QSD 2.8 e 4.2 90-866920080

Cummins MerCruiser Diesel
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, MotorGuide, 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 2.8 AND 4.2 DIESEL ENGINE

STERNDRIVE MODELS
INSTALLATION MANUAL
Models Covered
Sterndrive
Models Covered Serial Number
QSD 2.8 Sterndrives 88300400 and Above
QSD 4.2 Sterndrives 88401000 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. 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.
Page i © 2008 Mercury Marine 90-866920080 OCTOBER 2008

NOTICE
Indicates a situation which, if not avoided, could result in engine or major component
failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
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........................................................................................................................................2
Quicksilver Products—Accessories................................................................................................................... 2
SeaCore Components and Castings.................................................................................................................3
Stainless Steel Fasteners.................................................................................................................................. 3
Trim‑in Limit Insert............................................................................................................................................. 3
Identification............................................................................................................................................................ 4
Serial Number Decal Placement.......................................................................................................................4
Engine Dataplate...............................................................................................................................................4
Bravo Sterndrive Serial Number and Identification...........................................................................................5
Bravo Transom Serial Number..........................................................................................................................6
Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 7
Internal Tie Bar Only.........................................................................................................................................7
Internal and External Tie Bar.............................................................................................................................7
External Power Steering....................................................................................................................................8
External Power Steering With Low External Tie Bar.........................................................................................8
Corrosion................................................................................................................................................................. 8
Corrosion Protection..........................................................................................................................................8
Anodes and the MerCathode System ....................................................................................................... 8
Reference Electrode Wire of the MerCathode System ............................................................................ 10
Anti‑Fouling Paint............................................................................................................................................11
SeaCore Components and Castings...............................................................................................................12
Stainless Steel Fasteners................................................................................................................................ 12
90-866920080 OCTOBER 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
NOTE: Securely tighten all fasteners not listed below.
NOTE: The propeller torque stated is a minimum torque value.
Description Nm lb. in. lb. ft.
75 55
Bravo One propeller nut
Then align tabs with grooves
81 60
Bravo Two propeller nut
Bravo Three front propeller nut 136 100
Bravo Three rear propeller nut 81 60
Transom assembly hardware 31 23
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.
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 listing.
These Guides are 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.
Page 2 / 12 90-866920080 OCTOBER 2008

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.
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.
90-866920080 OCTOBER 2008 Page 3 / 12

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 Placement
Three sets of engine, transom assembly, and sterndrive serial number decal strips are provided
with each power package. One set should be used for each of the following:
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance, and Warranty Manual identification page.
24124
Engine specification and serial number decal
Engine Dataplate
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 about the availability of a replacement.
Page 4 / 12 90-866920080 OCTOBER 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
Typical engine dataplate
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
Bravo Sterndrive Serial Number and Identification

The sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground
plate located on the port side of the Bravo sterndrive.
a b c
25906
a - Bar code c - Serial Number

b - Gear ratio d - Model number
90-866920080 OCTOBER 2008 Page 5 / 12

The serial number is also stamped on the sterndrive casting inside the back cover. This is used
as a permanent reference for Cummins MerCruiser Diesel Authorized Repair Facilities.
25907
Bravo sterndrive serial number stamping

a - Serial number stamping
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
Page 6 / 12 90-866920080 OCTOBER 2008

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.
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.
90-866920080 OCTOBER 2008 Page 7 / 12

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
Corrosion Protection
Cummins MerCruiser Diesel power packages are equipped with anodes to help protect them from
galvanic corrosion under moderate conditions. However, for severe conditions, or if using a
stainless steel propeller, it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a
MerCathode System be installed (some models have a MerCathode System as standard
equipment). A MerCathode Monitor also is available to allow the operator to check the operation
of the MerCathode System with the push of a button. Refer to the Diesel Parts And Accessories
Guide ( 90‑892645005) for part numbers.
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. A Quicksilver
Galvanic Isolator can be installed to block the passage of these currents while still providing a path
to ground for dangerous fault (shock) currents. Refer to the Diesel Parts And Accessories Guide
(90‑892645005) for part number.
IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and
anodes may be unable to handle the increased galvanic corrosion potential.
ANODES AND THE MERCATHODE SYSTEM
The following sacrificial anodes are installed at different locations on the power package. These
anodes help protect against galvanic corrosion by sacrificing their metal to be slowly eroded
instead of the metal components on the power package.
Page 8 / 12 90-866920080 OCTOBER 2008

MerCathode System—The electrode assembly replaces the anode block. The system should be
tested to ensure adequate output. The test should be performed where the boat is moored, using
a Quicksilver Reference Electrode and Test Meter. Contact your Authorized Cummins MerCruiser
Diesel repair facility.
5
1
4 3 6
7 20337
Typical boat package

1- Gearcase anodic plate 5 - Trim cylinder anodes
2- Anode plate 6 - Bearing carrier anodes
3- MerCathode System 7 - Propeller shaft Anode (Bravo Three
4- Anode kit standard)
IMPORTANT: Replace the sacrificial anodes if they are eroded 50 percent or more.
90-866920080 OCTOBER 2008 Page 9 / 12

Anodes and MerCathode System Locations

Description Location Figure
Mounted on the underside of the lower

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

to the underside of the gimbal housing.
The MerCathode controller is mounted
MerCathode System
on the engine or on the boat transom.
The controller harness connects to the
electrode harness. 20340
Anode kit (if equipped) Mounted to the boat transom.
20341
Trim cylinder anodes Mounted on each of the trim cylinders.
20342
Located in front of the propeller,

Bearing carrier anode (Bravo One) between the front side of the propeller
and the gear housing.
20343
Propeller shaft anode (Bravo Three) Located behind the aft propeller.
20344
REFERENCE ELECTRODE WIRE OF THE MERCATHODE SYSTEM
NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do
not use any cleaning equipment such as brushes or high‑pressure washers to clean the
MerCathode assembly.
Page 10 / 12 90-866920080 OCTOBER 2008

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

a - MerCathode reference electrode b - Anode
wire—do not pressure‑wash
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.
90-866920080 OCTOBER 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.
SeaCore Components and Castings
Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel
components and particular aluminum castings with special coatings. Do not replace SeaCore
components with non‑SeaCore. Use only the specified Mercury MerCruiser 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
fasteners
Page 12 / 12 90-866920080 OCTOBER 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
90-866920080 OCTOBER 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 90-866920080 OCTOBER 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
Distance between starboard and port engine mount 57.2 cm (22½ in.)
Mount adjustment up and down (minimum) 6 mm (¼ 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.
90-866920080 OCTOBER 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 90-866920080 OCTOBER 2008

SECTION - 3 EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Exhaust System....................................................................................................................................................... 2
Exhaust Elbow Height............................................................................................................................................. 2
Measuring Procedure.............................................................................................................................................. 3
3
Measuring Methods................................................................................................................................................. 3
Straight Edge Method........................................................................................................................................3
Clear Hose Method...........................................................................................................................................4
90-866920080 OCTOBER 2008 Page 1 / 6

EXHAUST SYSTEM SECTION - 3
Exhaust System
! WARNING
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
d a
c
23512
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
Page 2 / 6 90-866920080 OCTOBER 2008

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.
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).
90-866920080 OCTOBER 2008 Page 3 / 6

4. Compare the measurement to the specifications. See Exhaust Elbow Height.
c b
a
e
d
23514
Typical
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 90-866920080 OCTOBER 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
23518
Typical
a - Waterline d - Weight
b - Top of exhaust elbow e - Measurement—waterline to top of
c - Clear plastic hose exhaust elbow
90-866920080 OCTOBER 2008 Page 5 / 6

NOTES:
Page 6 / 6 90-866920080 OCTOBER 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..................................................................................................................... 3
90-866920080 OCTOBER 2008 Page 1 / 4

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
Consider the following additional fuel connection requirements. Refer to marine regulations
(USCG, EU‑RCD, and so on) and the standards they reference (ABYC, SAE, ISO, and so on) for
complete guidelines.
NOTE: Not all requirements are listed here.
• The fuel supply line pickup must be at least 25 mm (1 in.) from the bottom of the tank to
prevent picking up impurities. The fuel inlet fitting is an 8 mm (5/16 in.) fitting attached to the
fuel filter.
• A flexible fuel line must be used to connect the fuel supply line to the fuel inlet fitting on the
engine to absorb deflection when the engine is operating.
• Fuel supply lines must not be smaller than 8 mm (5/16 in.) inner diameter.
• On multi‑engine diesel installations, use a separate tube for the fuel supply line for each
engine.
• Use larger diameter (than previously specified) lines and fittings on installations requiring long
lines or numerous fittings.
• Install fuel lines of the proper length and free of stress.
• Secure fuel lines to prevent vibration, chafing, or both.
Page 2 / 4 90-866920080 OCTOBER 2008

SECTION - 4 FUEL SYSTEM
• Avoid sharp bends in fuel lines.

• Ensure that the fuel inlet restriction meets the following specification:
Models Description Specification

2.8 147 mm Hg (5.8 in. Hg)
Maximum fuel inlet restriction
4.2 188 mm Hg (7.4 in. Hg)
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
Flow rate 227 liters/hour (60 U.S. gal/hour)
Primary fuel water separator
Filtration 10 micron
Description Qty. Part Number

SAE Threads 1 35‑850481A1
Racor Model 500® fuel filter (Or equivalent).
Metric Threads 1 35‑809867
Select a suitable position in the fuel system between the 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.
90-866920080 OCTOBER 2008 Page 3 / 4

FUEL SYSTEM SECTION - 4
NOTES:
Page 4 / 4 90-866920080 OCTOBER 2008

SECTION - 5 COOLING SYSTEM
SECTION 5 - COOLING SYSTEM

Table of Contents
Seawater Connections............................................................................................................................................ 2
Specifications.......................................................................................................................................................... 2
Through‑Hull or Transom‑Mounted Seawater Pickup............................................................................................. 2
Requirements....................................................................................................................................................2
Installation.........................................................................................................................................................3
Seacock................................................................................................................................................................... 3
Requirements ................................................................................................................................................... 3
Installation ........................................................................................................................................................ 4
Seawater Hoses...................................................................................................................................................... 4
Requirements ................................................................................................................................................... 4
Installation ........................................................................................................................................................ 4
Seawater Strainer.................................................................................................................................................... 4
Requirements ................................................................................................................................................... 4
Installation ........................................................................................................................................................ 4
5
Hot Water Heater Installation.................................................................................................................................. 5
Supply Hose Connection...................................................................................................................................6
Return Hose Connection...................................................................................................................................6
Water Flow........................................................................................................................................................7
Cooling System Flow Diagram—Typical................................................................................................................. 8
90-866920080 OCTOBER 2008 Page 1 / 10

COOLING SYSTEM SECTION - 5
Lubricant, Sealant, Adhesives

Marine Caulking Seawater inlet mounting surfaces Obtain Locally
7 Loctite 271 Threadlocker Seawater inlet nut 92-809819
Seawater Connections
In certain applications, these models may need to 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 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
Description All Models
Seawater pickup
Minimum 150 L/min. (40 US gal/min)
(through‑the‑hull or through‑the‑transom mounted)
Seacock size
At least: 38 mm (1‑1/2 in.)
(internal cross‑sectional area)
Seawater inlet hose inner diameter Minimum 38 mm (1‑1/2 in.)
Seawater strainer flow rate Minimum 150 L/min. (40 US gal/min)
Seawater inlet restriction Maximum 125 mm Hg (5 in. Hg)
Through‑Hull or Transom‑Mounted Seawater Pickup

Requirements
All QSD 4.2 models using a Bravo 2 or Bravo 3 sterndrive require a through‑hull or through‑transom
seawater pickup. QSD 4.2 models using a Bravo 1 sterndrive and all QSD 2.8 models that use a
through‑hull or through‑transom seawater pickup must have a large enough pickup to permit
sufficient seawater flow to the engine seawater pump for adequate engine cooling. The seawater
pickup also must supply a positive head while underway. The seawater pickup should be located
as close to the seawater pickup pump inlet as possible and in an area where an uninterrupted,
solid stream of seawater will flow past when the boat is underway.
Models Seawater Pickup Requirement

2.8 with Bravo One Through‑hull, through‑transom, or through‑drive
2.8 with Bravo Two Through‑hull, through‑transom, or through‑drive
2.8 with Bravo Three Through‑hull, through‑transom, or through‑drive
4.2 with Bravo One Through‑hull, through‑transom, or through‑drive
4.2 with Bravo Two Through‑hull or through‑transom
4.2 with Bravo Three Through‑hull or through‑transom
IMPORTANT: Do not install a through‑hull or transom‑mounted seawater pickup directly in line

with the propeller, as the pickup may create turbulence and allow air to flow into the propeller
slipstream. This will cause propeller ventilation and will adversely affect boat performance. Refer
to the Cummins MerCruiser Diesel Applications Manual (90‑866350050) for additional information.
Page 2 / 10 90-866920080 OCTOBER 2008

Installation
NOTE: If using other than the Quicksilver through‑hull seawater pickup shown, refer to the
manufacturer's instructions provided with the seawater pickup.
1. Install the Quicksilver through‑hull seawater pickup:
a. Drill a 50 mm (2 in.) hole through the hull in an appropriate location. See
Requirements.
b. Apply marine caulking (sealer) to mounting surface on the seawater pickup where hull
contact will occur when the pickup is installed.
Description Where Used Part Number

Marine Caulking Seawater inlet mounting surfaces Obtain locally
c. Ensure that the slots in the water pickup are facing forward (toward the bow of the boat),
and install the water pickup through the hull.
d. Apply marine caulking as needed inside the boat.
e. Position the washer on the fitting and install the large nut.
f. Apply sealant to the threads of the nut and install on the pickup on the inside of the boat.
Torque the nut.
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

Seawater inlet mounting
Marine Caulking Obtain Locally
surfaces

7 Loctite 271 Threadlocker Seawater inlet nut 92-809819

Seawater inlet nut 42 35
NOTE: If the pickup being installed does not have mounting screws on the underside where
mounted to the hull, ensure that the slots are still facing forward after the nut is torqued.
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.
90-866920080 OCTOBER 2008 Page 3 / 10

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 installation procedures.
Seawater Strainer
Requirements
The strainer used must be of sufficient size to ensure that an adequate supply of water will be
maintained for cooling the engine. Refer to Section 5: Cooling System—Specifications.
Installation
If using a seawater strainer other than the Quicksilver Seawater Filter, refer to the manufacturer's
instructions for installation, operation, and maintenance.
IMPORTANT: Read and observe the following when mounting and connecting a Quicksilver
seawater strainer:
• Mount the seawater strainer in a vibration free location.
• Never mount the seawater strainer on the engine.
• The seawater strainer must be mounted below the level of the seawater pump.
Page 4 / 10 90-866920080 OCTOBER 2008

• Do not kink the hoses.

• Do not allow the hoses to come in contact with hot or moving parts.
1. Position the seawater strainer in the appropriate location and below the level of the seawater
pump.
2. Ensure the arrow that indicates the direction of seawater flow points toward the seawater
pump.
3. Install the seawater strainer using flat washers and lag bolts
37290
Typical
Hot Water Heater Installation

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.
These in‑line diesel engines have bayonet fittings installed at the factory. These bayonet fittings
have a valve that can be opened or closed as required with a screwdriver.
21920
a - Valve
90-866920080 OCTOBER 2008 Page 5 / 10

Supply Hose Connection
23497
Typical engine
a - Hot water supply bayonet fitting with valve
Return Hose Connection
25856
Typical engine
a - Hot water return bayonet fitting with valve
Page 6 / 10 90-866920080 OCTOBER 2008

Water Flow
Water flow must be from the engine supply hose connection to the inlet of the hot water heater.
The water returns from the outlet on the heater to the return hose connection on the engine.
23537
Typical
90-866920080 OCTOBER 2008 Page 7 / 10

Cooling System Flow Diagram—Typical
4
i
g
d
c
h
5
f b
8
1
2
23470
2.8 shown, 4.2 similar
Page 8 / 10 90-866920080 OCTOBER 2008

Closed cooling system

a‑ Engine water circulating pump
b‑ Engine block
c‑ Cylinder heads
d‑ Coolant manifold
e‑ Intake and exhaust manifold assembly
f‑ Thermostat housing
g‑ Heat exchanger
h‑ Fluid cooler
i‑ Expansion tank
j‑ Turbocharger
Seawater system
1‑ 2.8 seawater pump (seawater inlet)
2‑ Engine oil cooler
3‑ Fuel cooler
4‑ Aftercooler
5‑ Heat exchanger
6‑ Fluid cooler
7‑ Sterndrive model exhaust riser or inboard model exhaust elbow (seawater overboard)
8‑ 4.2 seawater pump (seawater inlet)
90-866920080 OCTOBER 2008 Page 9 / 10

NOTES:
Page 10 / 10 90-866920080 OCTOBER 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....................................................................................................................................6
Tape Measure Method......................................................................................................................................6
Cutting Out The Transom..................................................................................................................................7
Checking The Transom Thickness....................................................................................................................8
Transom Connections............................................................................................................................................. 9
Exhaust Tube....................................................................................................................................................9
Installing Gimbal Housing Assembly.................................................................................................................9
Installing the Inner Transom Plate .................................................................................................................. 10
Connecting Speedometer Pickup....................................................................................................................12
Installing Sterndrive Seawater Pickup.............................................................................................................12
Installing the Sterndrive Seawater Block‑Off Plate.......................................................................................... 13
6
Gear Lube Monitor Connection At Gimbal Housing........................................................................................16
Installing Power‑Assisted Steering System (If Equipped)..................................................................................... 18
Power Trim Pump.................................................................................................................................................. 22
Mounting the Power Trim Pump......................................................................................................................22
Hydraulic Hose Connections—Power Trim Pump .......................................................................................... 23
Engine Installation and Alignment......................................................................................................................... 24
Engine Preparation..........................................................................................................................................24
Preparing the Transom....................................................................................................................................25
Connecting the Battery Cables to the Engine.................................................................................................26
Engine Installation...........................................................................................................................................27
Alignment........................................................................................................................................................31
Exhaust System Connections.........................................................................................................................34
Electrical Connections........................................................................................................................................... 36
Quick‑Connect MerCathode System Connection............................................................................................ 36
Continuity Circuit.............................................................................................................................................36
Mounting the Vessel Integration Panel (VIP)..................................................................................................37
Engine to VIP Harness....................................................................................................................................38
Vessel Sensor Harness...................................................................................................................................38
14‑Pin Helm Extension Harness.....................................................................................................................39
Non‑DTS Helm Harness.................................................................................................................................. 39
Vessel Integration Panel (VIP) Connections...................................................................................................40
Trim Position Sender Connection.................................................................................................................... 41
Power Trim Pump Connection........................................................................................................................41
Neutral Safety Switch Connection...................................................................................................................41
Fluid Connections.................................................................................................................................................. 42
Gear Lube Monitor..........................................................................................................................................42
Power‑Assisted Steering Hoses......................................................................................................................43
Hoses With Quick‑Connect Fittings ......................................................................................................... 43
Seacock and Connector..................................................................................................................................44
Seawater Strainer............................................................................................................................................44
Seawater Hoses..............................................................................................................................................44
Fuel Lines........................................................................................................................................................45
90-866920080 OCTOBER 2008 Page 1 / 62

DRIVE SYSTEM AND ENGINE MOUNTING SECTION - 6
Shift Cable Installation........................................................................................................................................... 46

Shift Cable Travel............................................................................................................................................46
Shift Cable Installation and Adjustment...........................................................................................................46
Sterndrive Installation............................................................................................................................................ 50
Bravo Sterndrive Installation...........................................................................................................................50
Additional Trim Limit Spacer Kit......................................................................................................................57
Speedometer Connections ‑ Bravo Models..................................................................................................... 60
Page 2 / 62 90-866920080 OCTOBER 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
2-4-C Marine Lubricant with O-ring seals
95 92-802859A 1
Teflon Trim cylinder hardware
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
90-866920080 OCTOBER 2008 Page 3 / 62

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 / 62 90-866920080 OCTOBER 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. The best mounting location for a particular boat, however, can be determined only by
testing.
1. Below 40 km/h (25 MPH): Subtract 13 mm (1/2 in.) from the X‑dimension.
2. Heavy duty applications: Subtract 25 mm (1 in.) from the X‑dimension.
3. Above 40 km/h (25 MPH): Use the X‑dimension shown.
4. Above 80 km/h (50 MPH): 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. Do not
increase the X-dimension by more than the following:
Maximum Increase In X-dimension

Bravo One and Three 76 mm (3 in.)
Bravo Two 25 mm (1 in.)
Extreme care should be taken when raising the sterndrive to ensure that the water supply does
not become aerated. 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-hull or
through-transom fitting, the sterndrive height will not cause cooling water aeration.
IMPORTANT: Damage to Cummins MerCruiser Diesel products caused by too high of an installed
height will not be covered by Mercury MerCruiser warranty.
90-866920080 OCTOBER 2008 Page 5 / 62

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.)
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.)
Page 6 / 62 90-866920080 OCTOBER 2008

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.
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.
90-866920080 OCTOBER 2008 Page 7 / 62

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 / 62 90-866920080 OCTOBER 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
Transom Connections
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.
90-866920080 OCTOBER 2008 Page 9 / 62

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 10 / 62 90-866920080 OCTOBER 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
90-866920080 OCTOBER 2008 Page 11 / 62

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 12 / 62 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 2008 Page 13 / 62

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 14 / 62 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 2008 Page 15 / 62

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 16 / 62 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 2008 Page 17 / 62

Installing Power‑Assisted Steering System (If Equipped)

NOTE: For dual installations, the power‑assisted steering unit can be mounted on the port or
starboard transom assembly. Measure the exact distance between power package centerlines.
Select the tie bar from the Diesel Parts And Accessory Guide (90‑892645005) or the Mercury
Parts and Accessories Guide (90‑42000006). Before proceeding, refer to Section 1—Multiple
Sterndrive Steering Tie Bar Arrangements and tie bar installation instructions.
1. Remove the protective shipping caps.
2. Inspect the bushings for debris. Lubricate the power steering bushings.
b
b
a
b
26055
a - Bushing b - Protective shipping caps

34 Special Lubricant 101 Power steering bushings 92-802865Q02
3. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.
b
21631
a - Upper pivot bolt b - Lower pivot bolt

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 18 / 62 90-866920080 OCTOBER 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.
a
b
b
a 21632
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 further to align the flats on bolt head with the tabs on
the washer.
a
b b
a
21691
a - Pivot bolt b - Bent tab
! 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.
90-866920080 OCTOBER 2008 Page 19 / 62

10. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tube
in the directions shown so that it will be less difficult to pull it out or push it in during connection.
a a
b
b
8496
a - Port b - Control valve cable guide tube
11. Connect the clevis to the steering lever.

a. Lubricate the clevis pin.

34 Special Lubricant 101 Clevis pin 92-802865Q02
b. Insert the clevis pin.
b
a
20396
a - Clevis b - Clevis pin
c. Insert the cotter pin.

d. Spread both ends of the cotter pin.
a a 20399
a - Cotter pin c - Steering lever

b - Clevis pin
Page 20 / 62 90-866920080 OCTOBER 2008

IMPORTANT: The Quicksilver RideGuide steering cable has a self‑locking coupler nut and does
not require an external locking sleeve or locking plate.
7255
a - 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.
7827
a - Steering cable and outer casing
12. Connect the steering cable as follows:

a. Coat the steering cable end with a liberal amount of lubricant.

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.
c. Using a suitable wrench, hold the flat surfaces on the cable guide tube vertically.
90-866920080 OCTOBER 2008 Page 21 / 62

d. Torque the coupler nut. Ensure that the flat surfaces remain aligned vertically.
d
g
e f
c
a b
d
7830
a- Steering cable e- End of steering cable

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 22 / 62 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 2008 Page 23 / 62

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 24 / 62 90-866920080 OCTOBER 2008


91 Engine Coupler Spline Grease Coupler splines 92-802869A 1
Preparing the Transom

! WARNING
Leaks in the exhaust system can cause serious injury or death due to carbon monoxide
poisoning. Inspect all exhaust components for damage before installing.
NOTICE
Damaged or incorrectly installed O‑rings that are submerged can cause water leaks, resulting
in property damage or possible sinking of the boat. Always inspect O‑rings before installing to
ensure they are seated properly.
1. Ensure that the exhaust pipe and gimbal housing mating surfaces are clean and free of nicks
and scratches.
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.
90-866920080 OCTOBER 2008 Page 25 / 62

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
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.
Page 26 / 62 90-866920080 OCTOBER 2008

3. Connect the negative (–) battery cable to the standard connection point.
24518
a - Positive (+) battery cable c - Standard negative (–) battery cable
b - Starter solenoid stud
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 boot over the positive terminal (+) after sealant is dry.
b
(+) a
16794
Typical
a - Positive (+) battery cable b - Rubber boot
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 mount adjusting nuts are positioned midway on the studs so that
adequate up and down adjustment exists for engine alignment.
90-866920080 OCTOBER 2008 Page 27 / 62

2. Lubricate the coupler splines.
23500
a - Grease fitting b - Coupler splines

91 Engine Coupler Spline Grease Coupler splines 92-802869A 1
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.
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
Page 28 / 62 90-866920080 OCTOBER 2008

4. Remove the front port lifting eye access cover in the engine cover or remove the entire engine
cover to gain access to the lifting eyes.
d a
c b
26041
a - Engine cover c - Front starboard side lifting eye
b - Front port side lifting eye access d - Rear lifting eye
cover
! 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.
5. Attach a suitable sling and lifting arm to the engine lifting eyes and adjust so that engine is
level when suspended.
! WARNING
Failure of the lifting eyes will cause the engine to fall suddenly from the hoist, resulting in serious
injury, death, or property damage. Keep the engine level while it is hoisted. Do not tilt the engine
more than 12° in any direction during installation.
90-866920080 OCTOBER 2008 Page 29 / 62

6. Lift the engine into position in the boat using an overhead hoist.
d
c
25857
Typical
a - Front starboard side engine lifting c - Rear engine lifting eye
eye (back side of engine) d - Suitable sling and lifting arm
b - Front port side engine lifting eye
IMPORTANT: When lowering 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.
Page 30 / 62 90-866920080 OCTOBER 2008

9. Install and torque 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

Rear engine mounting bolts 51 38
10. Adjust the front engine mounts until they rest on the boat stringers.
11. Set the engine on the boat stringers.
12. Relieve the tension on the hoist.
13. Disconnect the sling from the engine lifting eyes.
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.
90-866920080 OCTOBER 2008 Page 31 / 62

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 32 / 62 90-866920080 OCTOBER 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
90-866920080 OCTOBER 2008 Page 33 / 62

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 34 / 62 90-866920080 OCTOBER 2008

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

Exhaust system hose clamps 3.4–6.8 30–60
90-866920080 OCTOBER 2008 Page 35 / 62

Electrical Connections
Quick‑Connect MerCathode System Connection
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 d - Brown wire—from electrode on

transom assembly (through the transom assembly (through the
quick‑connect fitting) quick‑connect fitting)
b - Red/purple wire—to positive (+) e - Male and female quick‑connect
battery 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
Continuity Circuit
1. Connect the continuity circuit wire from the transom assembly to the engine. Tighten the inner
transom plate screw securely.
Page 36 / 62 90-866920080 OCTOBER 2008

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
• 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.
• it 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.
a
a
27820
a - Mounting screw (6 total, 2 not visible)
90-866920080 OCTOBER 2008 Page 37 / 62

Engine to VIP 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.
• 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.
2. Connect the engine to VIP harness to the engine connections on the back of the engine.
a
24147
a - Power connector b - Engine to VIP harness 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.
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.
Page 38 / 62 90-866920080 OCTOBER 2008

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.
• 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.
90-866920080 OCTOBER 2008 Page 39 / 62

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 to VIP harness to the VIP (40‑pin connector).
3. Connect the 14‑pin helm extension 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 extension harness
b - Engine to VIP harness connector connector
Page 40 / 62 90-866920080 OCTOBER 2008

Trim Position Sender Connection

1. Connect the trim position sender from gimbal housing to the vessel sensor 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.
90-866920080 OCTOBER 2008 Page 41 / 62

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
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 42 / 62 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 2008 Page 43 / 62

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 the Quicksilver seawater strainer
installation, if not already installed.
Seawater Hoses
IMPORTANT: Use wire‑reinforced hose of adequate wall thickness to prevent it from collapsing
from pump suction. Anchor hoses to the vessel. Secure the hose connections with hose clamps.
Page 44 / 62 90-866920080 OCTOBER 2008

1. Ensure that the hose reducer is installed in the end of the seawater inlet hose that will connect
to the sterndrive seawater inlet fitting.
b a c
d
7951
a - Hose reducer c - Hose reducer flange

b - Seawater inlet hose d - End of hose
NOTE: The flange of a properly installed hose reducer will contact the end of the hose.
IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come
in to contact with steering system components, the engine coupler, or the drive shaft.
2. If equipped with a seawater strainer:
a. Install the seawater hose from the seawater pickup fitting to the seawater strainer inlet.
b. Install the seawater hose from the seawater strainer outlet to the seawater pump inlet
hose connector.
3. If not equipped with a seawater strainer, install the seawater hose from the seawater pickup
fitting to the seawater pump inlet hose connector.
4. Tighten the seawater hose clamps securely.
h
c b
g a
f
h
e h
h 23451
Typical seawater hose connections
a- Standard seawater inlet fitting, optional seacock hose connection not shown
b- Hose reducer
c- Seawater hose to seawater strainer
d- Optional quicksilver seawater strainer
e- Seawater hose to seawater pump
f- Seawater pump hose connector
g- Below seawater pump level
h- Hose clamp
Fuel Lines
1. Remove the protective cap or plug.
2. Connect a flexible fuel hose to the fuel inlet fitting.
90-866920080 OCTOBER 2008 Page 45 / 62

3. Secure with hose clamps.
b c
25717
2.8 shown, 4.2 similar
a - Fuel inlet fitting c - Protective cap
b - Water‑separating fuel filter
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.
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
Page 46 / 62 90-866920080 OCTOBER 2008

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
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.
90-866920080 OCTOBER 2008 Page 47 / 62

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.
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.
Page 48 / 62 90-866920080 OCTOBER 2008

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.
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.
b
c
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.
90-866920080 OCTOBER 2008 Page 49 / 62

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.
b
c
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.

Sterndrive Installation
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
Page 50 / 62 90-866920080 OCTOBER 2008

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
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.
90-866920080 OCTOBER 2008 Page 51 / 62

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

91 Engine Coupler Spline Grease U-joint O-rings 92-802869A 1
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
Page 52 / 62 90-866920080 OCTOBER 2008

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

2-4-C Marine Lubricant with
95 O-ring seals 92-802859A 1
Teflon
90-866920080 OCTOBER 2008 Page 53 / 62

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.
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
Page 54 / 62 90-866920080 OCTOBER 2008

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:

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
90-866920080 OCTOBER 2008 Page 55 / 62

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
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
Page 56 / 62 90-866920080 OCTOBER 2008

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
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.
1. Install the trim cylinders. See Trim Cylinder Installation.
2. Set the trim and trailer limit during predelivery preparation. Refer to Setting Trailer and Trim
Limit in the Predelivery Preparation and Storage section.
90-866920080 OCTOBER 2008 Page 57 / 62

If the trim position sender is set so that the drive will make contact with any part of the vessel or
swim platform and the CDS tool is unavailable to set the trim and trailer limit, then an additional
trim limit spacer kit is required. Install the kit before connecting the trim cylinders to the sterndrive.
The trim limit spacer kit keeps the sterndrive from contacting the swim platform preventing
sterndrive or vessel damage.
1. Install the trim limit spacer kit (91‑15768A3).
2. Refer to the instruction sheet contained in the kit.
3. Install the trim cylinders. See Trim Cylinder Installation.
Trim Cylinder Installation
1. Install the front mounting hardware of the trim cylinder as shown.
2. Lubricate the anchor pin threads to prevent the threads from galling.
3. Hand‑thread the locknuts onto the pin. Do not tighten at this time.
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

95 Trim cylinder hardware 92-802859A 1
Teflon
Page 58 / 62 90-866920080 OCTOBER 2008

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.
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)

95 Trim cylinder hardware 92-802859A 1
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.
90-866920080 OCTOBER 2008 Page 59 / 62

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.
2. Insert speedometer tube fitting into opening on topside of anti‑ventilation plate, in position
shown.
5319
a - Tube fitting b - Opening
Page 60 / 62 90-866920080 OCTOBER 2008

3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
5320
a - Fitting installed (handle pointing forward)
90-866920080 OCTOBER 2008 Page 61 / 62

NOTES:
Page 62 / 62 90-866920080 OCTOBER 2008

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

Table of Contents
Electrical System Precautions................................................................................................................................. 2
Battery..................................................................................................................................................................... 2
Selecting the Battery.........................................................................................................................................2
Battery Precautions for Multiple Engines..........................................................................................................2
Battery Cables......................................................................................................................................................... 3
Selecting the Battery Cables.............................................................................................................................3
Battery Cable Installation Requirements...........................................................................................................3
Instrumentation........................................................................................................................................................ 4
General Information...........................................................................................................................................4
Power Trim System Installation.........................................................................................................................4
Wiring Diagrams...................................................................................................................................................... 5
MerCathode System.......................................................................................................................................... 5
90-866920080 OCTOBER 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
Selecting the Battery
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards, and Coast Guard
regulations must be adhered to when installing a battery. Be sure battery cable installation meets
the pull test requirements and that the positive battery terminal is properly insulated in accordance
with regulations.
IMPORTANT: It is recommended (required in some states) that the battery be installed 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

2.8 and 4.2 750 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 90-866920080 OCTOBER 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.
Battery Cables
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.
90-866920080 OCTOBER 2008 Page 3 / 6

• 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.
• 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 the Mercury Parts and
Accessories Guide (90‑42000006) for selection.
The SmartCraft data is carried in the 14‑pin system without the use of a special data harness.
All QSD engines require the use of a tachometer.
The five basic gauges that are also available with the engine are:
1. Fuel gauge
2. Oil pressure
3. Engine coolant temperature
4. Voltmeter
5. Trim gauge
When using SmartCraft instrumentation, instrument harness wire connectors are labeled. Connect
them onto the individual SmartCraft instruments, switches, and panels. The instrumentation
harness ends are provided for connection into the appropriate extension harness ends. The wiring
harnesses will then be ready to route to the engine compartment.
Refer to the appropriate manuals that accompany your instrumentation package.
Power Trim System Installation
See Section 8 - Remote Controls.
Page 4 / 6 90-866920080 OCTOBER 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
90-866920080 OCTOBER 2008 Page 5 / 6

NOTES:
Page 6 / 6 90-866920080 OCTOBER 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
90-866920080 OCTOBER 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 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 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 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 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 90-866920080 OCTOBER 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
Description Specification
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.

90-866920080 OCTOBER 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 fasten any items to the throttle cables.
1. Install the end guide of the throttle cable anchor stud in the third hole from the end of the
throttle position sensor (TPS) lever.
2. Place the remote throttle lever in the neutral and idle position.
3. Install the cable end guide on the throttle lever. Hand tighten the locknut only.
4. Install the throttle cable barrel anchor stud in the third hole from the left on the top row of the
anchor bracket. Hand tighten the locknut only.
a e
e
b
d c
23707
a - Throttle position sensor (TPS) d - Cable barrel
b - Throttle cable end guide e - Anchor stud
c - Flat washer and locknut
Page 8 / 10 90-866920080 OCTOBER 2008

IMPORTANT: The engine will reach 100% WOT before the TPS reaches the mechanical stop.
Adjust the throttle cable so that the throttle position sensor does not contact the mechanical stop
at 100% WOT. Contact between the TPS at WOT and the mechanical stop could result in
premature TPS failure.
5. If using the CDS tool to adjust the throttle cable:
a. Move the throttle lever forward until the CDS tool reads 100% WOT.
b. Adjust the throttle cable end guide and barrel anchor stud so that the throttle position
lever can move past 100% WOT but will not contact the TPS mechanical stop.
6. If the CDS tool is unavailable, then adjust the throttle cable as follows:
a. Move the throttle lever forward to the WOT location.
b. Measure the distance between the anchor stud on the throttle lever and the and the
center of the anchor stud on the cable barrel as shown. The distance between them at
WOT is 140 mm (5 ½ in.).
c
a
26385
a - Cable end guide anchor stud
b - Throttle cable barrel location on anchor bracket
c - 140 mm (5 ½ in.)
c. Adjust the throttle cable end guide and barrel anchor stud to the dimensions specified
and ensure that the throttle position lever is not contacting the TPS WOT mechanical
stop. The engine will reach 100% WOT before the TPS reaches the mechanical stop.
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 did not return to the idle position.
9. Place the remote control lever fully in the forward WOT position.
10. Operate the remote control and check that the throttle position sensor lever reaches wide‑open
or 100% throttle position.
90-866920080 OCTOBER 2008 Page 9 / 10

NOTES:
Page 10 / 10 90-866920080 OCTOBER 2008

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

STORAGE
Table of Contents
Predelivery Preparation........................................................................................................................................... 2
Engine Oil................................................................................................................................................................ 3
Checking...........................................................................................................................................................3
Filling.................................................................................................................................................................3
Engine Coolant........................................................................................................................................................ 4
Checking...........................................................................................................................................................4
Filling.................................................................................................................................................................5
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
Bravo Diesel Sterndrive Propeller Installation.................................................................................................13
Bravo One Models ................................................................................................................................... 13
Bravo Two Models ................................................................................................................................... 14
Bravo Three ............................................................................................................................................. 16 9
Engine Operation Testing...................................................................................................................................... 17
Testing Preparation.........................................................................................................................................17
Boat out of the Water......................................................................................................................................18
Boat in the Water.............................................................................................................................................19
Testing.............................................................................................................................................................20
Boat‑in‑the‑Water Tests..................................................................................................................................21
Engine Initial Break‑In Procedure ............................................................................................................ 21
Maximum RPM Test........................................................................................................................................22
After Operating the Engine..............................................................................................................................22
Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage............................................. 23
Cold Weather (Freezing Temperature) Storage..............................................................................................24
Preparing Your Power Package for Seasonal or Extended Storage...............................................................24
Draining the Seawater System........................................................................................................................25
Seasonal Storage Instructions........................................................................................................................27
Extended Storage Instructions........................................................................................................................28
Predelivery Inspection Checklist........................................................................................................................... 29
90-866920080 OCTOBER 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
Propeller Nut Tool 91‑805457T 1
Aids in the removal and installation of the front propeller nut.
10677
Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1
Blocks off the front water inlet holes on the dual water inlet
gearcases.
9194
Flushing Device 91‑44357Q 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.
Page 2 / 30 90-866920080 OCTOBER 2008

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.
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.
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.
23196
Typical
a - Dipstick c - Minimum mark
b - Maximum mark
Filling
IMPORTANT: Do not overfill the engine with oil.
90-866920080 OCTOBER 2008 Page 3 / 30

1. Remove the oil fill cap.
23244
Typical
a - Oil fill cap
2. Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick.
Capacity
2.8 Fluid Type
Liters (U.S. qts)
Engine Oil (With Filter) 8.9 liter (9.4 U.S. qts) 4‑Cycle 15W40 Marine Engine Oil
Capacity
4.2 Fluid Type
Liters (U.S. qts)
Engine Oil (With Filter) 13.8 liter (14.6 U.S. qts) 4‑Cycle 15W40 Marine Engine Oil
IMPORTANT: When refilling the engine with oil always use the dipstick to determine how much
oil is required.
3. Install the oil fill cap.
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: When possible, check the engine coolant before starting the engine.
1. Allow the engine to cool.
2. Remove the pressure cap from the coolant expansion tank.
Page 4 / 30 90-866920080 OCTOBER 2008

3. The coolant level in the coolant expansion tank should be above the coolant level indicator
attached to the bottom of the coolant cap.
a
37255
a - Filler neck
b - Coolant cap
c - Level indicator
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.
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.
d. Add the specified coolant as necessary. Refer toFilling.
IMPORTANT: Tighten the pressure cap to prevent coolant loss.
5. If the coolant level is correct, install the pressure cap and tighten.
Filling
1. Allow the engine to cool.
2. Remove the pressure cap from the coolant expansion tank.
90-866920080 OCTOBER 2008 Page 5 / 30

3. If the coolant is low in the coolant expansion tank, add the specified coolant as necessary to
bring the level above the coolant level indicator attached to the bottom of the coolant cap.
a
37255
a - Filler neck
b - Coolant cap
c - Level indicator
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
IMPORTANT: When installing the pressure cap, be sure to tighten it securely to prevent coolant
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.
a. The proper fluid level with the engine cold should be between the full cold mark and the
end of the dipstick.
Page 6 / 30 90-866920080 OCTOBER 2008

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.
90-866920080 OCTOBER 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 90-866920080 OCTOBER 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
90-866920080 OCTOBER 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

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. 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 90-866920080 OCTOBER 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.
90-866920080 OCTOBER 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 rated
revolutions per minute (RPM). Use an accurate service tachometer to verify engine operating
RPM.
It is the responsibility of the boat manufacturer and the selling dealer to equip the power package
with the correct propellers. Refer to Quicksilver publication 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 is below the engine rated RPM, the propeller must be changed to prevent
loss of performance and possible engine damage. On the other hand, operating an engine above
the engine rated RPM will cause higher than normal wear or damage.
After initial propeller selection, the following common problems may require that the propeller be
changed to a lower pitch:
Page 12 / 30 90-866920080 OCTOBER 2008

1. Warmer weather and greater humidity cause an RPM loss (not as significant on Electronic
Control models).
2. Operating in a higher elevation causes an RPM loss (not as significant on Electronic Control
models).
3. Operating with increased load (additional passengers, pulling skiers, etc.)
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller.
However, do not operate at full throttle when using the lower pitch propeller but not pulling skiers.
Because of the many variables of boat design, only testing will determine the best propeller for a
particular application. Available propellers are listed in the CMD Diesel Parts And Accessories
Guide (90‑892645005).
See Boat in the Water Tests, Maximum RPM Test in this power package installation manual.
Bravo Diesel 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.
! WARNING
a
b
4826
a - Wood block c - Propeller nut under socket

b - Propeller
BRAVO ONE MODELS

IMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the direction
of rotation of the propeller shaft.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.

34 Special Lubricant 101 Propeller shaft splines 92-802865Q02

95 Propeller shaft splines 92-802859A 1
Teflon
90-866920080 OCTOBER 2008 Page 13 / 30

NOTE: Anti‑corrosion grease is for saltwater applications only.

2. Install the propeller with the attaching hardware as shown.
3. Torque the propeller nut.
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

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.
5. Bend the three tabs down into the grooves.
a b c
4750
a - Prop d - Tab bent down

b - Tab washer e - Propeller nut
c - Drive sleeve adapter
BRAVO TWO MODELS

IMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the direction
of rotation of the propeller shaft.
Page 14 / 30 90-866920080 OCTOBER 2008



Teflon

2. Install the propeller with the attaching hardware as shown.
3. Torque the propeller nut.
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

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.
5. Bend the three tabs down into the grooves.
a b c
4750
a - Prop d - Tab bent down

b - Tab washer e - Propeller nut
c - Drive sleeve adapter
90-866920080 OCTOBER 2008 Page 15 / 30

BRAVO THREE


Teflon
Teflon

2. Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller
hub.
3. Align splines and place front propeller on propeller shaft.
4. Install the front propeller locknut and torque using the Propeller Nut Tool.
Propeller Nut Tool 91‑805457T 1

Bravo Three front propeller nut 136 100
5. Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub.
6. Align the splines and install the aft propeller.
7. Install the propeller nut and torque.
Bravo Three rear propeller nut 81 60
8. Install the propeller shaft anode and screw and torque.
e
f
b
d
c
a
i
j
g h
5304
Bravo Three
a- Rear propeller nut f- Front propeller thrust hub
b- Rear propeller g- Propeller shaft anode screw
c- Rear propeller thrust hub h- Flat washer
d- Front propeller nut i- Star washer
e- Front propeller j- Propeller shaft anode

Propeller shaft anode screw 19 168
Page 16 / 30 90-866920080 OCTOBER 2008

Engine Operation Testing

! WARNING
Failure to comply with regulations can result in injury from fire or explosion. Electrical system
components on this engine are not rated as external ignition–protected (EIP). Do not store or
use gasoline on boats equipped with these engines, unless provisions have been made to
exclude gasoline vapors from the engine compartment (REF: 33 CFR).
! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious
injury or death. Use caution when performing a test that requires the engine running, and remove
the propeller to avoid injury.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat
and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
1. Ensure that the cooling system drain plugs and petcocks are installed and tight.
2. Ensure that the cooling system hoses are installed and clamped securely.
Testing Preparation
! WARNING
Leaving the helm unattended while performing tests with the boat in the water may result in loss
of boat control causing serious injury or death. Ensure someone is at the helm at all times, unless
the boat is secured to a dock.
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.
90-866920080 OCTOBER 2008 Page 17 / 30

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. If using a flushing attachment, ensure that
the correct device is used for the type of water pickup found on the sterndrive.
16828
Dual water pickup Side pickup
Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1
Flushing Device 91‑44357Q 2
Boat out of the Water

The following information is for engine operation tests with the boat out of the water:
! WARNING
1. If the propeller was previously installed, remove the propeller.

IMPORTANT: If using a flushing attachment (sometimes referred to as a flush test device) over
the water inlet holes and a water supply hose as shown, do not use full water source pressure.
2. Install a flushing attachment over the sterndrive water inlet holes.
a a
b b
c
21514 21515
Flushing attachments for dual water pickup Flushing attachments for side water pickup
a - Flushing device c - Dual water pickup flush gearcase seal
b - Hose attachment kit
3. Connect a hose between the flushing attachment and a water source.
Page 18 / 30 90-866920080 OCTOBER 2008

4. Open the water source about 1/2 maximum. Do not use full water pressure.
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.
5. On engines with a through-hull water inlet, supply sufficient cooling water to the engine's
seawater pump.
a
a
26143 26150
2.8 4.2
a - Seawater pump
6. Proceed to Testing.
Boat in the Water
The following information is for engine operation tests with the boat in the water:
! WARNING
IMPORTANT: If using a test tank, the water level must be above the water inlet holes on the
sterndrive or the through‑hull pickup.
1. On engines with sterndrive water inlet, ensure that the water level is above the water inlet
holes on the sterndrive.
a
b
22193
Typical with sterndrive seawater inlet

a - Minimum water level b - Water inlet holes
90-866920080 OCTOBER 2008 Page 19 / 30

2. On engines with through-hull water inlet, ensure that the water level is above the water
inlet holes on the through‑hull water inlet.
3. Proceed to Testing.
Testing
! WARNING
1. Place the sterndrive in the full down (in) position.

2. Supply water to the engine either by putting the boat in the water or by using the correct flush
attachments.
3. Refer to the Operation, Maintenance, and Warranty Manual for starting information.
4. Start the engine.
5. In throttle‑only mode, operate at a fast idle RPM until the water temperature is normal.
6. Watch all the gauges for normal readings.
7. Set the engine to idle RPM.
8. Turn the steering wheel starboard then port and ensure that the sterndrive turns in the correct
direction.
9. Inspect the engine compartment for water, oil, fuel, and exhaust leaks.
NOTE: The operator at the remote control handle should feel a slight detent before and after each
gear: FORWARD‑detent‑NEUTRAL‑detent‑REVERSE. The sterndrive is shifting properly when
the sterndrive shifts with minimal effort in and out of each gear at idle speed position.
IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle
is engaged. Check the Shift cable Installation and Adjustment and the Sterndrive Installation to
locate and fix the problem. Refer to Section 6.
10. Ensure that the remote control shift cable installation results in correct forward and reverse
gear operation.
a. Move the remote control handle to FORWARD, idle speed position.
b. Check that the 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. Remove the sterndrive and check for proper shift hook ups.
ii. 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.
11. Check power steering system for lugging (engine RPM drops or power steering pump tone
changes) condition.
a. Turn the steering wheel left (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.
b. Turn the steering wheel right (starboard) until it stops, and continue to apply pressure.
If the pump lugs, check the following:
Page 20 / 30 90-866920080 OCTOBER 2008

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.
12. Turn the key switch to the "OFF" position to stop the engine.
13. Lubricate the steering cable and clevis.
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
14. Restart the engine and observe the sterndrive. If the sterndrive moves slowly to one side or
the other, 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.
15. Position the sterndrive so it is straight back.
16. Turn the key switch to the "OFF" position to stop the engine.
17. If operating with the boat out of the water, discontinue supplying cooling water to the power
package.
18. Remove the fill cap and 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:
90-866920080 OCTOBER 2008 Page 21 / 30

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.
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.
Page 22 / 30 90-866920080 OCTOBER 2008

NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze
damage. Drain the seawater section of the cooling system immediately after operation or before
any length of storage in freezing temperatures. If the boat is in the water, keep the seacock
closed until restarting the engine to prevent water from flowing back into the cooling system. If
the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
IMPORTANT: As a precautionary measure, attach a tag to the key switch or steering wheel of the
boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose
before starting the engine.
2. If the power package will not be used for an extended period of time, or will be exposed to
freezing temperatures, drain the water from the seawater cooling system. See Cold Weather
(Freezing Temperature), Seasonal Storage, or Extended Storage.
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.
90-866920080 OCTOBER 2008 Page 23 / 30

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.
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
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.
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.
1. Supply cooling water to the water inlet holes or seawater pump inlet.
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.
Page 24 / 30 90-866920080 OCTOBER 2008

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 cold weather (freezing temperature),
seasonal storage, or extended storage.
IMPORTANT: The boat must not be operating during this procedure.
! 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.
1. Remove the boat from the water if possible.

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.
3. Make the engine as level as possible to ensure complete draining of the seawater system.
NOTE: The anode assembly on the back of the fluid cooler can be used as a drain plug.
4. Remove the drain plug from the aft end cover of the fluid cooler.
a
b
23710
Typical engine
a - Anode assembly drain plug
b - Fluid cooler
90-866920080 OCTOBER 2008 Page 25 / 30

5. Remove the drain plug, or fitting (if equipped), from the aft end cover of the engine oil cooler.
a
b 23295
Typical engine
a - Engine oil cooler
b - Drain plug, or fitting if equipped
NOTE: In the following steps, the hoses may require lowering or bending to allow seawater to
drain completely.
6. Disconnect the seawater inlet hose from the connector on the seawater pump hose and drain.
c a
a
b b
23480 23649
2.8 4.2
a - Seawater inlet hose
b - Connector
c - Seawater pump hose
7. Repeatedly clean out the drain holes using a stiff piece of wire until the seawater section is
completely drained.
8. On models equipped with a seawater strainer:
a. Remove the drain plug and washer if equipped.
b. Remove both hoses from the seawater strainer and drain them completely.
c. Drain and empty the seawater strainer.
d. Connect the hoses and tighten the hose clamps.
Page 26 / 30 90-866920080 OCTOBER 2008

e. Install the sealing washer and drain plug, if equipped.
37290
Typical
9. 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.

19 Perfect Seal Drain plug or fitting threads 92-34227 1
10. Connect all hoses. Tighten the hose clamps.

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 5.6 liters (6 U.S. quarts) 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.
90-866920080 OCTOBER 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. Start the engine and operate at idle speed until the antifreeze mixture has been pumped into
the engine seawater cooling system.
6. Stop the engine.
7. Remove the temporary hose from the seawater pump.
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.
8. Place the sterndrive in the full down (in) position.
9. Follow the battery manufacturer's instructions for storage and store the battery.
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.
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.
Page 28 / 30 90-866920080 OCTOBER 2008

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.)
90-866920080 OCTOBER 2008 Page 29 / 30

NOTES:
Page 30 / 30 90-866920080 OCTOBER 2008

QSD 2.8 e 4.2 90-866920080

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QSD 2.8 e 4.2 90-866920080

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Cummins MerCruiser Diesel

QSD 2.8 AND 4.2 DIESEL ENGINE

Notice to Boat Manufacturer and Installer

Page i © 2008 Mercury Marine 90-866920080 OCTOBER 2008

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

SECTION 1 - IMPORTANT INFORMATION 1

90-866920080 OCTOBER 2008 Page 1 / 12

Lubricants, Sealants, Adhesives

Page 2 / 12 90-866920080 OCTOBER 2008

SeaCore Components and Castings

Tube Ref No. Description Where Used Part No.

Trim‑in Limit Insert

90-866920080 OCTOBER 2008 Page 3 / 12

Page 4 / 12 90-866920080 OCTOBER 2008

Bravo Sterndrive Serial Number and Identification

a - Bar code c - Serial Number

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Bravo sterndrive serial number stamping

Bravo Transom Serial Number

Bravo transom assembly U‑bolt plate

Page 6 / 12 90-866920080 OCTOBER 2008

Multiple Sterndrive Steering Tie Bar Arrangements

Internal Tie Bar Only

90-866920080 OCTOBER 2008 Page 7 / 12

External Power Steering

Page 8 / 12 90-866920080 OCTOBER 2008

Typical boat package

90-866920080 OCTOBER 2008 Page 9 / 12

Anodes and MerCathode System Locations

Mounted on the underside of the lower

Ventilation plate anode Mounted on the front of the gearcase.

The MerCathode electrode is mounted

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

Trim cylinder anodes Mounted on each of the trim cylinders.

Located in front of the propeller,

REFERENCE ELECTRODE WIRE OF THE MERCATHODE SYSTEM

Page 10 / 12 90-866920080 OCTOBER 2008

MerCathode—mounted to the underside of the gimbal housing

90-866920080 OCTOBER 2008 Page 11 / 12

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

Tube Ref No. Description Where Used Part No.

Page 12 / 12 90-866920080 OCTOBER 2008

SECTION 2 - BOAT CONSTRUCTION

90-866920080 OCTOBER 2008 Page 1 / 4

Transom Thickness and Surface Plane

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

Page 2 / 4 90-866920080 OCTOBER 2008

Checking Transom Thickness

90-866920080 OCTOBER 2008 Page 3 / 4

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

Page 4 / 4 90-866920080 OCTOBER 2008

SECTION 3 - EXHAUST SYSTEM

90-866920080 OCTOBER 2008 Page 1 / 6

Exhaust Elbow Height

Model "c" = "a" Minus "b"

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

Page 2 / 6 90-866920080 OCTOBER 2008

Description All Models

90-866920080 OCTOBER 2008 Page 3 / 6

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

Clear Hose Method

Page 4 / 6 90-866920080 OCTOBER 2008

90-866920080 OCTOBER 2008 Page 5 / 6

Page 6 / 6 90-866920080 OCTOBER 2008