Page 1: Table Of Contents
..... . . Recommendation ....Propeller Installation (Bravo One and Two) 87 Seawater Connections - General Propeller Installation (Bravo Three) .
Page 2: General Information
It is assumed that these personnel are familiar with marine product application and the installation procedures of these products, or like or similar products manufactured and mar- keted by Mercury Marine. Furthermore, it is assumed that they are familiar with, if not trained in, the recommended installation procedures of these products.
Page 3: Bravo Three Notice: Trim-In Limit Pin
GASOLINE ENGINES BRAVO MODELS Bravo Three Notice: Trim-In Limit Pin Insert NOTE: Bravo One, Two and Three Models are equipped with a Trim-In Limit Pin Insert. It has been brought to our attention that some boats (predominantly deep-Vee heavy boats) will roll up on their side under certain, specific, operating conditions.
Page 4: Recommendations
• Bravo applications which require that the sterndrive unit be mounted more than 3 in. (75mm) above the standard “X” dimension (i.e., catamarans, certain stepped bottom boats, etc.). For those applications, we recommend our Performance Products models with a Super Speedmaster sterndrive unit which are designed specifically for surfaced propeller operation.
Page 5: Multiple Steering Tie Bar Arrangements
Opalocka, FL 33054 Phone: (305) 681-1815 On dual or triple engine high speed applications, Mercury MerCruiser recommends the use of a Quicksilver Priority Valve Kit (Part Number 79691A4). This kit allows two power steering pumps to be used and helps to ensure that power assist will be maintained if one engine or power steering pump should stop functioning (engine runs out of fuel, etc.).
Page 6: Quicksilver Products
90362A3) should be installed so as to limit this potential tilt differential to about 20°. IMPORTANT: Mercury Marine 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 sterndrive connected to the internal power steering system.
Page 7: Installation Products
Hose Barb Fitting 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) Front Propeller Nuts (Bravo Three) Rear Rear Engine Mounts Steering Cable Coupler Nut...
Page 8: Serial Number Decal Placement
Operation, Maintenance and Warranty Manual identification page. Corrosion Protection Mercury MerCruiser 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).
Page 9: Antifouling Paint
• Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40mm) UNPAINTED area on transom of the boat around these items.
Page 10: Installation Requirements
INDEX GASOLINE ENGINES BRAVO MODELS Installation Requirements Boat Construction TRANSOM THICKNESS AND SURFACE IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts. Transom thickness and surface must conform to the following: Transom Specifications Thickness Between 2 - 2-1/4 in.
Page 11 INDEX GASOLINE ENGINES BRAVO MODELS ENGINE COMPARTMENT WARNING 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 12 INDEX GASOLINE ENGINES BRAVO MODELS Combustion Air Requirements Engine compartments with natural draft ventilation must have vent openings of sufficient size and location to accomplish the tasks previously outlined. IMPORTANT: The size of ventilation openings must be increased if any auxiliary equipment is located in the engine compartment.
Page 13 +20° to +176° F (–7° to +80° C) without failure.” Carburetors, throttle body injection (TBI) units and components for multi-port EFI systems used by Mercury MerCruiser meet this specification. Under the hottest outside air temperature condition at which the boat will be operated, the air temperature inside the engine compartment, measured at the flame arrestor, shall not exceed176°...
Page 14: Exhaust System
INDEX GASOLINE ENGINES BRAVO MODELS Exhaust System MEASURING PROCEDURE 1. Fill all fuel, water, gray water and heater tanks to maximum capacity. NOTE: Weight can be added in these locations to simulate full loaded condition. 2. Add maximum allowable cargo weight to boat in areas where it will be stowed, including refrigerator and lockers.
Page 15 INDEX GASOLINE ENGINES BRAVO MODELS 6. On all applications: a. Move load weight and cargo weight to stern of boat to simulate greatest “stern-down” attitude the boat will encounter such as when loading. IMPORTANT: Be sure to consider swim platform loading and PWCs.
Page 16 INDEX GASOLINE ENGINES BRAVO MODELS 8. If measurements are less than shown in Step 7., exhaust elbow risers must be installed to achieve proper dimension. 70621 Typical Riser Installation Exhaust Elbow Restrictor Gasket Riser Open Gasket (4 Slots) Exhaust Manifold Additional information: •...
Page 17 • The exhaust system on Mercury MerCruiser engines must have a minimum of 4 in. (102 mm) of vertical drop between the exhaust elbow outlet and the exhaust outlet of the boat.
Page 18 Exhaust system tuning can be affected by various factors that are beyond the control of Mercury MerCruiser. Following are several factors that can affect exhaust system tuning: • Type and configuration of exhaust outlet.
Page 19 Exhaust Elbow 454 AND 502 MAG BRAVO MODEL EXHAUST RECOMMENDATION IMPORTANT: To get maximum performance from Magnum Bravo Models, through the transom or hull exhaust is required. NOTE: If noise regulations do not allow the use of through the transom or hull exhaust, an exhaust pipe kit (Quicksilver Part Number 44266A6) must be installed for through the prop exhaust.
Page 20: Fuel Delivery System
INDEX GASOLINE ENGINES BRAVO MODELS Fuel Delivery System WARNING Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad- hered to when constructing the engine compartment. GENERAL The main concern of a boat’s fuel system is safety; this must be achieved through a techni- cally sound installation and constant inspection.
Page 21 INDEX GASOLINE ENGINES BRAVO MODELS 6. Larger diameter (than previously specified) lines and fittings must be used on installa- tions requiring long lines or numerous fittings. 7. Fuel line(s) should be installed free of stress and firmly secured to prevent vibration and/ or chafing.
Page 22: Battery
INDEX GASOLINE 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 23 INDEX GASOLINE ENGINES BRAVO MODELS MULTIPLE EFI ENGINE BATTERY PRECAUTIONS Situation Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charging current.
Page 24: Efi Electrical System Precautions
We recommend the use of Quicksilver Instrumentation and Wiring Harnesses which have been specifically designed for compatibility with our engines, and to the same high quality and performance standards. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for selection.
Page 25: Power Trim Control
Power Trim Control Any of the Quicksilver panel or in-handle type trim controls (that are specified for use with Mercury MerCruiser sterndrives) can be used with this Power Trim system. Install trim con- trol in accordance with instructions that accompany it.
Page 26: Propeller Selection
INDEX GASOLINE ENGINES BRAVO MODELS 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 27: Hot Water Heater Installation Recommendation
INDEX GASOLINE ENGINES BRAVO MODELS RPM REV-LIMITER IMPORTANT: When selecting a propeller consider this additional information, if ap- plicable: The engines listed in the following chart are equipped with a rpm rev-limiter that is set to an upper (or limited) rpm amount. This limit is slightly above the normal operat- ing range of the engine and is designed to help prevent damage from excessive en- gine rpm.
Page 28 INDEX GASOLINE ENGINES BRAVO MODELS CAUTION Avoid engine overheating which could result in engine damage. On models equipped with Closed Cooling, an air pocket may form in the closed cooling system if some coolant is lost from the system and the cabin heater or hot water is mounted higher than the fill cap on the heat exchanger.
Page 29: Seawater Connections - General Information
INDEX GASOLINE ENGINES BRAVO MODELS RETURN HOSE CONNECTION 75480 Seawater or Closed Cooling System Location For Hot Water Return Seawater Connections - General Information SEAWATER PICKUP HOSE Seawater inlet hose connections must be made with wire reinforced hose of adequate wall thickness to prevent it from collapsing from pump suction.
Page 30: Throttle/Shift Remote Control And Cables
INDEX GASOLINE ENGINES BRAVO MODELS Throttle/Shift Remote Control and Cables To ensure proper shift and throttle operation, we recommend the use of a Quicksilver remote control and cables. Refer to “Quicksilver Accessories Guide” for selection. However, if a control other than Quicksilver is to be used, control must provide a shift cable travel (at the shift plate end) of 2-7/8 in.
Page 31 INDEX GASOLINE ENGINES BRAVO MODELS STEERING CABLE SPECIFICATIONS IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions. 21435 Coupler Nut - 7/8 - 14 UNF - 28 Thread 11-3/4 in.
Page 32: Transom Cutout
In applications where cooling water to the engine is supplied by a through the hull or through the transom fitting, the sterndrive height will not cause cooling water aeration. IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed height will not be covered by Mercury MerCruiser warranty.
Page 33: Finding Crankshaft Vertical Centerline
INDEX GASOLINE ENGINES BRAVO MODELS Finding Crankshaft Vertical Centerline SINGLE ENGINE Locate and mark vertical centerline on transom. 71620 Vertical Centerline DUAL ENGINE 1. Locate and mark boat vertical centerline “a” on transom. 71620 Vertical Centerline 2. Locate and mark crankshaft vertical centerlines “a” on transom.
Page 34: Finding Crankshaft Horizontal Centerline ("X" Dimension)
INDEX GASOLINE ENGINES BRAVO MODELS Finding Crankshaft Horizontal Centerline (“X” Dimension) ° “X” Dimension can be measured by the “90 Tool Method” or by the “Tape Measure Method.” ° TOOL METHOD ° 1. Construct 90 tool. 90° 71621 Dimension From Chart Below Measurement: 4 Ft.
Page 35 Transom angle must be known, then measure “X” Dimension with tape measure. 1. Determine “X” Dimension from the following chart. Tape Measure Method Charts Model Bravo One / Two / Three Transom Angle This dimension should only be raised or lowered after proper testing.
Page 36: Cutting Transom
INDEX GASOLINE ENGINES BRAVO MODELS 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: Be certain that centerlines on either the template or transom drilling fixture align with lines previously marked on transom.
Page 37: Checking Transom Thickness
3. If required, remove and discard clamps and bellows from gimbal housing. IMPORTANT: When installing through the propeller exhaust: • With Bravo One and Bravo Two Sterndrives an exhaust tube MAY BE INSTALLED for a slight increase in performance. •...
Page 38 • With any application, installation of an exhaust tube will increase exhaust noise. NOTE: Exhaust tube parts are provided with a Bravo Three Sterndrive. They are located in the sterndrive unit box. 4. If required, install exhaust tube on gimbal housing as follows: a.
Page 39: Installing Inner Transom Plate
INDEX GASOLINE ENGINES BRAVO MODELS Installing 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. IMPORTANT: Tightening the transom assembly fasteners using an X-pattern torque sequence as defined in the illustration below.
Page 40: Installing Power Trim Pump
INDEX GASOLINE ENGINES BRAVO MODELS Installing Power Trim Pump NOTE: See 90-863152 for mounting hole template. 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.
Page 41: Installing Steering System
INDEX GASOLINE ENGINES BRAVO MODELS Installing Steering System HYDRAULIC (HELM) STEERING If your power package is equipped with Compact Hydraulic Steering (Helm Steering), refer to the “Compact Hydraulic Steering Installation Instructions” in the box with the Hydraulic Steering components. Complete the installation of the Hydraulic Steering system before proceeding to “Connecting Speedometer Pickup.”...
Page 42 INDEX GASOLINE ENGINES BRAVO MODELS 4. Torque pivot bolts to 25 lb-ft (34 Nm). Bend washer tabs against corresponding flats on bolt heads. 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 43 INDEX GASOLINE 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.
Page 44: Connecting Speedometer Pickup
INDEX GASOLINE ENGINES BRAVO MODELS Connecting Speedometer Pickup IMPORTANT: Do not remove plug from speedometer pickup tube fitting unless connection is to be utilized, as water leakage into boat will occur, especially while underway. The connection for the speedometer pickup can be accessed through a hole and fitting in the inner transom plate.
Page 45: Connecting Drive Unit Gear Lube Monitor Hose
INDEX GASOLINE ENGINES BRAVO MODELS Connecting Sterndrive Unit Gear Lube Monitor Hose To Gimbal Housing ° 1. Connect the gear lube monitor hose to a quick release 90 fitting. 2. Connect fitting to the gimbal housing. IMPORTANT: Hose must not come in contact with steering system components or the engine coupler, U-joint shaft or drive shaft.
Page 46: Engine Installation
INDEX GASOLINE ENGINES BRAVO MODELS Engine Installation Driveshaft Extension Models If your power package is equipped with a driveshaft extension, refer to the Driveshaft Exten- sion Installation Instructions (90-862858) included with your engine package. Engine Preparation 1. Remove and read all tags attached to engine.
Page 47: Transom Preparation
INDEX GASOLINE ENGINES BRAVO MODELS 5. Remove shipping plug from coupler and lubricate splines with Quicksilver Engine Cou- pler Spline Grease, P/N 816391A4. 6. Loosen hose clamps and remove exhaust pipe and bellows from engine. 50724 Exhaust Pipe Bellows Clamps...
Page 48 INDEX GASOLINE ENGINES BRAVO MODELS 1. Depending upon boat configuration, follow instructions a. or b.: a. Through the Prop Exhaust Models: Install exhaust pipe assembly as shown, using four bolts and lockwashers. Torque bolts to 23 lb-ft (31 Nm). b. Through the Transom Exhaust Models: Install block off plate as shown, using four bolts and lockwashers.
Page 49: Installing Engine/Alignment
INDEX GASOLINE ENGINES BRAVO MODELS Installing Engine/Alignment NOTE: An engine mount drilling fixture (91-806794A1) can be used to align and adjust en- gine mounts. Refer to instructions with fixture for proper use. 1. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended.
Page 50 INDEX GASOLINE ENGINES BRAVO MODELS 4. Install both rear engine mounting bolts and hardware as shown. Torque to 38 lb-ft (51 Nm). Do not relieve hoist tension. 5. Align engine as follows: a. Fold perforated area in bell housing dust cover.
Page 51 INDEX GASOLINE ENGINES BRAVO MODELS c. If the tool does not fit, remove it and carefully raise or lower the front end of the engine as necessary, and attempt to insert the alignment tool. d. Repeat step c. until the alignment tool installs easily (SLIDES FREELY WITH TWO FINGERS) all the way into and out of engine coupler splines.
Page 52 INDEX GASOLINE ENGINES BRAVO MODELS 8. Recheck alignment with alignment tool. Tool must enter coupling splines freely. If not, readjust front mounts. 9. When alignment is correct, tighten locknut securely. Recheck alignment. 10. Bend tab down on adjusting nut. 71649...
Page 53: Coolant Recovery System (If Equipped)
INDEX GASOLINE ENGINES BRAVO MODELS Coolant Recovery System (If Equipped) 1. Connect plastic tubing to bayonet fitting on heat exchanger. Secure with tubing clamp provided. 70548 Plastic Tubing Tubing Clamp 2. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: a.
Page 54: Engine Connections
INDEX GASOLINE ENGINES BRAVO MODELS Engine Connections IMPORTANT: When routing all wire harnesses and hoses, ensure they are routed and secured to avoid coming in contact with hot spots on engine or moving parts. 1. Connect water hose to water tube and secure with hose clamp.
Page 55 INDEX GASOLINE ENGINES BRAVO MODELS IMPORTANT: Avoid using excessive hose when routing it to gear lube monitor. Hose should be routed directly to oil reservoir in as straight a line as possible to avoid low spots (traps) in the system.
Page 56 INDEX GASOLINE ENGINES BRAVO MODELS CAUTION Route hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hose. IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leakage.
Page 57 INDEX GASOLINE ENGINES BRAVO MODELS 7. Connect fuel line to appropriate location as shown. Refer to the following caution for proper tightening. CAUTION Remove plastic plug from fuel inlet hole. Apply #592 Loctite Pipe Sealant with Teflon to threads of fuel inlet line connector. DO NOT USE TEFLON TAPE. To prevent cracking the casting and/or fuel leaks, turn inlet connector in by hand until finger tight, then tighten connector to 1-3/4 to 2-1/4 turns with wrench.
Page 58 INDEX GASOLINE ENGINES BRAVO MODELS 8. Depending upon boat configuration, follow instructions a., b. or c.: CAUTION Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots which could eventually result in burned-through exhaust hoses.
Page 59 INDEX GASOLINE ENGINES BRAVO MODELS b. V8 Models - Through The Prop Exhaust: Tighten all exhaust tube hose clamps securely. 22059 Hose Clamps Exhaust Tube c. V6 Models - Through The Prop Exhaust (One-Piece Exhaust Manifolds): Tighten all exhaust tube hose clamps securely.
Page 60 INDEX GASOLINE ENGINES BRAVO MODELS 10. Connect power trim pump wires to battery. 76631 Positive Battery Lead Negative Battery Lead 11. Connect trim position sender wires (from transom assembly) to engine harness. 12. Connect wires to MerCathode controller assembly as shown. Apply a thin coat of Liquid Neoprene to all connections.
Page 61 INDEX GASOLINE ENGINES BRAVO MODELS 13. Installing Audio Warning Horn: a. Select a location for audio warning horn which meets all of the following: • Horn can be easily heard yet is out of sight. • A location which is accessible for installation or maintenance.
Page 62: Quick Drain Oil Installation
INDEX GASOLINE ENGINES BRAVO MODELS Quick Drain Oil Installation (If Equipped) 1. Install flange over cable. 2. Fasten flange to hull with appropriate fasteners (not provided). 3. Install bilge drain plug in hull. 76882 Bilge Drain Plug Tether Quick Oil Drain Hose Plug...
Page 63: Shift/Throttle Cables Installation And Adjustments
Arrow Indicates Direction Of Motion • Bravo Three - Front propeller on sterndrive unit is always LH Rotation and rear propeller is always RH Rotation. Shift cable end guide must move in direction A, when control lever is placed in Forward gear position.
Page 64 INDEX GASOLINE ENGINES BRAVO MODELS 3. Install sterndrive unit shift cable. 71658 Washers (2) Lock Nut - Tighten Until Contact. Then Back Off 1/2 Turn Cotter Pin - Insert From Top And Spread Both Ends 4. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place, using a piece of tape over the barrel retainer.
Page 65 INDEX GASOLINE ENGINES BRAVO MODELS a. Temporarily install control cable end guide into shift lever and insert anchor pin. b. Adjust control 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 66 9. Shift remote control lever into full forward position. Place end of adjustment tool in barrel retainer. RH rotation Bravo One, Two and Three Models: 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.
Page 67: Troubleshooting Shift Problems
INDEX GASOLINE 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 68 INDEX GASOLINE ENGINES BRAVO MODELS 4. Do not strap or clamp the control cables to any other cables or rigid structure within 3 ft. (915 mm)of the control box. 5. Be sure the cable is not allowed to be kinked.
Page 69: Throttle Cable Installation And Adjustment
INDEX GASOLINE ENGINES BRAVO MODELS Throttle Cable Installation and Adjustment CARBURETED MODELS 1. Place remote control handle(s) in neutral/idle position. IMPORTANT: Be sure that cable is routed to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.
Page 70 INDEX GASOLINE ENGINES BRAVO MODELS 70392 72014 71159 4 BBL V6 Models Cable End Guide Flat Washer And Locknut – Tighten Until Nut Contacts, Then Loosen 1/2 Turn Cable Barrel Throttle Lever [Contacts In Idle Position] Idle Speed Adjustment Screw...
Page 71 INDEX GASOLINE ENGINES BRAVO MODELS 4.3L EFI, 5.0L EFI, 5.7L EFI, MX 6.2L MPI AND 350 MAG MPI MODELS 1. Place remote control handle(s) in neutral idle position. IMPORTANT: Be sure that cable is routed to avoid sharp bends and/or contact with moving parts.
Page 72 INDEX GASOLINE ENGINES BRAVO MODELS 454 MAG MPI AND 502 MAG MPI MODELS 1. Place remote control handle(s) in neutral idle position. IMPORTANT: Be sure that cable is routed to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.
Page 73 INDEX GASOLINE ENGINES BRAVO MODELS 3. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever). Adjust barrel on throttle cable to align with hole in anchor plate.
Page 74 INDEX GASOLINE ENGINES BRAVO MODELS 7. Reinstall flame arrestor and tighten screws securely. Connect crankcase vent hose to flame arrestor as shown. 75115 Crankcase Vent Hose 7.4L MPI MODELS 1. Place remote control handle(s) in neutral idle position. 2. Remove starboard side engine cover.
Page 75 INDEX GASOLINE ENGINES BRAVO MODELS 4. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever). Adjust barrel on throttle cable to align with hole in anchor plate.
Page 76: Sterndrive Unit Installation
INDEX GASOLINE ENGINES BRAVO MODELS 7. Return remote control throttle lever to idle position and ensure that throttle plate is com- pletely closed. 75452 Throttle Plates 8. Reinstall flame arrestor and tighten clamp securely. Sterndrive Unit Installation 1. Remove trim cylinder support and dust cover from bell housing studs. Retain elastic stop nuts and flat washers.
Page 77 INDEX GASOLINE ENGINES BRAVO MODELS 3. Push in on dribble valve until gear lube appears. 72471 Dribble Valve 4. Once gear lube appears, release dribble valve. 5. Fill monitor to FILL mark. 6. Replace monitor cap. 7. Coat studs with 2-4-C Marine Lubricant with Teflon.
Page 78 INDEX GASOLINE ENGINES BRAVO MODELS 8. Lubricate U-joint shaft splines and U-joint shaft O-rings with Quicksilver Engine Coupler Spline Grease. 72458 Typical Splines O-rings 9. Check drive shaft bellows for cleanliness and absence of debris. 72472 Drive shaft Bellows Page 78 of 116...
Page 79 INDEX GASOLINE ENGINES BRAVO MODELS 10. Lubricate O-ring seals with 2-4-C Marine Lubricant with Teflon. 72183 O-Ring Seals 11. Pull out shift linkage as far as it moves. Jaws will open, as shown. 72460 Shift Linkage IMPORTANT: As sterndrive is inserted into sterndrive unit, entry of the bell housing shift cable must be closely checked to make sure cable enters the jaws of shift link- age assembly in the sterndrive.
Page 80 INDEX GASOLINE ENGINES BRAVO MODELS 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”...
Page 81 IMPORTANT: On Bravo One, Two and Three Models, the Trim-In Limit Pin must be properly positioned before installing the trim cylinder anchor pin in the following steps. 15. Ensure that the Trim-In Limit Pin is positioned as shown for the appropriate Bravo model. 75157 Bravo One and Two (Positioned Forward)
Page 82 INDEX GASOLINE ENGINES BRAVO MODELS 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; “Trim-In Limit Pin.”...
Page 83 INDEX GASOLINE ENGINES BRAVO MODELS 20. Insert speedometer tube fitting into opening on topside of anti-ventilation plate, in posi- tion shown. 22025 Tube Fitting Opening 21. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
Page 84: Predelivery Preparation
INDEX GASOLINE ENGINES BRAVO MODELS Predelivery Preparation NOTICE Before starting Predelivery read “General Information” and “Installation Require- ments” completely. Once the power package installation is complete, the following final steps should be taken to prepare power package for delivery to the customer. It is the boat manufacturer’s respon- sibility to perform these procedures, or to make arrangement with the dealer to have these procedures completed.
Page 85: Trim Position Sender Adjustment
INDEX GASOLINE ENGINES BRAVO MODELS 2. Raise and lower sterndrive unit (to the full up position) 6 to 10 times to purge air from system. Check oil level visually, (with sterndrive unit in the full down position). Oil level should be maintained at bottom lip of fill neck.
Page 86 INDEX GASOLINE ENGINES BRAVO MODELS CAUTION DO NOT start engine in the following step or damage to sterndrive unit and engine could result from lack of cooling water. 2. Turn ignition key to RUN position. 3. Trim sterndrive unit to the full DOWN/IN position.
Page 87: Power Steering Fluid
NOTE: When first starting engine, be prepared to add fluid to pump. 71672 76859 Fill Cap Dipstick Propeller Installation (Bravo One and Two) IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. WARNING Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller.
Page 88 INDEX GASOLINE ENGINES BRAVO MODELS 2. Install propeller with attaching hardware as shown. Tighten nut a minimum of 55lb-ft (75 Nm), then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer. Bend the 3 tabs down into grooves.
Page 89: Propeller Installation (Bravo Three)
INDEX GASOLINE ENGINES BRAVO MODELS Propeller Installation (Bravo Three) IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. WARNING Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller.
Page 90: Test Running Engine
INDEX GASOLINE ENGINES BRAVO MODELS Test Running Engine WARNING If engine is to be tested with boat out of water, the propeller must be removed to avoid injury. IMPORTANT: If using a test tank, ensure water level is above water intake holes.
Page 91 1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight. NOTE: Refer to Operation, Maintenance and Warranty Manual for operating specifications. Refer to the appropriate Mercury MerCruiser Service Manual for fluid capacity information. 2. Check crankcase oil level.
Page 92: Boat-Ln-The-Water Tests
1. Ensure that throttle cable has been adjusted properly. 2. If idle speed is still not correct, it may be necessary to perform EFI System Diagnostic Tests on the idle circuit. Refer to the appropriate Mercury MerCruiser Service Manual for procedures.
Page 93 INDEX GASOLINE ENGINES BRAVO MODELS ENGINE IDLE SPEED (CARBURETED MODELS) CAUTION Avoid engine damage. Ensure that cooling water is supplied to the engine if it will be run with boat out of the water. See instructions in the Operation, Maintenance and Warranty Manual entitled “Flushing Cooling System,”...
Page 94: Cold Weather Or Extended Storage Draining Instructions
INDEX GASOLINE ENGINES BRAVO MODELS Cold Weather or Extended Storage Draining Instructions CAUTION Sterndrive unit should be stored in full DOWN position. Universal Joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to service.
Page 95 INDEX GASOLINE ENGINES BRAVO MODELS 1. Ensure engine is as level as possible to ensure complete draining of cooling system. 2. Remove drain plugs from the following locations, if equipped: a. Port and starboard side of cylinder block. b. Bottom of exhaust manifold(s).
Page 96 8. After cooling system has been drained completely, install drain plugs, reconnect hoses and tighten all hose clamps securely. IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage.
Page 97 INDEX GASOLINE ENGINES BRAVO MODELS CLOSED COOLED (COOLANT) MODELS The following information outlines the procedures for draining the seawater section of the closed cooling systems. IMPORTANT: Drain seawater section of closed cooling system only. CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses.
Page 98 INDEX GASOLINE ENGINES BRAVO MODELS IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. 1. Ensure engine is as level as possible to ensure complete draining of cooling system. 2. Remove drain plug(s) from bottom of exhaust manifold(s).
Page 99 INDEX GASOLINE ENGINES BRAVO MODELS 7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. DO NOT allow engine to start. 8. Make sure gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed.
Page 100: Quicksilver Instrumentation Wiring Diagrams
INDEX GASOLINE ENGINES BRAVO MODELS Quicksilver Instrumentation Wiring Diagrams MCM Gasoline Engine SINGLE STATION INSTALLATIONS - TYPICAL BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE...
Page 101 INDEX GASOLINE ENGINES BRAVO MODELS Refer to gauge manufacturer’s instructions for specific connections. NOTE: Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Con- nection and Slide Rubber Sleeve over Connection. NOTE: Power for a Fused Accessory Panel May Be Taken from This Connection. Load Must Not Exceed 40 Amps.
Page 102: Power Trim System Wiring Diagram
INDEX GASOLINE ENGINES BRAVO MODELS Power Trim System Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN...
Page 103: Mercathode System Wiring Diagram
INDEX GASOLINE ENGINES BRAVO MODELS MerCathode System Wiring Diagram 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 104: Mcm Gasoline Engine Wiring Diagrams
INDEX GASOLINE ENGINES BRAVO MODELS MCM Gasoline Engine Wiring Diagrams MCM 4.3L/4.3LH Bravo Engines BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED...
Page 105 INDEX GASOLINE ENGINES BRAVO MODELS MCM 5.0L and 5.7L Bravo Engines BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN...
Page 106 INDEX GASOLINE ENGINES BRAVO MODELS MCM 4.3L EFI, 5.0L EFI, 5.7L EFI, 350 Mag MPI, 6.2L MPI, 454 Mag MPI and 502 Mag MPI - Starting and Charging System Harnesses 90 Amp Fuse 76061 A - Audio Warning Components C - Charging and Starting Components...
Page 107 INDEX GASOLINE ENGINES BRAVO MODELS MCM 7.4L MPI Starting and Charging System Harness BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED...
Page 108 INDEX GASOLINE ENGINES BRAVO MODELS MCM 4.3L EFI, 5.0L EFI and 5.7L EFI Bravo Engines - Fuel and Ignition System Harness NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system har- ness. NOTE: Component position and orientation shown is arranged for visual clarity and ease of circuit identification.
Page 109 Positive (+) Power Wire To Engine Circuit Manifold Absolute Pressure (MAP) Sensor Breaker Idle Air Control (IAC) 16 - Shift Plate (Not used on Bravo models) Throttle Position (TP) Sensor 17 - Oil Pressure (Audio Warning System) Engine Coolant Temperature (ECT) Sensor...
Page 110 INDEX GASOLINE ENGINES BRAVO MODELS MCM 454 & 502 Mag MPI Models - Fuel and Ignition System Harness NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system har- ness. NOTE: Component position and orientation shown is arranged for visual clarity and ease of circuit identification.
Page 111 INDEX GASOLINE ENGINES BRAVO MODELS MCM 7.4L MPI Bravo - Fuel and Ignition System Harness NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system har- ness. NOTE: Component position and orientation shown is arranged for visual clarity and ease of circuit identification.
Page 112: Water Flow Diagrams
INDEX GASOLINE ENGINES BRAVO MODELS Water Flow Diagrams 262 CID BRAVO ENGINES NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water flow paths remain similar on all engines. 75148...
Page 113 GASOLINE ENGINES BRAVO MODELS V8 Engines - Seawater (Raw Water) Cooling System 305 CID, 350 CID AND 6.2L BRAVO ENGINES NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water flow paths remain similar on all engines.
Page 114 INDEX GASOLINE ENGINES BRAVO MODELS 454 AND 502 CID BRAVO ENGINES NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water flow paths remain similar on all engines. 75151 Seawater Intake (From Sterndrive)
Page 115 INDEX GASOLINE ENGINES BRAVO MODELS V6 and V8 Engines - Closed (Coolant) Cooling System NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water and coolant flow paths remain similar on all engines.
Page 116: Predelivery Inspection
INDEX GASOLINE ENGINES BRAVO MODELS Predelivery Inspection Check/ Check/ Applicable Adjust Applicable Adjust CHECK BEFORE RUNNING ON THE WATER TEST Drain plug in and petcocks Engine alignment (Inboards only) closed Seawater inlet valve open Starter neutral safety switch operation Engine mounts tight...

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