Mercury Alpha

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GASOLINE STERNDRIVE INSTALLATION MANUAL

90-860172011 Page 125 of 137

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Table of Contents2
General Information3
- Notice to Boat Manufacturer/Installer3
Torque Specifications4
Lubricants / Sealants / Adhesives5
Special Tools6
Alpha Notice: Increased Trim-In Range Capability6
Bravo Three Notice: Trim-In Limit Insert7
Quicksilver Products7
- Accessories7
Serial Number Decal Placement8
Corrosion Protection8
- Anti-Fouling Paint9
Boat Construction10
- Transom Thickness and Surface10
- Engine Bed11
- Crankshaft Vertical Centerline11
- Crankshaft Horizontal Centerline12
- Transom Cutout14
Seawater Connections - General Information16
- Seawater Pickup16
Preliminary Connections18
- Power Trim Pump18
- Fuel Inlet Fitting19
Transom Connections20
- Installing Gimbal Housing20
- Installing Inner Transom Plate21
- Connecting Speedometer Pickup22
- Fluid Connections23
- Installing Steering System25
- Transom Preparation35
Driveshaft Extension Models39
Engine Preparation39
Engine Installation40
- Exhaust System43
- Methods for Measuring Exhaust Elbow Height46
- Exhaust System Hose / Tube Connections48
- Engine Alignment49
- Hot Water Heater Installation53
Electrical Connections55
- Installing Continuity Wire55
- Instrumentation Connections56
- Trim Position Sender Connections57
- Mercathode Connections57
- Audio Warning System Connections58
- Power Trim Pump Connections59
Fluid Connections61
- Gear Lube Monitor Hose61
- Fluid Connections Gear Lube Monitor Hose61
- Power Steering Hoses62
- Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups62
- Alpha or Bravo Models Using Alternative Water Pickups63
- Coolant Recovery System66
Shift Cable Installation67
- Alpha Models - Drive Unit Not Installed67
- Bravo Models72
Throttle Cable Installation and Adjustment76
Sterndrive Unit Installation77
- Alpha Models79
- Bravo Models82
- All Models86
Speedometer Connection87
- Alpha Models87
- Bravo Models88
Shift Cable Installation89
- Alpha Models - Drive Unit Installed89
- Troubleshooting Shift Problems95
Predelivery Preparation98
- Power Steering Fluid98
- Filling Coolant Recovery Bottle99
- Power Trim Pump99
- Trim Position Sender Adjustment100
- Propeller Selection101
- Propeller Installation102
- Battery106
- Test Running Engine107
- Boat in the Water Tests111
Cold Weather and Extended Storage114
Draining Instructions114
- 3.0L Single Point Drain115
- V6 and V8 Seawater (Raw-Water) Cooled Models119
- V6 and V8 Closed Cooled Models122
- All Models124
Wiring Diagrams126
- Instrumentation126
Power Trim System128
Mercathode System Wiring Diagram129
MCM Gasoline Engine Wiring Diagrams130
- 3.0L Engines130
- MCM 4.3L, 5.0L and 5.7L Alpha Engines131
- MCM 4.3L Bravo Engines132
- MCM 5.0L and 5.7L Bravo Engines133
Water Flow Diagrams134
- 181 CID / 3.0L Engines134
- V8 Engines - Seawater Cooled135
- V6 and V8 Engines - Closed Cooled136
Predelivery Inspection137

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