Mercury MerCruiser Bravo One Installation Manual Download

Page: 62 / 90

D7.3L D-TRONIC DIESEL ENGINES - BRAVO MODELS

Page 62 of 90

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.

75955

a -

Gear Lube Monitor

b -

Cap

3. Push in on dribble valve until gear lube appears.

72471

a -

Dribble Valve

4. Once gear lube appears, release dribble valve.
5. Fill monitor to FILL mark.
6. Replace monitor cap.

Summary of Contents for MerCruiser Bravo One

Page 1: ...im 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...

Page 2: ...mon hand tools and the special Mercury Marine or recom mended tools from other suppliers It is the responsibility of the OEM to select the appropriate engine transom drive package including the correc...

Page 3: ...unsafe situation The roll is caused by stern lift created from excessive drive unit trim in Under these extreme stern lift bow down conditions instability can be created which may cause the boat to r...

Page 4: ...mmed much differently than the other a dual trim control kit Part Number 90362A3 should be installed so as to limit this potential tilt differential to about 20 EXTERNAL POWER STEERING When boat speed...

Page 5: ...side of U S A order through Distribution Center or Distributor INSTALLATION PRODUCTS DESCRIPTION PART NUMBER Quicksilver Engine Coupler Spline Grease 92 816391A4 Quicksilver 2 4 C Marine Lubricant 92...

Page 6: ...Operation and Maintenance Manual identification page Corrosion Protection MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions Howe...

Page 7: ...at hull or boat transom cop per 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 betwe...

Page 8: ...Covers 8 in 203 mm to either side of the vertical centerline f Transom Angle 10 Degrees to 16 Degrees ENGINE BED Distance between starboard and port engine mount is 22 1 2 in 572mm Engine bed must po...

Page 9: ...e heated air should be discharged from the highest point If a separate air shaft or similar is used to provide engine compartment ventilation or addi tional ventilation care must be taken to prevent s...

Page 10: ...ceed outside air temperature by more than 30 F 17 C Since many factors influence engine compartment temperature temperature measure ments should always be carried out Compartment Temperature Testing T...

Page 11: ...covered by MerCruiser Warranty unless this damage is the result of defective part s Determine if an exhaust riser kit or a water lift muffler kit is required by taking measurements a and b with boat a...

Page 12: ...livery system 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 The fuel system from the filler pipe to...

Page 13: ...or numerous fittings 5 Fuel line s should be installed free of stress and firmly secured to prevent vibration and or chafing 6 Sharp bends in fuel lines should be avoided 7 A flexible fuel line must b...

Page 14: ...nut connectors Battery capacity rating of at least Engine Cyl type Minimum Required Cranking Battery Size 8 V D7 3L D Tronic and D7 3L D Tronic LD 1500 cca 1920 mca or 300 Ah Battery Cables Select pr...

Page 15: ...e six basic gauges that must be used with the engine are Tachometer Oil Pressure Water Temperature Voltmeter Cruise Log Engine Hour Meter Trim Gauge When using the instrumentation instrument harness w...

Page 16: ...Tronic and D7 3L D Tronic LD 4 155 Power Trim 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 T...

Page 17: ...damage Generally there is a 200 rpm change between propeller pitches After initial propeller selection the following common problems may require that the propel ler be changed to a lower pitch Warmer...

Page 18: ...formation and procedures IMPORTANT Do not reposition engine temperature switch it must remain where in stalled by factory CAUTION Heater must be mounted lower than the fill cap on the heat exchanger I...

Page 19: ...serve the following to select the proper seawater pickup hose seacock size and seawater strainer Seawater Connections General Information SEAWATER PICKUP HOSE Seawater inlet hose connections must be m...

Page 20: ...spection and cleaning Strainer should be installed in water inlet hose after the seacock water inlet valve to allow operator to shut off water when cleaning strainer Throttle Shift Remote Control and...

Page 21: ...use loss of steering which could cause damage to the boat and or injury All current production Quicksilver Ride Guide steering cables have a self locking coupler nut and do not require an external loc...

Page 22: ...1435 C L a b c d g h i l e j f k a Coupler Nut 7 8 14 UNF 28 Thread b 11 3 4 in 298 mm Min c Interface Point d 1 2 in 12 700 mm Max e 420 in 10 668 mm Min Flat f 102 in 0 508 mm Min Radius g 5 8 in 15...

Page 23: ...plications but pulling power for skiing will decrease During testing X Dimension should be increased 1 2 in 13mm at a time until desired performance is achieved but in no case should it ever be increa...

Page 24: ...ical Centerline 2 Locate and mark crankshaft vertical centerlines a on transom 22033 b a a c c a Draw Crankshaft Vertical Centerline through Desired Mounting Locations b Minimum Distance between Crank...

Page 25: ...it Add to dimension a 90 TOOL VERTICAL DIMENSION CHART Sterndrive Unit Location Bravo One Two Three 13 9 16 in 345mm IMPORTANT This dimension should only be raised or lowered after proper testing 2 De...

Page 26: ...ter proper testing 16 14 5 16 in 364 mm 15 14 1 4 in 362 mm 14 14 3 16 in 360 mm 13 14 1 8 in 359 mm 12 14 1 16 in 357 mm 11 14 in 356 mm 10 13 15 16 354 mm 2 Measure and layout horizontal centerlines...

Page 27: ...on Be certain that centerlines on either the template or transom drilling fixture align with lines previously marked on transom Be sure to drill 1 4 in pilot holes for hole saw guide at a 60 angle and...

Page 28: ...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 c...

Page 29: ...emoved and an exhaust tube MUST BE INSTALLED NOTE Exhaust tube parts Quicksilver Part Number 78458A1 are provided with a Bravo Three Drive They are located in the drive unit box 3 Install exhaust tube...

Page 30: ...center and using a circular pattern move outward Tighten in small increments and go around the pattern several times until the proper torque is achieved IMPORTANT Steering lever continuity circuit wir...

Page 31: ...c d e f g b a Black Hose UP Circuit b Gray Hose DOWN Circuit c Harness Connector d Clamp e Trim Limit Switch Wire with Blue Sleeve to BLUE WHITE Harness Wire f Trim Limit Switch Wire with Purple Slee...

Page 32: ...ant 101 73898 a B a Bushings b Special Lubricant 101 2 Remove upper and lower pivot bolts and ensure threads are well lubricated with Special Lubricant 101 3 Install steering assembly as follows a Pos...

Page 33: ...id 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 First move the spool assembly in the directio...

Page 34: ...e Guide Tube e Steering Cable End f Clevis g Clevis Pin h Cotter Pin IMPORTANT Slight feedback in the steering system could be encountered if the cable guide tube flat surfaces are not positioned vert...

Page 35: ...Fitting 3 Connect hose from speedometer to barb fitting Secure hose with cable tie 4 Mount speedometer hose to transom with hose clip and screw Hose must not come in contact with steering system compo...

Page 36: ...de additional cooling to the drive assembly The exhaust water bypass outlet provided with instructions for installation must be installed within the Preferred or Alternative Area as indicated on the t...

Page 37: ...ket Torque screws with star washers to 45 lb in 5 Nm 75313 c a b 75314 a b c a Plate b Gasket c Screw And Washer CAUTION Avoid drive unit damage Quick release button on gear lube monitor 90 hose fitti...

Page 38: ...d clip can be reused if they are moved out of the way while cutting the water hose 1 Move existing sta strap and clip Cut the water hose in the area shown Loosen clamp and remove short piece of hose r...

Page 39: ...ther material that could cause a poor electrical connection b After battery cables are connected apply a thin coat of Liquid Neoprene to the termi nals c Be sure to slide rubber boot over positive ter...

Page 40: ...oove or water and exhaust may leak into boat 22059 a b a Gimbal Housing Mating Surface b O ring 1 Install exhaust pipe assembly as shown using four 4 bolts and thick lockwashers Torque bolts to 20 25...

Page 41: ...so that engine is level when suspended 2 Lift engine into position in boat using an overhead hoist CAUTION When lowering engine into position DO NOT set engine on shift cable Shift cable outer casing...

Page 42: ...l both rear engine mounting bolts and hardware as shown Torque to 35 40 lb ft 47 54 Nm 22032 a c b d g f e a Rear Engine Mount b Inner Transom Plate Mount c Bolt d Washer e Spacer f Fiber Washer g Dou...

Page 43: ...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 76012 a b 71961 a Engine Sling In Starbo...

Page 44: ...in gimbal bearing or engine coupler b Attempt to insert the solid end of the alignment tool thru the gimbal bearing and into the engine coupler splines c If the tool does not fit remove it and careful...

Page 45: ...ont mounts 11 When alignment is correct tighten locknut or nut with lockwasher on each mount se curely 12 Bend tab washer down against flat on adjusting nut NOTE Coat both nuts and threaded portion of...

Page 46: ...install water pickup Position wash er on fitting and install large nut Tighten nut securely 70355 70589 f a e d e c b a f a Seawater Pickup Thru Hull Fitting b Washer c Large Nut d Hull of Boat e Mari...

Page 47: ...nt the seawater strainer on the engine Hoses must not be kinked Hoses must not allowed to come in contact with hot or moving parts on the engine Seawater strainer must be mounted BELOW the level of th...

Page 48: ...le for observing coolant level and filling 3 Mount coolant recovery bottle and mounting bracket in desired location using two 3 4 in long screws and flat washers 4 Route plastic tubing to recovery bot...

Page 49: ...Route hoses exactly as shown below This will help avoid stress on the hose fittings and will help avoid kinks in the hose 1 Connect power steering hoses to control valve Position hoses as shown IMPORT...

Page 50: ...ypical a Elbow b Tube c Hose Clamps 4 d Pipe Electrical Connections CONTINUITY CIRCUIT 1 Connect continuity circuit wire supplied with engine package from engine to transom assembly Tighten inner tran...

Page 51: ...anel dash lights is a three position toggle switch It must be wired and installed correctly to provide proper operation of the systems Refer to the following special installation instructions a Hold t...

Page 52: ...dividual gauges Mount Engine System Monitor Panel to dashboard following Instruction Sheet Template 6 Connect instrument extension harnesses to instrument harness ends Connector collars must be fully...

Page 53: ...Remote Control d Rubber Sleeves TRIM POSITION SENDER CONNECTION 1 Connect trim position sender leads from gimbal housing to leads from engine harness 24841 BLK BLK a b YEL 107 BLK GND3 a From Engine...

Page 54: ...cable end guide moves in direction B when control lever is placed in Forward remote control is setup for LEFT HAND LH propeller rotation 71656 A B Bravo One And Two c Bravo Three Front propeller on dr...

Page 55: ...etainer 23242 6 Locate center of remote control and control cable play backlash a Shift remote control to neutral b Push in on shift cable end with enough pressure to remove play and mark position a o...

Page 56: ...cable barrel from stud without first removing end guide anchor pin from shift lever and removing cable Attempting to bend shift cable to install or remove barrel will place undue stress on cable end g...

Page 57: ...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 When adjustm...

Page 58: ...control box is mounted too far back toward any fiberglass structure the cables will be interfered with this will cause very hard shift ing NOTE The control box housing can be rotated in 30 increments...

Page 59: ...ted into either forward or reverse 7 Check to make sure that the engine was not set down on the intermediate shift cable during installation as this will crush the inner cable tubing and cause imprope...

Page 60: ...arrel end bracket Select the hole in the cable barrel end bracket that is closest to the distance of 7 1 8 in 181 mm between studs 76025 a b c d e a Accelerator Position Sensor APS IVS b APS IVS Ancho...

Page 61: ...and back off 1 2 turn 5 Place remote control lever in full forward wide open throttle W O T position 6 Check to ensure Accelerator Position Sensor lever is contacting internal override spring Be cert...

Page 62: ...nd dust cover from bell housing studs Retain locknuts and flat washers 2 Remove cap and fill gear lube monitor 75955 a b a Gear Lube Monitor b Cap 3 Push in on dribble valve until gear lube appears 72...

Page 63: ...GINES BRAVO MODELS Page 63 of 90 7 Coat studs with 2 4 C Marine Lubricant 72471 a a Studs 6 8 Lubricate U joint shaft splines and U joint shaft O rings with Engine Coupler Spline Grease 22026 a b Typi...

Page 64: ...bricate O ring seals with 2 4 C Marine Lubricant 72183 a a O Ring Seals 11 Pull out shift linkage as far as it moves Jaws will open as shown 72460 a a Shift Linkage IMPORTANT As sterndrive is inserted...

Page 65: ...ually 72457 b a a Shift Linkage Assembly b Shift Cable 13 Place drive shaft housing in position on bell housing and install drive unit as follows a Position trim cylinders so they point straight backw...

Page 66: ...ts 6 and Flat Washers 5 IMPORTANT On Bravo One Two and Three Models the Trim In Limit Pin Insert must be properly positioned before installing the trim cylinder anchor pin in the fol lowing steps 15 E...

Page 67: ...installing rubber bushings use a water and soap solution DO NOT use oil or grease 16 Install trim cylinders on aft end of drive unit with hardware as shown Coat anchor pin threads with 2 4 C Marine Lu...

Page 68: ...between gimbal housing and sterndrive immediately atop the transom end of the anti ventilation plate 20 Insert speedometer tube fitting into opening on topside of anti ventilation plate in posi tion...

Page 69: ...D battery cable to positive battery terminal 4 Make sure that all battery terminal connections are tight then spray terminals with a bat tery connection sealant to help retard corrosion Power Trim Pum...

Page 70: ...e fitting s to 100 150 lb in 11 16 Nm Trim Position Sender Adjustment 1 Loosen both trim position sender attaching screws 71220 a b a Attaching Screws b Trim Position Sender CAUTION DO NOT start engin...

Page 71: ...0 4 Rotate trim position sender as required to show full DOWN IN position on dashboard instrument as shown 71671 a a Trim Gauge Needle 5 Tighten retaining screws and turn ignition key to the OFF posit...

Page 72: ...ill be damaged 1 Position drive unit so that it is straight back 2 Remove fill cap from power steering fluid reservoir and check fluid level Fill to FULL COLD line do not over fill 76955 71672 a b a a...

Page 73: ...oil level after first use 70121 a b a Oil Vent Screw and Sealing Washer b Oil Vent Hole Propeller Installation BRAVO ONE AND TWO IMPORTANT Correct rotation propeller MUST match direction of rotation o...

Page 74: ...tab washer align with grooves on spline washer Bend the 3 tabs down into grooves 75492 a b c f h e g d Bravo One a Forward Thrust Hub b Flo Torque Drive Hub c Propeller d Continuity Washer e Drive Sl...

Page 75: ...propeller shaft splines with one of the following Quicksilver lubricants Special Lubricant 101 2 4 C Marine Lubricant 2 Install propellers with attaching hardware as follows a Slide forward thrust hub...

Page 76: ...e is to be tested on land water must be supplied to seawater pickup pump DO NOT run engine above 1500 rpm as suction created could cause water hose to collapse causing water supply to be cut off 1 If...

Page 77: ...ion between gimbal ring and gimbal housing and all moving steering components 2 Check that steering lever is not contacting cutout in transom If contact is being made modify cutout b Turn steering whe...

Page 78: ...is nothing attached to steering cable casing Cable must be free to move when actuated 15 Check power steering pump fluid level a Position drive unit so it is straight back Turn off engine b Remove cap...

Page 79: ...e rpm with an average load aboard the boat Best all around performance is obtained with the D7 3L D Tronic engine propped at 3800 rpm and the D7 3L D Tronic engine propped at 3600 rpm IMPORTANT Consid...

Page 80: ...rect propeller selection IMPORTANT Do not run at maximum rpm for more than 2 minutes After Running Engine CAUTION If Power Package will not be used for an extended period of time or will be exposed to...

Page 81: ...precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine IMPORTANT...

Page 82: ...to blow any remaining water from the tubes in the heat exchanger b The drain plug on the lower side of the engine oil cooler c The aftercooler drain plugs located on the starboard and port aftercooler...

Page 83: ...s at seawater strainer and drain hose s completely Remove drain plug and empty seawater strainer Reconnect hoses Tighten hose clamps securely Install drain plug Tighten securely 71362 a b c c a Seawa...

Page 84: ...YEL YELLOW LT OR LIT LIGHT DRK DARK b c d e f g h a D7 3L D TRONIC DIESEL ENGINES BRAVO MODELS Page 84 of 90 Power Trim System Wiring Diagram a 20 Amp Fuse b Ground Bolt Floor Mount c UP Solenoid d 1...

Page 85: ...GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LT OR LIT LIGHT DRK DARK 73596 a b c D7 3L D TRONIC DIESEL ENGINES BRAVO MODELS Page 85 of 90 MerCathode System Wiring Diagra...

Page 86: ...y GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 15 1 5 4 3 2 a b c d e 7 8 9 10 11 12 13 14 6 D7 3L D TRONIC DIESEL ENGINES BRAVO MODELS Page 86 of 9...

Page 87: ...t c Oil Pressure Warning Light d Charge Indicator Light e Preheat Indicator Light 7 Panel Lights Audio Warning Test Switch 8 Key Switch 9 Neutral Start Safety Circuit Remote Control 10 Hour Meter Gaug...

Page 88: ...D7 3L D TRONIC DIESEL ENGINES BRAVO MODELS Page 88 of 90 Cooling System Flow Diagram 76205 1 2 3 4 8 9 10 7 c a A B C F G B D D E H 5 b 6...

Page 89: ...awater 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 A Circulating Pump Closed...

Page 90: ...l connections tight Idle RPM within specifications Correct rotation propeller installed and torqued Throttle shift and steering system Forward Neutral Reverse fasteners tightened properly gear operati...

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