Mercury Alpha Installation Manual

GASOLINE STERNDRIVE INSTALLATION MANUAL
Page 2 of 137 90-860172011
Table Of Contents
General Information 3. . . . . . . . . . . . . . . . .
Notice to Boat Manufacturer/Installer 3. . . . .
Torque Specifications 4. . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 5. . . . . . . . . .
Special Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alpha Notice: Increased Trim-In Range
Capability 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In Limit Insert 7. . . . .
Quicksilver Products 7. . . . . . . . . . . . . . . . . . . . . .
Accessories 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 8. . . . . . . . . . . .
Corrosion Protection 8. . . . . . . . . . . . . . . . . . . . . .
Anti-fouling Paint 9. . . . . . . . . . . . . . . . . . . . . .
Boat Construction 10. . . . . . . . . . . . . . . . . . . . . . .
Transom Thickness and Surface 10. . . . . . . .
Engine Bed 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Vertical Centerline 11. . . . . . . . . . .
Crankshaft Horizontal Centerline
(X-Dimension) 12. . . . . . . . . . . . . . . . . . . . . .
Transom Cutout 14. . . . . . . . . . . . . . . . . . . . . .
Seawater Connections - General
Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Pickup 16. . . . . . . . . . . . . . . . . . . . .
Preliminary Connections 18. . . . . . . . . . . . . . . . .
Power Trim Pump 18. . . . . . . . . . . . . . . . . . . .
Fuel Inlet Fitting 19. . . . . . . . . . . . . . . . . . . . . .
Transom Connections 20. . . . . . . . . . . . . . . . . . .
Installing Gimbal Housing 20. . . . . . . . . . . . . .
Installing Inner Transom Plate 21. . . . . . . . . .
Connecting Speedometer Pickup 22. . . . . . .
Fluid Connections 23. . . . . . . . . . . . . . . . . . . .
Installing Steering System 25. . . . . . . . . . . . .
Transom Preparation 35. . . . . . . . . . . . . . . . . .
Driveshaft Extension Models 39. . . . . . . . . . . . . .
Engine Preparation 39. . . . . . . . . . . . . . . . . . . . . .
Engine Installation 40. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 43. . . . . . . . . . . . . . . . . . . . . .
Methods for Measuring Exhaust
Elbow Height 46. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System Hose / Tube
Connections 48. . . . . . . . . . . . . . . . . . . . . . . .
Engine Alignment 49. . . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation 53. . . . . . . . . . .
Electrical Connections 55. . . . . . . . . . . . . . . . . . .
Installing Continuity Wire 55. . . . . . . . . . . . . .
Instrumentation Connections 56. . . . . . . . . . .
Trim Position Sender Connections 57. . . . . .
MerCathode Connections 57. . . . . . . . . . . . . .
Audio Warning System Connections 58. . . .
Power Trim Pump Connections 59. . . . . . . . .
Fluid Connections 61. . . . . . . . . . . . . . . . . . . . . . .
Gear Lube Monitor Hose 61. . . . . . . . . . . . . .
Power Steering Hoses 62. . . . . . . . . . . . . . . .
Bravo Models and Alpha Seawater
Cooled Models Using Sterndrive
Water Pickups 62. . . . . . . . . . . . . . . . . . . . . .
Alpha or Bravo Models Using
Alternative Water Pickups 63. . . . . . . . . . . .
Coolant Recovery System 66. . . . . . . . . . . . .
Shift Cable Installation 67. . . . . . . . . . . . . . . . . . .
Alpha Models - Drive Unit Not
Installed 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Models 72. . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation and
Adjustment 76. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit Installation 77. . . . . . . . . . . . . . . .
Alpha Models 79. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Models 82. . . . . . . . . . . . . . . . . . . . . . . .
All Models 86. . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Connection 87. . . . . . . . . . . . . . . .
Alpha Models 87. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Models 88. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 89. . . . . . . . . . . . . . . . . . .
Alpha Models - Drive Unit Installed 89. . . . . .
Troubleshooting Shift Problems 95. . . . . . . . .
Predelivery Preparation 98. . . . . . . . . . . . . . . . . .
Power Steering Fluid 98. . . . . . . . . . . . . . . . . .
Filling Coolant Recovery Bottle 99. . . . . . . . .
Power Trim Pump 99. . . . . . . . . . . . . . . . . . . .
Trim Position Sender Adjustment 100. . . . . .
Propeller Selection 101. . . . . . . . . . . . . . . . . . .
Propeller Installation 102. . . . . . . . . . . . . . . . .
Battery 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Running Engine 107. . . . . . . . . . . . . . . . .
Boat In The Water Tests 111. . . . . . . . . . . . . . .
Cold Weather and Extended Storage 114. . . . .
Draining Instructions 114. . . . . . . . . . . . . . . . . . . .
3.0L Single Point Drain 115. . . . . . . . . . . . . . .
V6 And V8 Seawater (Raw-Water)
Cooled Models 119. . . . . . . . . . . . . . . . . . . . .
V6 And V8 Closed Cooled Models 122. . . . .
All Models 124. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 126. . . . . . . . . . . . . . . . . . . . . . .
Instrumentation 126. . . . . . . . . . . . . . . . . . . . . .
Power Trim System 128. . . . . . . . . . . . . . . . . . . . .
MerCathode System Wiring Diagram 129. . . . .
MCM Gasoline Engine Wiring Diagrams 130. . .
3.0L Engines 130. . . . . . . . . . . . . . . . . . . . . . . .
MCM 4.3L, 5.0L And 5.7L Alpha
Engines 131. . . . . . . . . . . . . . . . . . . . . . . . . . .
MCM 4.3L Bravo Engines 132. . . . . . . . . . . . .
MCM 5.0L and 5.7L Bravo Engines 133. . . .
Water Flow Diagrams 134. . . . . . . . . . . . . . . . . . .
181 cid / 3.0L Engines 134. . . . . . . . . . . . . . . .
V8 Engines - Seawater Cooled 135. . . . . . . .
V6 and V8 Engines - Closed Cooled 136. . .
Predelivery Inspection 137. . . . . . . . . . . . . . . . . .

Mercury Alpha Specifications

General

Brand	Mercury
Model	Alpha
Category	Engine
Language	English