Mercury INSTALLATION MANUAL D7.3L D-TRONIC - Manual

90-861180990 SEPTEMBER 1999 Printed in U.S.A. -  1999, Mercury Marine Page 1 of 90
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, and Ride-Guide.
INSTALLATION MANUAL D7.3L D-TRONIC
DIESEL ENGINES - BRAVO MODELS
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed with the Product for the Owner’s
Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information 2 . . . . . . . . . . . . . . . . . . . . . . .
Notice to Installer 2 . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In Limit Pin 3 . . . . . .
Multiple Sterndrive Steering Tie Bar
Arrangements 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Products 5 . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 6 . . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 6 . . . . . . . . . . .
Corrosion Protection 6 . . . . . . . . . . . . . . . . . . . . .
Antifouling Paint 7 . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 8 . . . . . . . . . . . . . . . . .
Boat Construction 8 . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 11 . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 12 . . . . . . . . . . . . . . . . . . .
General 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables 14 . . . . . . . . . . . . . . . . . . . . . . . . .
EDI Electrical System Precautions 15 . . . . . . . .
Instrumentation 15 . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Control 16 . . . . . . . . . . . . . . . . . . . . .
Power Trim Pump Location 16 . . . . . . . . . . . . . .
Propeller Selection 17 . . . . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation
Recommendation 18 . . . . . . . . . . . . . . . . . . . . . .
Seawater Connections 19 . . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and Cables 20 . .
Steering Helm and Cable 21 . . . . . . . . . . . . . . . .
Transom Cutout 23 . . . . . . . . . . . . . . . . . . . . . . . . . .
Finding Crankshaft Vertical Centerline 24 . . . . .
Finding Crankshaft Horizontal Centerline
(“X” Dimension) 25 . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Transom 27 . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transom Thickness 28 . . . . . . . . . . . . .
Installing Transom Assembly 29 . . . . . . . . . . . . .
Gimbal Housing 29 . . . . . . . . . . . . . . . . . . . . . . . .
Inner Transom Plate 30 . . . . . . . . . . . . . . . . . . . .
Power Trim Pump 31 . . . . . . . . . . . . . . . . . . . . . .
Steering System 32 . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Pickup 35 . . . . . . . . . . . . . . . . . . . .
Drive Unit Gear Lube Monitor Hose 35 . . . . . . .
Exhaust Water Bypass 36 . . . . . . . . . . . . . . . . . .
Drive Unit Seawater Routing 37 . . . . . . . . . . . . .
Engine Installation 39 . . . . . . . . . . . . . . . . . . . . . . .
Engine Preparation 39 . . . . . . . . . . . . . . . . . . . . .
Transom Preparation 40 . . . . . . . . . . . . . . . . . . . .
Installing Engine / Alignment 41 . . . . . . . . . . . . .
Engine Connections 46 . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Seawater Pickup and Seacock 46 .
Seawater Strainer 47 . . . . . . . . . . . . . . . . . . . . . .
Closed Cooling Recovery Bottle 48 . . . . . . . . . .
Fuel Lines 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Hydraulic Hoses 49 . . . . . . . . . .
Exhaust System 50 . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 50 . . . . . . . . . . . . . . . . . . .
Shift Cable Installation and Adjustment 54 . . . .
Troubleshooting Shift Problems 58 . . . . . . . . . . .
Throttle Cable Installation and Adjustment 60 .
Sterndrive Unit Installation 62 . . . . . . . . . . . . . . .
Predelivery Preparation 69 . . . . . . . . . . . . . . . . . . .
Power Trim System Wiring Diagram 84 . . . . . . .
MerCathode System Wiring Diagram 85 . . . . . .
Quicksilver Instrumentation Wiring 86 . . . . . . . .
Cooling System Flow Diagram 88 . . . . . . . . . . . .
Predelivery Inspection 90 . . . . . . . . . . . . . . . . . . . .