Mercury INSTALLATION MANUAL D7.3L D-TRONIC User Manual

90-861180990 SEPTEMBER 1999 Printed in U.S.A. -  1999, Mercury Marine Page 1 of 90
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, and Ride-Guide.
INSTALLATION MANUAL D7.3L D-TRONIC
DIESEL ENGINES - BRAVO MODELS
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed with the Product for the Owner’s
Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information 2. . . . . . . . . . . . . . . . . . . . . . .
Notice to Installer 2. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In Limit Pin 3. . . . . .
Multiple Sterndrive Steering Tie Bar
Arrangements 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Products 5. . . . . . . . . . . . . . . . . . . . .
Torque Specifications 6. . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 6. . . . . . . . . . .
Corrosion Protection 6. . . . . . . . . . . . . . . . . . . . .
Antifouling Paint 7. . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 8. . . . . . . . . . . . . . . . .
Boat Construction 8. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 11. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 12. . . . . . . . . . . . . . . . . . .
General 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables 14. . . . . . . . . . . . . . . . . . . . . . . . .
EDI Electrical System Precautions 15. . . . . . . .
Instrumentation 15. . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Control 16. . . . . . . . . . . . . . . . . . . . .
Power Trim 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 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Finding Crankshaft Vertical Centerline 24. . . . .
Finding Crankshaft Horizontal Centerline
(“X” Dimension) 25. . . . . . . . . . . . . . . . . . . . . . . .
Cutting Transom 27. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transom Thickness 28. . . . . . . . . . . . .
Installing Transom Assembly 29. . . . . . . . . . . . .
Gimbal Housing 29. . . . . . . . . . . . . . . . . . . . . . . .
Inner Transom Plate 30. . . . . . . . . . . . . . . . . . . .
Power Trim Pump 31. . . . . . . . . . . . . . . . . . . . . .
Steering System 32. . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Pickup 35. . . . . . . . . . . . . . . . . . . .
Drive Unit Gear Lube Monitor Hose 35. . . . . . .
Exhaust Water Bypass 36. . . . . . . . . . . . . . . . . .
Drive Unit Seawater Routing 37. . . . . . . . . . . . .
Engine Installation 39. . . . . . . . . . . . . . . . . . . . . . .
Engine Preparation 39. . . . . . . . . . . . . . . . . . . . .
Transom Preparation 40. . . . . . . . . . . . . . . . . . . .
Installing Engine / Alignment 41. . . . . . . . . . . . .
Engine Connections 46. . . . . . . . . . . . . . . . . . . . . .
Quicksilver Seawater Pickup and Seacock 46.
Seawater Strainer 47. . . . . . . . . . . . . . . . . . . . . .
Closed Cooling Recovery Bottle 48. . . . . . . . . .
Fuel Lines 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Hydraulic Hoses 49. . . . . . . . . .
Exhaust System 50. . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 50. . . . . . . . . . . . . . . . . . .
Shift Cable Installation and Adjustment 54. . . .
Troubleshooting Shift Problems 58. . . . . . . . . . .
Throttle Cable Installation and Adjustment 60.
Sterndrive Unit Installation 62. . . . . . . . . . . . . . .
Predelivery Preparation 69. . . . . . . . . . . . . . . . . . .
Power Trim System Wiring Diagram 84. . . . . . .
MerCathode System Wiring Diagram 85. . . . . .
Quicksilver Instrumentation Wiring 86. . . . . . . .
Cooling System Flow Diagram 88. . . . . . . . . . . .
Predelivery Inspection 90. . . . . . . . . . . . . . . . . . . .

Mercury INSTALLATION MANUAL D7.3L D-TRONIC Specifications

General

Category	Engine
Name	Mercury INSTALLATION MANUAL D7.3L D-TRONIC
Displacement	7.3L
Fuel Type	Diesel
Aspiration	Turbocharged
Cylinders	6
Cooling System	Liquid Cooled

Summary

General Information

Notice to Installer

Important instructions for installers regarding hazards and safety precautions.

Notice on Bravo Trim-In Limit

Information on the trim-in limit pin and potential boat rolling issues under specific conditions.

Multiple Sterndrive Steering Tie Bar Arrangements

INTERNAL TIE BAR ONLY

Recommended for boats under 60 MPH, connects slave to primary sterndrive.

INTERNAL AND EXTERNAL TIE BAR

For moderate performance (60-70 MPH) or reduced backlash; requires dual trim control.

EXTERNAL POWER STEERING

For speeds over 70 MPH; includes external tie bar and steering cylinders.

Quicksilver Products

ACCESSORIES

Lists available Quicksilver remote controls, steering systems, and propellers.

INSTALLATION PRODUCTS

Lists specific Quicksilver installation tools and parts with part numbers.

Torque Specifications

Installation Requirements

Boat Construction

Specifies transom and engine bed requirements for proper installation.

ENGINE COMPARTMENT

ENGINE COMPARTMENT VENTILATION

Details requirements for engine compartment ventilation for cooling and air supply.

Exhaust System

Fuel Delivery System

FUEL CONNECTIONS

Guidelines for connecting fuel lines, including diameter and routing.

Battery

Battery Cables

Guidance on selecting and installing appropriate battery cables based on length.

Instrumentation

Power Trim Control

Information on compatible trim controls and their installation.

Propeller Selection

RPM REV-LIMITER

Information on the engine's RPM limiter and its impact on propeller choice.

Seawater Connections

Steering Helm and Cable

STEERING CABLE SPECIFICATIONS

Detailed specifications for steering cable dimensions and requirements.

Transom Cutout

Finding Crankshaft Vertical Centerline

DUAL ENGINE

Procedure for locating and marking vertical centerlines for dual engines.

Finding Crankshaft Horizontal Centerline (“X” Dimension)

TAPE MEASURE METHOD

Method to determine horizontal centerline using tape measure and transom angle.

Installing Engine / Alignment

Shift Cable Installation and Adjustment

Throttle Cable Installation and Adjustment

Sterndrive Unit Installation

Test Running Engine

Boat-In-The-Water Tests

ENGINE INITIAL BREAK-IN PROCEDURE

Procedure for breaking in a new engine to ensure proper seating of components.

MAXIMUM RPM TEST

Method to verify correct propeller selection by checking WOT RPM.

After Running Engine

Post-operation checks and storage preparation for the engine and drive unit.

Predelivery Inspection