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INSTALLATION MANUAL D7.3L D-TRONIC
DIESEL ENGINES - BRAVO MODELS
After Completing Installation, These Instructions Should Be Placed with the Product for the Owner's
Future Use.
Predelivery Preparation Instructions Must be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
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90-861180990 SEPTEMBER 1999
NOTICE to INSTALLER
NOTICE to COMMISSIONING DEALER
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The following are registered trademarks of
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Related Manuals for Mercury INSTALLATION MANUAL D7.3L D-TRONIC
Summary of Contents for Mercury INSTALLATION MANUAL D7.3L D-TRONIC
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Page 1: Table Of Contents
INSTALLATION MANUAL D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS After Completing Installation, These Instructions Should Be Placed with the Product for the Owner’s Future Use. Predelivery Preparation Instructions Must be Performed Before Delivering Boat To The Product Owner. Table of Contents General Information . -
Page 2: General Information
Mercury Marine. That they have been trained in the recommended installation procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. -
Page 3: Bravo Three Notice: Trim-In Limit Pin
Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE EN- GINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VA- PORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could re- sult in fire, explosion and/or severe personal injury. -
Page 4: Multiple Sterndrive Steering Tie Bar Arrangements
Tie Bar” statements). Again this system does not use an internal tie bar. Mercury Marine does not recommend the use of an external tie bar ONLY (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. -
Page 5: Quicksilver Products
Quicksilver remote controls, steering systems, propellers, etc. are available for this product. Refer to “Quicksilver Accessories Guide” for complete listing. This “Guide” is available from: Attn: Parts Department Mercury Marine W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 OR –... -
Page 6: Torque Specifications
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Torque Specifications Speedometer Pickup Barb Fitting Exhaust Pipe or Block-off Plate Power Steering Hydraulic Hose Fittings Power Trim Pump Hose Fittings Propeller Nut (Bravo One and Two) Propeller Nuts (Bravo Three) Propeller Nuts (Bravo Three) Rear Engine Mounts Steering Cable Coupler Nut Steering System (Pivot Bolts) -
Page 7: Antifouling Paint
Antifouling 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. -
Page 8: Installation Requirements
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Installation Requirements Boat Construction TRANSOM Transom Thickness - 2 in. (51mm) Minimum to 2-1/4 in.(57mm) Maximum Inner Surface of Transom Must Be Parallel Within 1/8 in. (3mm) in Area Covered by Transom Plate (e) and Remain Within Transom Thickness Limits. Outer Surface of Transom Must Be Parallel Within 1/16 in. - Page 9 ENGINE COMPARTMENT Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad- hered to when constructing the engine compartment. Care must be exercised in the design and construction of the engine compartment. Seams must be located so that any rain water, which may leak through the seams, is directed away from the air intake system.
- Page 10 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Multiplying the engine air flow (cfm) by 0.1 will generally determine the combustion air vent size requirement (per engine). Therefore: Engine Combustion Air Flow (cfm) X 0.1 Engine Combustion Air Flow (m 22.8 D7.3 D-Tronic Example: : For engine combustion air only - NOT total engine compartment ventilation requirement.
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Page 11: Exhaust System
Exhaust System IMPORTANT: It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install the exhaust system. Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine. Damage caused by water in the engine will not be covered by MerCruiser Warranty, unless this damage is the result of defective part(s). -
Page 12: Fuel Delivery System
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Some engines may be equipped with a factory installed exhaust riser. Verify that the riser provides the required dimension “c”, or a distance greater than “c”, as indicated. Model All Models Typical Engine With Riser From Waterline to Top of Transom From Highest Point on Exhaust Riser to Top of Transom Equals (a) minus (b) - Page 13 4. The tank breather pipe must have an inner diameter of at least 1/2 in. (13mm) and must be fitted with a swan neck to prevent water from entering the tank. It is recommended that 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.
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Page 14: Battery
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Battery IMPORTANT: Boating industry standards (BIA, ABYC, etc.) federal standards and Coast Guard regulations must be adhered to when installing battery. Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. -
Page 15: Edi Electrical System Precautions
EDI Electrical System Precautions NOTE: The following precautions apply to all EDI model Engines. Avoid damage to the Electronic Direct Injection (EDI) electrical system and compo- nents. Refer to the following precautions when working on or around the EDI electri- cal harness or when adding other electrical accessories: DO NOT tap accessories into engine harness. -
Page 16: Power Trim Control
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS D7.3L D-Tronic Shown - All Similar Engine Harness Connector Extension Harness Connector (From Instruments) Electrical Bracket TACHOMETER SPECIAL INFORMATION IMPORTANT: If using a tachometer from another manufacturer, do not use the mag- netic tachometer pickup (or related wiring) mounted on the flywheel housing. If using the Quicksilver Tachometer provided with the engine package, the appropriate set- ting of the switch located on the back of the tachometer is given in the following chart. -
Page 17: Propeller Selection
Propeller Selection GENERAL INFORMATION IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open-throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s). -
Page 18: Hot Water Heater Installation Recommendation
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Hot Water Heater Installation Recommendation IMPORTANT: When connecting a cabin heater or hot water heater, certain require- ments must be met, including, but not limited to the following: Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5/8 in. -
Page 19: Seawater Connections
RETURN HOSE CONNECTION Location on Water Circulation Pump for Hot Water Return (Bayonet Fitting Replaces Plug) Seawater Connections D7.3L D-Tronic and D7.3L D-Tronic LD models must be equipped with a through hull or through transom water supply to ensure sufficient water flow to the engine. The transom assembly needs to be modified with the water passage block-off plate kit (P/N 818304A1) provided. -
Page 20: Throttle/Shift Remote Control And Cables
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS SEAWATER STRAINER Strainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling the engine. Amount listed is in gallons per minute and (liters per minute). Install seawater strainer in an area where it will be easily accessible for inspection and cleaning. -
Page 21: Steering Helm And Cable
Steering Helm and Cable 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 hand- book. The steering cable coupler nut must also have a means of locking it to the guide tube as specified in ABYC requirements. - Page 22 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS POWER STEERING EQUIPPED UNITS ONLY: If steering cable with improper dimen- sions is installed, severe damage to transom assembly and/or steering system may result. 1. Steering cable must be the correct length, particularly when installed in larger boats. 2.
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Page 23: Transom Cutout
Transom Cutout Before Starting Installation Read “General Information” and “Installation Requirements” Sections Completely. IMPORTANT: The following instructions will provide a sterndrive unit mounting loca- tion that is suitable for most boats. Best mounting location for a particular boat, how- ever, can be determined only by testing. Bravo Models use items 1 - 4. -
Page 24: Finding Crankshaft Vertical Centerline
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Finding Crankshaft Vertical Centerline SINGLE ENGINE Locate and mark vertical centerline on transom. Vertical Centerline DUAL ENGINE 1. Locate and mark boat vertical centerline (a) on transom. Vertical Centerline 2. Locate and mark crankshaft vertical centerlines (a) on transom. Draw Crankshaft Vertical Centerline through Desired Mounting Locations Minimum Distance between Crankshaft Vertical Centerlines Crankshaft Vertical Centerlines Must Be an Equal Distance from Boat Vertical... -
Page 25: Finding Crankshaft Horizontal Centerline ("X" Dimension)
Finding Crankshaft Horizontal Centerline (“X” Dimension) “X” Dimension can be measured by the “90 Tool Method” or by the “Tape Measure Method.” 90 TOOL METHOD 1. Construct 90 tool. Dimension from Chart Below Measurement: 4 ft. (1.2 m) To Lower Drive Unit - Subtract from dimension “a”. To Raise Drive Unit - Add to dimension “a”. - Page 26 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS TAPE MEASURE METHOD Transom angle must be known, then measure “X” Dimension with tape measure. 1. Determine “X” Dimension from the following chart. Tape Measure Method Chart Model Transom Angle 2. Measure and layout horizontal centerlines as shown. Single Engine “X”...
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Page 27: Cutting Transom
Cutting Transom Transom cutout can be made by either using the Template [shipped with transom assembly] or the Transom Drilling Fixture Kit (purchased separately). Follow instructions indicated on template or provided with drilling fixture. IMPORTANT: Read and observe the following information: Be certain that centerlines on either the template or transom drilling fixture align with lines previously marked on transom. -
Page 28: Checking Transom Thickness
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Checking Transom Thickness Ensure transom surface thickness and flatness conform to minimums specified in “Installa- tion Requirements” listed previously. NOTE: Transom must be between 2” (51 mm) and 2-1/4” (57 mm) a distance of 8” (203 mm) to either side of the vertical centerline. -
Page 29: Installing Transom Assembly
Installing Transom Assembly Gimbal Housing 1. Carefully remove transom assembly from shipping carton. 2. Remove and read all tags which are attached to transom assembly. IMPORTANT: Read and observe the following regarding your engine and the thru- propeller exhaust system: With any application, installation of an exhaust tube will increase exhaust noise. -
Page 30: Inner Transom Plate
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Inner Transom Plate 1. Insert wires, hoses and shift cable through appropriate openings in inner transom plate. 2. Position gimbal housing on transom and hold in place. NOTE: When tightening transom assembly fasteners in the following step, start in the center and, using a circular pattern, move outward. -
Page 31: Power Trim Pump
Power Trim Pump 1. Mount pump in desired location. IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking out of system. Be careful not to cross-thread or overtighten hose fittings. Black Hose (UP Circuit) Gray Hose (DOWN Circuit) Harness Connector Clamp Trim Limit Switch Wire (with Blue Sleeve) - to BLUE/WHITE Harness Wire... -
Page 32: Steering System
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Steering System NOTE: For Dual Installations, Power steering unit can be mounted on port or starboard transom assembly. Measure exact distance between power package centerlines. Select a tie bar from Quicksilver Accessory Guide. Refer to tie bar installation instructions before pro- ceeding. - Page 33 4. Torque pivot bolts to 25 lb-ft (34 Nm). Bend washer tabs against corresponding flats on bolt heads. MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid from the ports. Wear eye protection. 5. The cylinder ram may be stiff and difficult to move when you attempt to pull it out or push it in for installation.
- Page 34 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 7. Connect steering cable as follows: a. Remove shipping cap from both ends of steering cable guide tube. b. Coat steering cable end with a liberal amount of Special Lubricant 101. c. Install steering cable and secure with hardware as shown. Steering Cable Grease Fitting Cable Coupler Nut...
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Page 35: Speedometer Pickup
Speedometer Pickup IMPORTANT: Do not disturb plug at speedometer fitting if no speedometer is to be fitted, or if an alternate speedometer pickup will be used. 1. Remove plug from speedometer pickup tube fitting. Fitting Plug Speedometer Pickup Tube Fitting 2. -
Page 36: Exhaust Water Bypass
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 3. Route hose to monitor bottle mounted on engine and cut off excess hose. IMPORTANT: Avoid using excessive hose when routing to gear lube monitor. Hose should be routed directly, in as straight a line as possible, to avoid low spots (traps) in the system. -
Page 37: Drive Unit Seawater Routing
Drive Unit Seawater Routing Seawater for engine cooling is supplied through a separate seawater pickup, not through the drive unit. Therefore, it is necessary to block the drive unit seawater passage and to cut the water hose that is located between the bell housing and the gimbal housing. This allows water to continue to circulate through the drive unit for cooling. - Page 38 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS SEAWATER HOSE NOTE: The trim limit switch wires and speedometer hose are attached to the water hose. Prior to cutting the hose, move the wires and speedometer hose to avoid cutting them when cutting water hose.
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Page 39: Engine Installation
Engine Installation Engine Preparation 1. Remove and read all tags attached to engine. 2. Remove all hardware that secures engine to shipping container. 3. Loosen fasteners and remove exhaust pipe and exhaust hose from pallet. 4. Connect battery cables to engine. Be sure to observe the following: a. -
Page 40: Transom Preparation
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Transom Preparation IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches, and O-ring must be properly seated in groove, or water and exhaust may leak into boat. Gimbal Housing Mating Surface O-ring 1. -
Page 41: Installing Engine / Alignment
Installing Engine / Alignment 1. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended. 2. Lift engine into position (in boat), using an overhead hoist. When lowering engine into position DO NOT set engine on shift cable. Shift cable outer casing can be crushed causing difficult or improper shifting. - Page 42 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 3. Align rear engine mounts with inner transom plate mounts. Set engine onto front mounts and inner transom plate mounts, while simultaneously aligning exhaust elbow with ex- haust tube. (Do not relieve hoist IMPORTANT: Engine attaching hardware must be installed in sequence shown.
- Page 43 7. Attach chain and hooks from suitable engine sling to starboard front lifting eye and port mounted Engine Lifting Eye Tool. Attach a suitable hoist to this sling. NOTE: Installing sling between specified lifting eyes will help equalize load on hoist during alignment procedure.
- Page 44 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS DO NOT use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Alignment Tool may cause improper alignment and damage to gimbal bearing and/or engine coupler. To avoid damage to gimbal bearing, engine coupler, or alignment tool: DO NOT attempt to force alignment tool! DO NOT raise or lower engine with alignment tool inserted (or partially inserted) in gimbal bearing or engine coupler.
- Page 45 IMPORTANT: Finished boat stringer must position engine so that a minimum mount adjustment exists after front mount is adjusted down to stringer. This allows for fu- ture adjustments. 9. Adjust front mount assembly until it touches stringer. 10. Recheck alignment with alignment tool. Tool must enter coupler splines freely. If not, readjust front mounts.
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Page 46: Engine Connections
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Engine Connections Quicksilver Seawater Pickup and Seacock 1. Drill a 2 in. (50mm) hole thru hull in appropriate location (Refer to “Installation Require- ments.”). 2. Apply marine caulking (sealer) to mounting surface on seawater pickup (thru-hull fitting) where hull contact will occur when installed. -
Page 47: Seawater Strainer
Seawater Strainer When using a seawater strainer other than Quicksilver Seawater Filter (Part Number 35-801763739) refer to manufacturer’s instructions for installation, operation and mainte- nance. Refer to the following when installing and connecting Quicksilver seawater strainer. IMPORTANT: Read and observe the following: Mount the seawater strainer in a vibration free location. -
Page 48: Closed Cooling Recovery Bottle
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Closed Cooling Recovery Bottle 1. Connect plastic tubing (from kit) to bayonet fitting on heat exchanger. Secure with tubing clamp provided. 2. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: a. -
Page 49: Fuel Lines
Fuel Lines 1. Connect flexible fuel line to fuel supply fitting. Secure with hose clamp. 2. Connect flexible fuel line to fuel return fitting. Secure with hose clamp. Fuel Supply Fitting Fuel Return Fitting Power Steering Hydraulic Hoses Route hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hose. -
Page 50: Exhaust System
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Exhaust System 1. Tighten exhaust tube hose clamps securely. Typical Elbow Tube Hose Clamps (4) Pipe Electrical Connections CONTINUITY CIRCUIT 1. Connect continuity circuit wire (supplied with engine package) from engine to transom assembly. - Page 51 INSTRUMENTS AND EXTENSION HARNESSES NOTE: If using other than Quicksilver instrumentation and harnesses, refer to manufactur- ers’ instructions. 1. Follow the appropriate instructions “a”, “b” and/or “c”, depending upon boat configura- tion: a. Prepare dash openings and/or mount gauges according to instructions provided with individual gauges.
- Page 52 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 3. Refer to Quicksilver Instrumentation Wiring Diagram. Using screws provided, connect the listed color coded wires to numbered switch terminals as shown. Harness Wire (Color Code) 40A YELLOW (YEL) 12C PURPLE (PPL) 4. Make sure that all instrument and switch connections are secure. Seal terminals with Liquid Neoprene (92-25711).
- Page 53 NEUTRAL SAFETY SWITCH CONNECTION 1. Connect neutral safety switch wires at instrument panel and remote control. Refer to ap- propriate wiring diagram. Secure connections as shown and coat with Liquid Neoprene. Slide rubber sleeve over connections. YEL/RED YEL/RED Instrument Harness Wires Two Wire Connector To Remote Control Rubber Sleeves...
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Page 54: Shift Cable Installation And Adjustment
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Shift Cable Installation and Adjustment NOTE: Shift Cable Adjustment Tool (91-12427) allows the shift cables to be installed and adjusted, with or without the sterndrive attached. IMPORTANT: The direction of propeller rotation (RH or LH) for this drive unit is deter- mined by the following method. - Page 55 4. Install drive unit shift cable. Washers (2) Lock Nut - Tighten Until Contact, Then Back Off 1/2 Turn Cotter Pin - Insert from Top and Spread Both Ends 5. Place adjustment tool over drive unit shift cable, as shown. Hold tool in place, using a piece of tape over the barrel retainer.
- Page 56 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 7. Adjust remote control shift cable as follows: a. Temporarily install shift cable end guide into shift lever, and insert anchor pin. b. Adjust shift cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of control cable end guide.
- Page 57 10. Shift remote control lever into full forward position. Place end of adjustment tool in barrel retainer. RH ROTATION BRAVO ONE, TWO, THREE AND BLACKHAWK MODEL: Rear slot in tool should fit over shift lever stud. LH ROTATION BRAVO ONE AND TWO: Forward slot in tool should fit over shift lever stud. If slot does not fit over stud, loosen shift lever stud and slide stud either direction, until slot in tool fits over stud.
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Page 58: Troubleshooting Shift Problems
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Troubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into forward gear. 1. When installing the control box in the side panel of the boat, make sure that the cables have enough clearance to operate. - Page 59 4. Do not strap or clamp the control cables to any other cables or rigid structure within three feet of the control box. 5. Be sure the cable is not permanently kinked. 6. Make sure there is proper clearance for cable movement when the control box is installed in the side panel.
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Page 60: Throttle Cable Installation And Adjustment
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Throttle Cable Installation and Adjustment IMPORTANT: When installing throttle cables, be sure that cables are routed in such a way as to avoid sharp bends and/or avoid contact with moving parts. DO NOT fasten any items to throttle cables. 1. - Page 61 Single Cable Shown (Dual Similar) Accelerator Position Sensor (APS/IVS) APS/IVS Anchor Stud Cable Barrel End Bracket Cable Barrel Anchor Stud Throttle Cable End Guide Cable Barrel Anchor Stud Flat Washer and Locknut Spacer - With Dual Cables Cable Barrel Locations - With Dual Cables 4.
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Page 62: Sterndrive Unit Installation
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Sterndrive Unit Installation 1. Remove trim cylinders’ support and dust cover from bell housing studs. Retain locknuts and flat washers. 2. Remove cap and fill gear lube monitor. Gear Lube Monitor 3. Push in on dribble valve until gear lube appears. Dribble Valve 4. - Page 63 7. Coat studs with 2-4-C Marine Lubricant. Studs (6) 8. Lubricate U-joint shaft splines and U-joint shaft O-rings with Engine Coupler Spline Grease. Typical Splines O-rings D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 72471 22026 Page 63 of 90...
- Page 64 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 9. Check drive shaft bellows for cleanliness and absence of debris. Driveshaft Bellows 10. Lubricate O-ring seals with 2-4-C Marine Lubricant. O-Ring Seals 11. Pull out shift linkage as far as it moves. “Jaws” will open, as shown. Shift Linkage IMPORTANT: As sterndrive is inserted into drive unit, entry of the bell housing shift cable must be closely checked to make sure cable enters the “jaws”...
- Page 65 12. Place Remote Control in 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”. IMPORTANT: If Bell Housing Shift Cable (b) does not line up to properly enter “jaws”...
- Page 66 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 14. Secure drive unit to bell housing with 5 flat washers and 6 locknuts. Torque to 50 Ib. ft. (68 N m). Do Not Install Flat Washer Here Elastic Stop Nuts (6) and Flat Washers (5) IMPORTANT: On Bravo One, Two and Three Models, the “Trim-In Limit Pin Insert”...
- Page 67 IMPORTANT: The position of the Trim-In Limit Pin on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested. Refer to statement at the front of this manual entitled; “Bravo Three Notice: Trim-In Limit Pin”. IMPORTANT: To aid in installing rubber bushings, use a water and soap solution.
- Page 68 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 18. On All Drive Units - Perform steps 19 through 21. 19. Raise drive to gain access to area between gimbal housing and sterndrive, immediately atop the transom end of the anti-ventilation plate. 20.
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Page 69: Predelivery Preparation
Predelivery Preparation Before starting Predelivery read “General Information” and “Installation Requirements” completely. Battery Connection IMPORTANT: Engine electrical system is negative (–) ground. 1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal. 2. Connect engine negative (–) battery cable (usually BLACK) to negative (–) battery termi- nal. -
Page 70: Trim Position Sender Adjustment
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Fill Neck 3. Check all trim line connection points for leaks. If fluid is visible at fittings, tighten fitting(s). Torque fitting(s) to 100-150 lb-in. (11-16 Nm). Trim Position Sender Adjustment 1. Loosen both trim position sender attaching screws. Attaching Screws Trim Position Sender DO NOT start engine in the following step or damage to drive unit and engine could... - Page 71 4. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown. Trim Gauge Needle 5. Tighten retaining screws and turn ignition key to the “OFF” position. Retaining Screws Trim Position Sender D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 71220 Page 71 of 90 71671...
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Page 72: Power Steering Fluid
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Power Steering Fluid IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid, or Dexron III auto- matic transmission fluid (ATF), in power steering system. DO NOT RUN POWER STEERING DRY, or pump will be damaged. 1. -
Page 73: Propeller Installation
1. With drive in full down position, remove oil vent screw. Failure to fill drive unit to level of vent hole will result in a low drive oil level. Gear lube monitor only MAINTAINS drive oil level and will not correct an improperly filled drive unit. - Page 74 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 2. Install propeller with attaching hardware as shown. Tighten nut a minimum of 55 lb-ft (75 Nm), then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer.
- Page 75 BRAVO THREE IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller. Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when tightening propeller nut.
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Page 76: Test Running Engine
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Test Running Engine Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE EN- GINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VA- PORS FROM ENGINE COMPARTMENT (REF: 33 CFR). - Page 77 8. Refer to “Operation and Maintenance Manual” and start engine. Run at idle rpm until water temperature is normal. 9. Watch all gauges for normal readings. 10. Turn steering wheel starboard, then port, and check to ensure drive unit turns the correct way.
- Page 78 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 14. Restart engine and observe drive unit. If drive unit creeps, an external tension may exist on steering cable. Ensure that there is nothing attached to steering cable casing. Cable must be free to move when actuated. 15.
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Page 79: Boat-In-The-Water Tests
Boat-In-The-Water Tests IMPORTANT: Engine alignment MUST BE CHECKED with boat in the water, fuel tanks filled, and with a normal load onboard. IMPORTANT: DO NOT perform the following with boat in a test tank or tied to dock. ENGINE INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. - Page 80 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS IMPORTANT: To run engine at maximum rpm before the Engine 20-Hour Break-In Pe- riod is complete, follow this procedure only after the Engine Initial Break-in Proce- dure has been completed: 1. Complete Engine Initial Break-In Procedures if not already accomplished. 2.
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Page 81: Cold Weather Or Extended Storage Draining Instructions
IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe) antifreeze be used in seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine en- gines. - Page 82 D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS 1. Close seacock, if so equipped, or disconnect and plug seawater inlet hose, if boat is to remain in the water. 2. Remove and drain the following: a. The end covers from both the port and starboard sides of heat exchanger. Drain tank completely.
- Page 83 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. 4. Remove seawater pump outlet hose from top of seawater pump and drain. Seawater Pump Outlet Hose Avoid water entering boat. Do not unplug or disconnect seawater inlet hose unless a seacock is present and it is closed.
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Page 84: Power Trim System Wiring Diagram
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Power Trim System Wiring Diagram 20 Amp Fuse Ground Bolt (Floor Mount) “UP” Solenoid 110 Amp Fuse “DOWN” Solenoid Trailer Switch Neutral Switch to Instrument Wiring Harness Trim Limit Switch Page 84 of 90 BLK = BLACK BLU = BLUE BRN = BROWN... -
Page 85: Mercathode System Wiring Diagram
MerCathode System Wiring Diagram Controller 20 Amp Fuse Electrode D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN= GREEN ORN= ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT= WHITE YEL = YELLOW... -
Page 86: Quicksilver Instrumentation Wiring
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Quicksilver Instrumentation Wiring BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light... - Page 87 Voltmeter Gauge Tachometer Gauge Water Temperature Gauge Oil Pressure Gauge Trim Gauge Engine System Monitor Panel - Check Engine Light - Engine Coolant High Temperature / Low Gear Lube Monitor Light - Oil Pressure Warning Light - Charge Indicator Light - Preheat Indicator Light Panel Lights/Audio Warning Test Switch Key Switch...
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Page 88: Cooling System Flow Diagram
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Cooling System Flow Diagram Page 88 of 90 76205... - Page 89 SEAWATER COOLING CIRCUIT (RAW WATER) 1 - Seawater Inlet 2 - Seawater Strainer 3 - Seawater Pump 4 - Aftercooler 5 - Engine Oil Cooler 6 - Heat Exchanger (Seawater Circuit) 7 - Power Steering Fluid Cooler 8 - Exhaust Pipe Water Jacket 9 - Seawater Outlet (Exhaust) 10- Seawater Outlet (Thru-Transom) CLOSED COOLING CIRCUIT (FRESH WATER/COOLANT)
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Page 90: Predelivery Inspection
D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS Predelivery Inspection Check/ Applicable Adjust CHECK BEFORE RUNNING Drain plug in and petcocks closed Seawater inlet valve open Engine mounts tight Engine alignment Drive unit fasteners torqued Power trim cylinders fasteners tight Battery fully charged and secured All electrical connections tight Exhaust system hose clamps tight...
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