant engine damage.
After initial propeller selection, the following conditions may require that the propeller be changed
to a lower pitch:
1. Operating during warmer weather and higher humidity (not as significant on Electronic Control
models)
Page 12 / 30 90-869261 MAY 2008

2. Operating at a higher elevation (not as significant on Electronic Control models)

3. Operating with an increased load (additional passengers, pulling skiers, etc.)
For better acceleration under high load tow conditions, use the next lower pitch propeller. Carefully
monitor engine RPM when using a low pitch propeller. A reduction in boat load causes an increase
in RPM. Do not exceed the engine's rated RPM.
Because of the many variables of boat design, only testing determines the best propeller for a
particular application. Available propellers are listed in the Cummins MerCruiser Diesel Parts
And Accessories Guide (90‑892645005) or Mercury Parts and Accessories Guide
(90‑42000006).
See Boat in the Water Tests, Maximum RPM Test in this power package installation manual.
Alpha Sterndrive Propeller Installation
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water
with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral
and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood
between the propeller blade and the anti‑ventilation plate.
7885
1. To aid in future removal of the propeller, liberally coat propeller shaft splines with lubricant.

34 Special Lubricant 101 Propeller shaft splines 92-802865Q02
IMPORTANT: The installation is correct when at least two threads of the propeller shaft are
exposed through the propeller nut after torquing it.
ALPHA MODELS
1. Install the propeller with the attaching hardware as shown.
2. Torque the nut, then continue to tighten until the three tabs on the tab washer align with the
grooves on spline washer.
90-869261 MAY 2008 Page 13 / 30

3. Bend the three tabs down into the grooves.
e
f
a
b
c
g 5301
a- Propeller shaft splines e - Drive sleeve adapter

b- Forward thrust hub f - Locking tab washer
c- Flo‑Torq II drive hub g - Propeller nut
d- Propeller

75 55
Alpha propeller nut
Then align tabs with grooves.
Bravo Diesel Sterndrive Propeller Installation

! WARNING
a
b
4826
a - Wood block
b - Propeller
c - Propeller nut under socket
Bravo One Propeller Installation

IMPORTANT: The selected propeller's rotation must match the forward gear direction of propeller
shaft rotation.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.
Page 14 / 30 90-869261 MAY 2008



95 Propeller shaft splines 92-802859A 1
Teflon
NOTE: Anti‑corrosion grease is for saltwater applications only.

3. Tighten the propeller nut to specification.
e
f
a
b
c
g 5301
Typical Bravo One models

a- Propeller shaft splines e - Drive sleeve adapter
b- Forward thrust hub f - Tab washer
c- Flo‑Torque II drive hub g - Propeller nut
d- Propeller
NOTE: The specified torque is a minimum torque value.

75 – 55
Bravo One propeller nut
4. Models equipped with the tab washer: Continue to tighten the propeller nut until the three
tabs on the tab washer align with the grooves on the spline washer.
90-869261 MAY 2008 Page 15 / 30

a b c
4750
a- Prop
b- Tab washer
c- Drive sleeve adapter
d- Tab bent down
e- Propeller nut
Bravo Two Propeller Installation

IMPORTANT: The selected propeller's rotation must match the forward gear direction of propeller
shaft rotation.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.


95 Propeller shaft splines 92-802859A 1
Teflon
NOTE: Anti‑corrosion grease is for saltwater applications only.

3. Tighten the propeller nut to specification.
c
d
f
a
b
8566
e
Bravo Two
a - Propeller shaft splines d - Spline washer
b - Forward thrust hub e - Tab washer
c - Propeller f - Propeller nut
NOTE: The torque stated is a minimum torque value.
Page 16 / 30 90-869261 MAY 2008


81 – 60
Bravo Two propeller nut
Then align tabs with groves
4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the
grooves on the spline washer.
a b c
4750
a- Prop
b- Tab washer
c- Drive sleeve adapter
d- Tab bent down
e- Propeller nut
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.
Boat in the Water
The following information is for engine operation tests with the boat in the water:
90-869261 MAY 2008 Page 17 / 30

! 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.
NOTICE
IMPORTANT: If using a test tank, ensure that an adequate supply of cooling seawater is available
to both the engine and sterndrive seawater pumps.
1. Ensure that the water level is above the water inlet holes of the sterndrive and will provide an
adequate supply of cooling seawater to the sterndrive seawater pump.
a
b
22193
Typical with sterndrive seawater inlet

a - Minimum water level b - Water inlet holes
2. Ensure that the water level is above the water inlet holes of the through‑hull water inlet and
will provide an adequate supply of cooling seawater to the engine seawater pump.
3. Proceed to Testing Preparation.
Boat out of the Water
The following information is for engine operation tests with the boat out of the water:
! WARNING
IMPORTANT: This CMD Alpha sterndrive power package has the sterndrive–to–engine seawater
supply port blocked off at the gimbal housing and uses an alternative seawater inlet to supply
cooling water for the engine. When operating the engine with the boat out of the water a supply
of cooling water must be provided to both the sterndrive and the engine during operation.
IMPORTANT: When using a flushing attachment over the sterndrive water inlet holes with a water
supply hose, do not use full water pressure.
1. Lower the sterndrive to full down (in) position.
2. Remove the propeller.
3. Install the appropriate flushing attachment over the sterndrive water inlet holes.
4. Connect a hose between the flushing attachment and a water source.
Page 18 / 30 90-869261 MAY 2008

5. Open the water source about 1/2 maximum pressure. Do not use full water pressure.
22194
Typical with sterndrive seawater inlet

a - Flushing attachment b - Water hose
IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using
a through‑hull water inlet need a supply of cooling water available to both the sterndrive and to
the engine during operation.
Flushing Attachment 44357Q 2

6. Connect a second flushing hose from a water source to the seawater inlet hose connector or
to the seawater pump inlet using an appropriate adapter.
25668
a - Seawater pump inlet c - Seawater pump outlet
b - Seawater pump d - Fuel cooler
7. With the sterndrive in the normal operating position, partially open the water sources (about
1/2 maximum flow).
8. Proceed to Testing Preparation.
Testing Preparation
! WARNING
90-869261 MAY 2008 Page 19 / 30

NOTE: Refer to the appropriate Cummins MerCruiser 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.
IMPORTANT: The sterndrive oil level in the gear lube monitor will rise and fall during sterndrive
operation. Always check the oil level in the monitor when the sterndrive is cool and the engine is
shut down.
4. Check the sterndrive oil level in the gear lube monitor.
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 sterndrive water inlets and
the through‑hull or through‑transom water inlets.
Testing
! WARNING
NOTE: Refer to the appropriate Cummins MerCruiser Diesel Operation, Maintenance, and
Warranty Manual for operating specifications and fluid capacities.
1. The engine should be shut off and cool before beginning this procedure.
2. Ensure that the cooling system is free of leaks.
3. Supply water to both the engine and sterndrive seawater pumps.
a. If the boat is in the water, confirm that both the engine and sterndrive seawater pickups
are below the surface of the water and have an adequate amount of cooling water.
b. If the boat is out of the water, supply adequate cooling water to both the sterndrive and
the engine. Refer to the Flushing the Seawater System section of the Operation,
Maintenance, and Warranty Manual.
4. Start the engine and operate at a fast idle RPM until the water temperature is normal. Refer
to the Operation, Maintenance, and Warranty Manual.
5. Check all of the gauges for normal readings.
6. Set the engine to idle RPM.
7. Turn the steering wheel to starboard then to port and confirm that the drive responds correctly.
8. Inspect the engine compartment for water, oil, fuel, and exhaust leaks.
9. Ensure that the remote control shift cable installation results in correct forward and reverse
gear operation.
NOTE: The operator at the remote control handle should feel a slight detent before and after each
gear. Forward‑detent‑Neutral‑detent‑Reverse
NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out
of each gear, Forward, Neutral, and Reverse, at idle speed position.
Page 20 / 30 90-869261 MAY 2008

a. Move the remote control handle to FORWARD, idle speed position.

b. Check that the sterndrive propeller shaft is turning in the FORWARD direction.
c. Shift the remote control handle to NEUTRAL, idle speed position.
d. Check that the sterndrive propeller shaft is not turning.
e. Shift the remote control handle to REVERSE, idle speed position.
f. Check that the sterndrive propeller shaft is turning in the REVERSE direction.
g. If the sterndrive will not shift:
i. Check that the shift cables are 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.
ii. Remove the sterndrive and check for proper shift linkage hook ups.
IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle
is engaged. Consult your Cummins MerCruiser Diesel Authorized Repair Facility for proper
adjustment.
10. Check power steering system for lugging condition (engine RPM drops or power steering
pump tone changes).
a. Turn the steering wheel left (to port) until it stops, and continue to apply pressure. If the
pump lugs, check the following:
i. Inspect for an obstruction between the gimbal ring and the gimbal housing and all
moving steering components.
ii. Ensure that the steering lever is not contacting the cutout in the transom. If contact
is being made, modify the cutout.
iii. Check steering cable end dimension with the cable fully extended. See Steering
Helm and Cable for proper steering cable dimensions.
b. Turn the steering wheel right (to starboard) until it stops, and continue to apply pressure.
If the pump lugs, check the following:
i. Inspect for an obstruction between the gimbal ring and the gimbal housing and all
moving steering components.
ii. Ensure that the steering lever is not contacting the cutout in the transom. If contact
is being made, modify the cutout.
iii. Check steering cable end dimension with the cable fully extended. See Steering
Helm and Cable for proper steering cable dimensions.
11. Turn the key switch to the "OFF" position to stop the engine.
12. Lubricate the steering cable and clevis.
90-869261 MAY 2008 Page 21 / 30

IMPORTANT: Ensure that the cable end that enters the clevis is heavily lubricated
A a d
A c
16829
a - Steering cable end c - Clevis pins and cotter pins

b - Clevis d - Steering lever

34 Special Lubricant 101 Steering cable and clevis 92-802865Q02
13. Restart the engine and observe the drive. If the drive creeps, an external tension may exist
on the steering cable. Ensure that there is nothing attached to the steering cable casing. The
cable must be free to move when actuated.
14. Position the drive unit so it is straight back.
15. Remove the cap/dipstick from the power steering fluid reservoir. Check the fluid level and add
as necessary. Do not overfill.
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: Cummins MerCruiser 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 3 minutes at each of the following RPMs: 1200 RPM, 2400
RPM, and 3000 RPM.
RPM, and 3400 RPM.
RPM, and the maximum engine rated RPM.
Page 22 / 30 90-869261 MAY 2008

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 (WOT), with
an average load aboard the boat. Refer to Section 11 - Predelivery in the Diesel Applications
Manual (90‑866350050) for complete information on propeller selection.
Operate the boat with full load on board at WOT. On sterndrive applications, adjust the power trim
to achieve optimum speed without using excessive trim. On all applications, if the RPM is above
the rated engine RPM use a higher pitch propeller. Use a lower pitch propeller if RPM is too low.
Typical RPM vs.

Description
Propeller Change
Sterndrive For every 2 in. change in pitch 200 RPM
IMPORTANT: The engines covered in this manual are equipped with an ECM that limits engine
RPM. Be sure that the propeller being used does not allow the engine to run against the limiter,
as a significant loss in performance will result.
NOTE: Use an accurate service tachometer to verify RPM.
Engine RPM Limiter Setting
Description Rated Engine RPM
(Begins At:)
Refer to CMD's Marine Performance Curves And
Sterndrive Models All Models
Data Sheet (www.Cummins.com).
To ensure proper propeller selection, continue testing propellers with increased pitch until the WOT
RPM is slightly less than the rated engine RPM, then select the next lowest pitch propeller for use.
Selecting the propeller in this manner ensures that the engine will attain rated engine RPM without
running excessively against the limiter.
IMPORTANT: To operate the engine at rated engine RPM before the engine 20‑hour break‑in
period is complete, follow this procedure only after completing the engine initial break‑in
procedure:
1. Complete the engine initial break‑in procedure if not already accomplished.
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 wide‑open throttle (WOT). If maximum rated RPM is not possible or the engine
operates against the governor, refer to the preceding information and to Section 11 -
Predelivery, in the Diesel Applications Manual (90‑866350050) for correct propeller selection.
IMPORTANT: Do not operate at WOT RPM for more than two minutes.
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 cold weather. 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 will be exposed to
freezing temperatures, drain the water from the seawater cooling system. See Cold Weather
(Freezing Temperature), Seasonal, or Extended Storage.
90-869261 MAY 2008 Page 23 / 30

NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing
the bellows to fail when returned to service and allowing water to enter the boat. Store the
sterndrive in the full down position.
3. If the power package is to be stored, position the sterndrive in the full down (in) position.
Cold Weather (Freezing Temperature), Seasonal Storage, and

Extended Storage
IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service be performed
by a Cummins MerCruiser Diesel Authorized Repair Facility. Damage caused by freezing IS NOT
covered by the Cummins MerCruiser Diesel Limited Warranty.
NOTICE
NOTE: 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.
You should consider a boat is in storage whenever it is not in operation. The amount of time that
the power package is not operated may be for a brief period, such as during a day, overnight, for
a season, or for an extended period of time. Certain precautions and procedures must be observed
to protect the power package from freeze damage, corrosion damage, or both types of damage
during storage.
Freeze damage can happen when water trapped in the seawater cooling system freezes. For
example, after operating the boat, exposure to freezing temperatures for even a brief period of
time could result in freeze damage.
Corrosion damage is the result of saltwater, polluted water, or water with a high mineral content
trapped in the seawater cooling system. Saltwater should not stay in an engine's cooling system
for even a brief storage time; drain and flush the seawater cooling system after each outing.
Cold weather operation refers to operating the boat whenever the possibility of freezing
temperatures exists. Likewise, cold weather (freezing temperature) storage refers to whenever
the boat is not being operated and the possibility of freezing temperatures exists. In such cases,
the seawater section of the cooling system must be completely drained immediately after
operation.
Seasonal storage refers to when the boat is not being operated for one month or more. The length
of time varies depending on the geographic location of the boat in storage. Seasonal storage
precautions and procedures include all of the steps for cold weather (freezing temperature) storage
and some additional steps that must be taken when storage will last longer than the short time of
cold weather (freezing temperature) storage.
Extended storage means storage for a period of time that may last for several seasons or longer.
Extended storage precautions and procedures include all of the steps for cold weather (freezing
temperature) storage and seasonal storage plus some additional steps.
See the specific procedures in this section related to the conditions and the length of storage for
your application.
Page 24 / 30 90-869261 MAY 2008

Cold Weather (Freezing Temperature) Storage

NOTICE
NOTE: 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.
1. Read all precautions and perform all procedures found in Draining the Seawater System
and drain the seawater section of the cooling system.
2. Place a caution tag at the helm advising the operator to unplug and connect the water inlet
hose or open the seacock, if equipped, before operating the boat.
3. For additional assurance against freezing and corrosion fill the seawater cooling system with
a mixture of propylene glycol antifreeze and tap water. See Seasonal Storage Instructions
in this section.
Preparing Your Power Package for Seasonal or Extended Storage
NOTICE
IMPORTANT: If the boat has already been removed from the water, supply a water source to the
water inlet holes before starting the engine. Follow all warnings and flushing attachment
procedures in Section 5 ‑ Flushing the Seawater System in the appropriate Cummins MerCruiser
Diesel Operation, Maintenance, and Warranty Manual.
1. Supply cooling water to both the sterndrive and the engine seawater pump inlets.
2. Start the engine and operate until it reaches normal operating temperature.
3. Stop the engine.
4. Change the engine oil and filter.
5. Start the engine and run it for about 15 minutes. Check for oil leaks.
6. Flush the seawater cooling system. Refer to the appropriate Cummins MerCruiser Diesel
Operation, Maintenance, and Warranty Manual.
Draining the Seawater System
! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the
boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the
seawater inlet hose, and ensure the bilge pump is operational before draining. Do not operate
the engine with the drain system open.
IMPORTANT: The engine must be as level as possible to ensure complete draining of the cooling
system.
Drain the seawater system of the power package before flushing, cold weather (freezing
temperatures), seasonal storage, or extended storage.
IMPORTANT: The boat must not be operating during this procedure.
1. Remove the boat from the water if possible.
90-869261 MAY 2008 Page 25 / 30

2. If the boat is to remain in the water, turn on the bilge pump, close the seacock (if equipped),
or disconnect and plug the seawater inlet hose.
25667
Typical seacock installation
3. Make the engine as level as possible to ensure complete draining of the seawater system.
4. Remove the drain plug from the heat exchanger.
25654
Seawater drain plug
5. Disconnect the seawater inlet hose from the seawater pump hose and drain.
25668
QSD 2.0 seawater pump
a- Seawater inlet
b- Seawater pump
c- Seawater pump outlet hose
d- Fuel cooler
6. Repeatedly clean out the drain holes using a stiff piece of wire until the seawater section is
completely drained.
Page 26 / 30 90-869261 MAY 2008

7. On models equipped with a seawater strainer, remove the hoses at the seawater strainer
and drain them completely. Drain and empty the seawater strainer. Reconnect the hoses and
tighten the hose clamps securely.
a 25831
a - Seawater inlet
b - Seawater outlet
c - Seawater strainer cover
8. After the seawater has completely drained, apply sealant to the threads of the drain plugs or
fittings (if equipped). Install and tighten the drain plugs or fittings securely.

19 Perfect Seal Drain plug or fitting threads 92-34227 1
9. Reconnect all hoses. Tighten the hose clamps securely.

Seasonal Storage Instructions
1. Read all precautions and perform all procedures found in Preparing Your Power Package
for Seasonal or Extended Storage.
2. Read all precautions and perform all procedures found in Draining the Seawater System,
and drain the seawater section of the cooling system.
NOTICE
IMPORTANT: Cummins MerCruiser Diesel recommends that propylene glycol antifreeze be used
in the seawater section of the cooling system for cold weather (freezing temperature), seasonal
storage, or extended storage. Make sure that the propylene glycol antifreeze contains a rust
inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol
manufacturer's recommendations.
3. Fill a container with approximately 7.50 liter (8.00 qt.) of propylene glycol antifreeze and tap
water mixed to manufacturer's recommendation to protect the engine to the lowest
temperature to which it will be exposed during cold weather or extended storage.
90-869261 MAY 2008 Page 27 / 30

4. Disconnect the seawater inlet hose from the seawater pump. Using an adapter, if required,
temporarily connect an appropriate length piece of hose to the seawater pump and place the
other end of the hose into the container of propylene glycol antifreeze and tap water.
c
23452
Typical
a - Seawater pump c - Container of propylene glycol
b - Temporary hose antifreeze and tap water
NOTE: Discharge of propylene glycol into the environment may be restricted by law. Dispose of
propylene glycol in accordance with federal, state, and local laws and guidelines.
5. Ensure that the sterndrive seawater pump is also supplied with water. Follow all warnings and
flushing attachment procedures in Section 5 - Flushing the Seawater System in the
appropriate Cummins MerCruiser Diesel Operation, Maintenance, and Warranty Manual.
NOTICE
6. Start the engine and operate at idle speed until the antifreeze mixture has been pumped into
the engine seawater cooling system.
7. Stop the engine.
8. Remove the temporary hoses from both of the seawater pump inlets.
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing
the bellows to fail when returned to service and allowing water to enter the boat. Store the
sterndrive in the full down position.
9. Place the sterndrive in the full down (in) position.
10. Store the boat battery according to the battery manufacturer's instructions.
Extended Storage Instructions
IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service be performed
by a Cummins MerCruiser Diesel Authorized Repair Facility.
1. Read all precautions and perform all procedures found in Preparing Your Power Package
for Seasonal or Extended Storage.
2. Read all precautions and perform all procedures found in Draining the Seawater System.
3. Read all precautions and perform all procedures found in Seasonal Storage Instructions.
IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to
direct sunlight.
Page 28 / 30 90-869261 MAY 2008

4. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Cummins
MerCruiser Diesel Authorized Repair Facility for additional information and service.
5. Place a caution tag at the instrument panel and in the engine compartment stating that the
seawater pump is out and not to operate the engine.
Predelivery Inspection Checklist

Check / Check /
Not Applicable CHECK BEFORE RUNNING Not Applicable ON THE WATER TEST
Adjust Adjust
⃞ ⃞ Drain plug in and petcocks closed ⃞ ⃞ Engine alignment (Inboards only)
Starter neutral safety switch
⃞ ⃞ Seawater inlet valve open ⃞ ⃞
operation
⃞ ⃞ Engine mounts tight ⃞ ⃞ Water pump operation
⃞ ⃞ Engine alignment ⃞ ⃞ Instrument(s) operation
⃞ ⃞ Drive unit fasteners torqued ⃞ ⃞ Fuel leaks
⃞ ⃞ Power trim cylinders fasteners tight ⃞ ⃞ Oil leaks
⃞ ⃞ Battery fully charged and secured ⃞ ⃞ Water leaks
⃞ ⃞ All electrical connections tight ⃞ ⃞ Exhaust leaks
⃞ ⃞ Exhaust system hose clamps tight ⃞ ⃞ Ignition timing
Idle________ RPM, within
⃞ ⃞ All fuel connections tight ⃞ ⃞
specifications
Correct rotation propeller (installed Forward ‑ Neutral ‑ Reverse gear
⃞ ⃞ ⃞ ⃞
and torqued) operation
Throttle, shift and steering system Steering operation throughout
⃞ ⃞ ⃞ ⃞
fasteners tightened properly range
Throttle plates open and close
⃞ ⃞ ⃞ ⃞ Acceleration from idle RPM
completely
WOT________ RPM within
⃞ ⃞ Crankcase oil level ⃞ ⃞ specifications (in FORWARD
gear)
⃞ ⃞ Power trim oil level ⃞ ⃞ Power trim operation
⃞ ⃞ Sterndrive oil level ⃞ ⃞ Trim tab adjustment
⃞ ⃞ Power steering fluid level ⃞ ⃞ Boat handling
⃞ ⃞ Closed cooling level AFTER ON WATER TEST
⃞ ⃞ Transmission fluid level ⃞ ⃞ Propeller nut torque
Fuel, oil, coolant, water and fluid
⃞ ⃞ Alternator belt tension ⃞ ⃞
leaks
⃞ ⃞ Seawater pickup pump belt tension ⃞ ⃞ Oil and fluid levels
Apply Quicksilver Corrosion
⃞ ⃞ Power steering pump belt tension ⃞ ⃞
Guard to engine package
C.A.R.B. Hang Tag and Owners
⃞ ⃞ Audio warning system operation ⃞ ⃞ 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.)
90-869261 MAY 2008 Page 29 / 30

NOTES:
Page 30 / 30 90-869261 MAY 2008

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Cummins MerCruiser Diesel

QSD 2.0L DIESEL STERNDRIVE MODELS

Notice to Boat Manufacturer and Installer

Page i © 2008 Mercury Marine 90-869261 MAY 2008

SECTION 1 - IMPORTANT INFORMATION 1

90-869261 MAY 2008 Page 1 / 12

Lubricants, Sealants, Adhesives

Torque Specifications—Bravo Sterndrive

Page 2 / 12 90-869261 MAY 2008

Description Nm lb–in. lb–ft

Tube Ref No. Description Where Used Part No.

Trim‑in Limit Insert

90-869261 MAY 2008 Page 3 / 12

Engine Data Plate

Page 4 / 12 90-869261 MAY 2008

Alpha Sterndrive Decal Identification

90-869261 MAY 2008 Page 5 / 12

Alpha Transom Serial Number

Page 6 / 12 90-869261 MAY 2008

Bravo Sterndrive Serial Number and Identification

Bravo sterndrive information on ground plate

Bravo sterndrive serial number stamping

90-869261 MAY 2008 Page 7 / 12

Bravo Transom Serial Number

Bravo transom assembly U‑bolt plate

Multiple Sterndrive Steering Tie Bar Arrangements

Page 8 / 12 90-869261 MAY 2008

Internal Tie Bar Only

90-869261 MAY 2008 Page 9 / 12

Sacrificial Anodes and the MerCathode System

Page 10 / 12 90-869261 MAY 2008

MerCathode—mounted to the underside of the gimbal housing

90-869261 MAY 2008 Page 11 / 12

a - Painted boat transom b - Minimum 40 mm (1‑1/2 in.)

Page 12 / 12 90-869261 MAY 2008

SECTION 2 - BOAT CONSTRUCTION

90-869261 MAY 2008 Page 1 / 4

Transom Thickness and Surface Plane

a - Transom thickness d - Transom plate coverage ‑ 203 mm

Page 2 / 4 90-869261 MAY 2008

Checking Transom Thickness

90-869261 MAY 2008 Page 3 / 4

According to ABYC H‑32‑89 specification, "Compartment Ventilation (Diesel)" states:

Page 4 / 4 90-869261 MAY 2008

SECTION 3 - EXHAUST SYSTEM

90-869261 MAY 2008 Page 1 / 6

QSD 2.0L Exhaust Elbow Height

Model "c" = "a" minus "b"

a - From waterline to top of transom c - "a" minus "b"

Page 2 / 6 90-869261 MAY 2008

Description All Models

90-869261 MAY 2008 Page 3 / 6

4. Compare the measurement to the specifications. See Exhaust Elbow Height.

Clear Hose Method

Page 4 / 6 90-869261 MAY 2008

90-869261 MAY 2008 Page 5 / 6

Page 6 / 6 90-869261 MAY 2008

SECTION 4 - FUEL SYSTEM

90-869261 MAY 2008 Page 1 / 6