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Mercury MerCruiser Alpha 5.7L, Instruction Manual, Page: 24 / 48

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Mercury MerCruiser Alpha 5.7L Instruction Manual Download Page 24

GASOLINE ENGINES SKI MODELS

Page 24 of 48

8. Bend one of the tabs on tab washer down onto flat of adjusting nut.

70646

d

a

a

b

c

a -

Clamping Screws and Nuts

b -

Locknut

c -

Tab On Tab Washer

d -

1-3/4 in. (45 mm)

9. Connect propeller shaft coupler to transmission output flange. Secure coupling together

with bolts, lockwashers and nuts. Torque to 50 lb-ft (68 Nm).

Seawater Pickup Pump Connection

1. Remove shipping cap. Connect seawater inlet hose to inlet fitting (bottom hose) on sea-

water pump.

75533

a

a -

Seawater Inlet Hose

Summary of Contents for MerCruiser Alpha 5.7L

Page 1: ...mission 5 Installation Requirements 6 Boat Construction 6 Exhaust System 9 Fuel Delivery System 10 Battery 13 Battery Cables 13 EFI Electrical System Precautions 14 Instrumentation 14 Propeller Select...

Page 2: ...GASOLINE ENGINES SKI MODELS Page 2 of 48 THIS PAGE IS INTENTIONALLY BLANK...

Page 3: ...ducts It is the responsibility of the OEM to select the appropriate engine transom drive package including the correct gear ratio and propeller for a given boat Making an appropriate selec tion requir...

Page 4: ...lb ft N m Engine Mount Bracket Screw 48 65 Trunnion Clamping Screw and Nut 50 68 Propeller Shaft Coupling Screw and Nut 50 68 Exhaust Manifold Screw 20 27 Fuel Line Inlet Fitting See Note Note Refer...

Page 5: ...tio in Forward Gear c Output Flange Rotation Decal in Forward Gear Propeller Rotation Propeller rotation is not necessarily the same as engine rotation Refer to the appropriate following information a...

Page 6: ...pe of application Installation Requirements Boat Construction ENGINE BED Distance between starboard and port engine mount is 22 1 2 in 572 mm Engine bed must position engine so that a minimum of 1 4 i...

Page 7: ...to restart after it has been shut off for a short period of time If it does restart the engine will quit when given the throttle to get the boat up on plane or to pull up a water skier For engines ut...

Page 8: ...ure test meter used shall be of the type that can be read without opening the engine cover 3 During the test in Step 4 engine compartments are to remain closed No outside air is to be forced into the...

Page 9: ...that will correctly position exhaust elbow Model c a Minus b All Models c Must Be 13 in 330 mm or More 22457 b c d a Typical Installation Shown a From Waterline To Top Of Transom b From Highest Point...

Page 10: ...eeded in the tank to help correct this condition Only a few points related to function and safety are listed here Refer to boating standards NMMA ABYC etc and Coast Guard regulations for complete guid...

Page 11: ...st Guard approved USCG Type A1 Diameter of fittings and lines must not be smaller than 5 16 in 8 mm I D on 350 cid 5 7L and Black Scorpion engines Diameter of fittings and lines must not be smaller th...

Page 12: ...s fittings or plugs installed into fuel pump or fuel filter base Use 592 Loctite Pipe Sealant with Teflon on threads of brass fittings or plugs DO NOT USE TEFLON TAPE Brass fittings or plugs should fi...

Page 13: ...al connectors Do not use a battery with wing nut connectors 3 Reserve battery capacity rating of at least Engine cyl type cid L Minimum Required Cranking Battery Size V8 Carb 350 5 7 375 cca 475 mca 9...

Page 14: ...ry panel is to be installed 40 amp current draw maximum be sure to connect it as shown in wiring diagram Do not connect accessory panel at any other location as wires in wiring harness may not be of s...

Page 15: ...ange Gasoline 1 Inch 150 If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating a...

Page 16: ...Recommended Operating RPM Range Rev Limit RPM Setting 5 7L 4400 4800 4900 350 Mag MPI 4600 5000 5100 MX 6 2L 4800 5200 5350 Black Scorpion 4800 5200 5300 Throttle Shift Remote Control and Cables Shif...

Page 17: ...t the proper hose from the following chart Seawater Pickup Hose Inner Diameter Gasoline Engines 1 1 4 in 32 mm SEACOCK SIZE Seacock used must have an internal cross sectional area equal to or greater...

Page 18: ...for complete installation information and procedures IMPORTANT Do not reposition engine temperature switch it must remain where in stalled by factory CAUTION On closed cooling models heater must be mo...

Page 19: ...Engine electrical system is negative ground IMPORTANT Before connecting battery cables make sure that grounding stud and starter solenoid terminal are free of paint or any other material that could c...

Page 20: ...Lift engine from pallet with an overhead hoist 2 Remove L shaped shipping bracket from both rear transmission mounts Retorque mount bracket attaching screw to 48 lb ft 65 N m IMPORTANT Engine mounts...

Page 21: ...hole forward if so designed Each mount base is downward Tighten clamping screws and nuts slightly to prevent moving in or out Mounts must be free to pivot when installing engine 70140 e g c a d b f Fr...

Page 22: ...e Alignment IMPORTANT Engine alignment MUST BE RECHECKED with boat in the water fuel tanks filled and with a normal load onboard Engine must be aligned so that transmission and propeller shaft couplin...

Page 23: ...NE TO THE LEFT OR RIGHT Loosen clamping screws and nuts on all 4 mount brackets and move engine to the left or right as necessary to obtain proper alignment A small amount of adjustment can be obtaine...

Page 24: ...b Locknut c Tab On Tab Washer d 1 3 4 in 45 mm 9 Connect propeller shaft coupler to transmission output flange Secure coupling together with bolts lockwashers and nuts Torque to 50 lb ft 68 Nm Seawat...

Page 25: ...ttle cable ATTACHING ADJUSTING THROTTLE CABLE CARBURETED MODELS 1 Lubricate cable ends and barrels 2 Place remote control throttle lever in idle position and attach cable end guide to carbure tor thro...

Page 26: ...4 Install cable end guide on throttle lever then push cable barrel end lightly toward throttle lever end This places a slight preload on shift cable to avoid slack in cable when moving remote control...

Page 27: ...ST BE Over This Letter When Propelling Boat IN REVERSE d Poppet Ball MUST BE Centered in Detent Hole for Each F N R Position For ward Gear Shown e Install Shift Lever Stud in This Hole If Necessary To...

Page 28: ...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 con...

Page 29: ...d of fuel pump with wrench while tightening swivel an additional 1 3 4 to 2 1 4 turns with a wrench 75523 a a Fuel Pump Fitting 3 Remove shipping cap from fuel fitting on water separating fuel filter...

Page 30: ...e bundle with sta strap provided c Connect PURPLE wire from horn to any I terminal or ignition switch Tighten con nection securely Refer To Wiring Diagram d Connect TAN BLUE wire from horn to TAN BLUE...

Page 31: ...ubes must be connected to exhaust elbows so that they do not restrict the flow of discharge water from the elbow If hoses tubes are connected incorrectly a hot spot in the hose tube can occur and can...

Page 32: ...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 for...

Page 33: ...rpm until normal operating temperature is reached 2 Run boat up on plane 3 Advance engine rpm in 200 rpm increments until engine reaches its maximum rated rpm To test if the correct propeller has been...

Page 34: ...e cylinder block CAUTION Avoid product damage Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sensor in the upper hole of the fitting This sen sor must not...

Page 35: ...to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow en gine to start 4 Loosen hose clamps and remove the following hoses a From transmission...

Page 36: ...ains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 6 For additional assurance against freezing and rust follow...

Page 37: ...damage Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sensor in the upper hole of the fitting This sen sor must not be loosened or removed It is tightened...

Page 38: ...or bend hoses to allow water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow en gine to start 4 Remove hoses from the following locations...

Page 39: ...glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 6 For additional assurance against fre...

Page 40: ...GASOLINE ENGINES SKI MODELS Page 40 of 48 THIS PAGE IS INTENTIONALLY BLANK...

Page 41: ...ew and Hex Nut Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection NOTE 2 Power for a Fused Accessory Panel May Be Taken from This Connection Load Must Not Exceed 40 Amps Panel...

Page 42: ...7L Inboard Engines 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 DRK Dark 75754 1 2 3 4 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 A...

Page 43: ...Alternator 2 Electric Choke 3 Ground Plug 4 Starter Motor 5 Oil Pressure Switch 6 Fuel Pump 7 Circuit Breaker 8 Neutral Safety Switch 9 Starter Slave Solenoid C Audio Warning Components 1 Oil Pressur...

Page 44: ...WHITE YEL YELLOW LIT LIGHT DRK DARK A B C 76062 3 1 1 2 c a b 2 1 5 6 7 4 GASOLINE ENGINES SKI MODELS Page 44 of 48 MIE 350 Mag MPI Black Scorpion and MX 6 2L MPI Engines Starting and Charging System...

Page 45: ...onents 1 Oil Pressure Sender 2 Wire Not Used C Charging and Starting Components 1 Alternator 2 Ground Stud 3 Starter 4 90 Amp Fuse DO NOT REMOVE 5 Circuit Breaker 6 Starter Slave Solenoid 7 Neutral Sa...

Page 46: ...and ease of circuit identification 1 Fuel Pump 2 Distributor 3 Coil 4 Knock Sensor KS Module 5 Data Link Connector DLC 6 Manifold Absolute Pressure MAP Sensor 7 Idle Air Control IAC 8 Throttle Positio...

Page 47: ...diagram may look different than on your particu lar power package but the water flow paths remain similar on all engines 1 Seawater Intake 2 Seawater Pump 3 Transmission Cooler 4 Fuel Cooler EFI Mode...

Page 48: ...tions tight Idle RPM within specifications Correct rotation propeller installed and torqued Throttle shift and steering system Forward Neutral Reverse fasteners tightened properly gear operation Throt...

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