Mercury 3.0L Carbureted Alpha Spezifikationen

Table Of Contents Section 1 - Fuel Systems Section 2 - Electrical Systems Section 3 - Exhaust and Cooling Systems Section 4 - Transom Assemblies

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Restrictor GasketRestrictor End of Gasket is StraightRestrictedOpen End of Gasket is ContouredOpen

Restrictor Gasket• Used on All Raw Water Cooled Engineson the Manifold.• Restrictor Opening Goes Toward End ThatBypass Water Comes From ThermostatHous

Full Flow GasketBoth Ends of Gasket are ContouredOpenOpen

Full Flow Gasket• Used on All Engines with Risers.• Goes Between the Riser and Exhaust Elbow.• Turbulator Points Upward.

Block Off GasketBoth Ends of Gasket are StraightClosedClosed

Block Off Gasket• Used on All Closed Cooled Engines.• Goes Between the Exhaust Manifold and Riser.• Turbulator Points Upward.

Installation Reminder• Current MIE Inboard and Tow Sports V-DriveRequirements.– Test & Verify Exhaust System Designs– 6.9-13.7 kPa (1-2 psi) Exhau

Dry Joint 14o Exhaust Elbow

Dry Joint Service Manual• Nbr 37 V8 Service Manual Supplement.– 90-864260020 Oct 2002.• Section 6 Cooling System.–All Models.– Seawater System.– Close

MCM Exhaust Elbow Height Change• Project Objectives– Provide V-6 and S.B. V-8 MCM engines with increased elbow height– Increase exhaust elbow outlet a

Quad-Rings and O-Rings for Fuel Pressure Gauge SchraderValve Adaptor Kit, P/N 91-803135.The following is a list of replacement sealing components for

Exhaust Elbow Height• System Overview– Current MIE elbow will become standard on all V-6 & S.B. V-8 MCM’s except inline ski• Increases height by 1

Exhaust Elbow Height 1.5” Elbow Only

Exhaust Elbow Height 3.2” Elbow, 1.7” Riser

Exhaust Elbow Height 4.5” Elbow, 3” Riser

Exhaust Elbow Height 7.5” Elbow, 6” Riser

Exhaust Elbow Height SummaryN/AN/AN/AN/AN/A6.006.00864309 (short) Elbow + 6.00" RiserN/AN/AN/AN/AN/A3.003.00864309 (short) Elbow + 3.00" Ris

Exhaust Elbow Height Turbulator will be removed from full flow gasket “New” PN 865786A01

Exhaust Elbow HeightIntermediate Pipes New intermediate pipes will be labeled with model, riser size and pn.Improved alignment with bullhornNew V6

Exhaust Elbow HeightIntermediate Pipes

Exhaust Elbow Height• System Overview– Flow control valve installed on thermostat housing for RWC 350 MAG & MX 6.2 MCM & MIE• Balances water f

Turn Key Start (TKS) Systemx This system will be installed on all carbureted engines. Production start will be during August through October of 2004

Exhaust Elbow Height• New Service Kit’s– 1.7 inch riser’s • 865995A01 RWC Warm Riser• 865996A01 FWC Warm Riser• 866007A01 RWC Tow Sports Warm Riser– S

Exhaust Elbow Height• New Service Kit’s– Intermediate Elbow Kit’s (2 elbows per kit)• 866000A01 V6 1.7” riser• 866001A01 V6 3” riser• 866002A01 V6 6”

Exhaust Elbow Height• Service Kit’s– Several existing kits will be impacted• CC for MPI & Carb• 3 & 6 inch riser• Long block

2005Product UpdateSection 4 Transom Assemblies 4

Table of Contents Quick Connects • Gear Lube Bottle Relocation • Oil Reservoir Hose • Power Trim Hoses • Power Steering Hoses • Bravo Trans

Transom Plate Assembly ComponentsQuick ConnectsAdded For Reduced Installation Timeand Secure Connections

Gear Lube Bottle Relocation• Project Definition– Relocate gear lube bottle to eliminateinterferences– Add inline quick connection to lube line• Benefi

New Oil Reservoir Quick ConnectsQuick Connect at Gimbal HsngDrive Lube MonitorThere is a new quick connect fitting between the oil reservoir bottle an

Drive Initiatives – January 2004 Power Trim Quick Connects • Project– Hydraulic quick connect fittings– Brass Construction – brass components shown i

Power Trim Quick ConnectsTrim Pump Fitting UpPressure at the AdapterTrim Hose Up Pressure and Quick Connect FittingTrim Hose Down PressureQuick Conne

- TKS fuel path is in the normally open position. Electric power causes a wax expanding device to expand thus causing the needle to meet the seat and

§ Power steering hose quick-connect fittings– Reduce installation time and opportunity for leaks• All Sterndrive models with power steeringNew DesignC

Drive Initiatives – January 2004Power Steering Quick Connects• Project Definition– Quick connect fittings– Nickel Plated Brass Construction– Affects A

Power Steering Quick ConnectsPower Steering Valve Outlet FittingPower Steering ValveInlet FittingPower Steering High Pressure HosePower Steering Retur

Drive Initiatives – January 2004Transom Water Hose FittingOLD DESIGNNEW DESIGN• Project– Redesign the inlet water fitting located on the transom.– Add

Drive Initiatives – January 2004Sea Pump Water Hose Quick Connect• Project– Provide easier installation for inlet hose via a quick connect junction in

• Project Definition– Quick connect fitting– Nickel Plated Brass / Plastic Construction– Affects Alpha and Bravo Drives• Benefits– Male connector fact

MerCathode Assembly• Project Definition– Add sealed connector in MerCathodeharness to reduce installation time– Improve aesthetics on product– SN 0M64

MerCathode Quick ConnectsThe service replacement MerCathode unit will come with the connector disassembled for ease in replacement through the hydraul

Drive Initiatives – January 2004Fuse change – Trim Pump • Project– Replace glass fuse assembly with flat blade style fuse• Benefits– Eliminate damage

New Trim Pump HarnessFuse and HolderNew Three Pin Connector

- Additional Coolant Temperature Switch:A second switch has been added to the system and it is located in a new thermostat housing on the 3.0L models

New and Current Trim Pump HarnessNew Three PinPackard ConnectorCurrent Three Blade Round Connector

Control Harness to Trim Pump Adapter HarnessesA02A02

Control Harness to Trim Pump Adapter Harness

Problem: Trim Pump Cap Leaks• Trim pump purges oil through side vents in rough water applications.Root Cause:• Cap vents are large enough to allow slo

Oil Bottle Float ChangeThe float in the oil reservoir bottle was improved to prevent it from sealing off the outlet when the bottle is filled from the

New Rear Engine Mount DesignAlpha Shown - Bravo Similar1 - Transom Plate Assembly2 - Pivot Bolts3 - Tab Washers4 - Screw Engine Mounting5 - Washer6 -

Drive Changes – June 2003Improved Engine Alignment• Project Definition– Address offset at nominal (detected by stack-up) at the rear engine mount / in

Old and New Style MountsOld Engine Mount New Engine Mount

Old Design Flywheel HousingMount Location

Inner Transom PlateFlywheel HousingRear Mount (old)Spring WasherOld Style Rear Mount Installed

x Troubleshooting and Repair: - The TKS system has very few repair parts: The TKS Module The oil pressure switch The coolant temperature switch and di

New Design Flywheel HousingMount Location

New Style Rear Mount InstalledRear Mount ( New)Flywheel HousingInner Transom Plate

Engine Placement When Using Old Style Rear Engine MountBoat StringerMisalignment Clearance Caused when old mount was used. Some Boatbuilders Compen

Boat StringerFront MountEngine Placement Using New Design Rear Engine MountNew Mount Design Lowers Engine To Height Specified In Installation Drawings

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Shift Plate Assembly June 2003• Project Definition– Redesign shift plate assembly to eliminate improper installation of shift interrupt and gear indic

Alpha Shift Plate – Exploded ViewCast in Switch Guide Bosses

x TKS Retro Fit Kit - Retro Fit Kits will be available for all engine lines, at the end of the year (2004):3.0 L 1996 – 2004 4.3 L 1998 – 2004 5.0 L

New Shift Levers for Alpha & Bravo Shift Plate Assemblies

Neutral Switch adjustment notch

Drive Initiatives – June 2003Intermediate Shift Cable• Project Definition– Alpha and Bravo intermediate shift cable redesign / resource to reduce fric

Alpha / Bravo Shift CablesBRAVOIntermediate Shift CablePart # 865437 A02ALPHAIntermediate Shift CablePart # 865436 A02

§ New internal “wig-wag” throttle and shift controls– Allows more flexible control cable routing– Reduced internal friction for smoother operation– Us

2005Product UpdateSection 5Sterndrives 5

Table of ContentsNew Alpha One Gen II Drive Shaft Housing Oil Seal Installation Tool Bravo Drive Updates and Changes x Bravo Engine Coupler Redesign

New Alpha One Generation IIDrive Shaft Housing Oil Seal Installation ToolNew Integrated Oil SealPart Number 26-86431991-817570T ( Two SealInstallation

New Alpha One Generation II Drive ShaftHousing Oil Seal Installation Tool91-864497

MEFI III to IV Conversion Kits• Project Objectives– Provide long term resolution to availability issues with MEFI III ECM– Prioritize highest v

Drive Initiatives – January 2004Improved Engine Coupler – Bravo Only• Project Definition– Change hub material from Aluminum to 12L14 Steel– Affects Al

Bravo Engine CouplersCurrent Bravo Small Block Current Bravo Big Block

Proposed New Design BravoEngine Coupler

•Shortened snout to provide installation clearance•Shielded for grease retention•Grease channel to direct lubrication to splines•Steel insertProposed

• The Bravo U-Joint Assembly has changed from the Rockwell U-joint assembly to the GKN assembly. • The Rockwell assembly is Grayin color, where as the

Comparison of Rockwell to the GKN U-Joint Assy.

GKN U-Joint Repair PartsAlpha / Bravo Std.• ALPHAUniversal Joint Assembly 864281A 2Stub Yoke Gear End 864282TCenter Socket 865503TSplined Yoke Engine

Rockwell U-Joint Assembly

Bravo Standard GKN U-Joint Assembly

Bravo “X” GKN U-Joint AssemblyRepair parts for the GKN “X” Drive U-Joint Assembly such as the part numbers for all of the individual replacement parts

MEFI III to IV Conversion Kits• System Overview– MEFI IV ECM which physically appears the same as a MEFI III • Pin out locations are different• Coil d

Bravo (X) U-Joint AssembliesNew L18 GKN U-Joint Assembly ( Bravo X Drives)

• Original style Driven gear (1999 & Prior)

• New style Replacement Gear for 1999 & prior aswell as current Bravo Drives.

• Old Style Cone Clutch New Upgrade cone clutch• with the number “7” with the Top Groove

• Original Chimney bearing positioning for 1999 & prior BravoDrives

MEFI III to IV Conversion Kits• Kit Components– MEFI IV ECM– Cross-Over harness– Secondary harnesses – Coil driver with heat sink – Coil driver bracke

• Proper positioning of the Top Cover and Drive ShaftHousing Chimney Bearing.

• 91-90773T 91-864220 91-862530• Original Upgrade 2000 & up

Individual Replacement Puller Tool part Numbers for BravoService Tool 91-90244A 1Bravo Service Tool 91-90244A 1 replacement part numbers. When you or

• We have had some reports of Bravo Three propeller shaft oil sealleakage.• Samples of the production oil seal were placed on test in ourengineering t

• The seal vendor was then contacted to set up a meeting on thequality and design issue of the oil seal.• The first thing that was done was to increas

• New improved propshaft seals – Bravo Three– New lip design, material and spring tension– Greatly reduces potential for leakage and earlyfailure

Bravo III Changes for 2003AdditionalAnode added to Gear Case and Propeller Shaft on June 17, 2003 S/N 0M179452

MEFI III to IV Conversion Kits• Installation Big Block– Mount the MEFI IV ECM with existing hardware– Connect the J1 & J2 connections on the cross

Bravo III Anode Design Targets¾Add 43% Anode Volume w/ Dual Gearcase and Propeller shaft Anode¾Baseline -current 17.41 in³ (285.3 cm³)¾Actual - added

Bravo III Bearing CarrierThreads machinedafter anodizing

• You may have also heard that the front propeller was hitting on thebearing carrier causing some surface rub damage.• It was found to be several issu

Bravo Three Bearing Carrier Damage / Propeller Defect

Bravo Three Bearing Carrier Damage / Propeller Defect• Heavy deposit on lower rib of propeller causing it to rub on thebearing carrier.• Heavy Devcon

Bravo Three Bearing Carrier Damage / Propeller Defect• Casting Flash on leading edge of propeller rib, Devcon across the face of the rib causing the p

Bravo Three Bearing Carrier Damage / Propeller Defect• The new version of the front propeller. • Version One is the Machined current version using the

Drive Initiatives – January 2004New Thrust Bearing• Project Definition– Redesigned bearing to improve durability.– Increased roller diameters– Bravo I

Drive Initiatives – January 2004New and Old Outer Propeller ShaftNew Shaft MarkingOlder Shaft Markings

MEFI III to IV Conversion KitsBig Block

Drive Initiatives – May 2004• Project Definition– initiatives directed at improving the following:• NVH / Shift Effort– Bravo shift lever detent– Revi

Drive Initiatives – May 2004Bravo Shift Lever Detent• Project Definition– Modify Detent Shape – Smooth detent transition from forward into neutral and

Bravo Shift Lever Detent SocketCurrent Bravo Shift Lever New Design Bravo Shift Lever

Bravo Shift Lever Detent SocketUsed in all Bravo X and XR Stern Drives with High Bump Brass SleevesUsed in all Standard Bravo Stern Drives with Low Bu

Drive Initiatives – May 2004Bravo Cone Clutch Redesign

Drive Initiatives – May 2004Bravo Cone Clutch RedesignCurrent Bravo Cone Clutch New Design Bravo Cone Clutch

Drive Initiatives – May 2004Bravo Styling• Project Definition– Restyling of • Upper Driveshaft Housing (DSH)• Rear Cover• Top Cover• Decals– No extern

Bravo Drive Shaft HousingThe “O” ring for the drive shaft housing shift shaft bore has been replaced with a new seal. Shift Cavity Seal19-865866

The “O” ring for the drive shaft housing shift shaft bore has been replaced with a new seal. Part Number 19-865866Bravo Drive Shaft HousingNew Designe

Introducing the New Bravo Jan, 2004 Shimming process• The Bravo drives for 2004 will have the gears in the drive shafthousing shimmed into position to

MEFI III to IV Conversion KitsBig Block

U-joint and Driven Gear Bearing Spacer Cup for all Bravo Drives• New U-joint shouldered bearing pack spacer cup and bearing.

U-joint and Driven Gear Shims and Chart• New U-joint shouldered bearing pack Chart and Shim.

Bravo 2004 Driven Gear Thrust Bearing Race and Chart

Gear Lash Specification Chart for Bravo 2004• Gear Tooth Count Gear Lash• 27 x 32 Spiral Tooth Gear .011 - .016• 27 x 29 Spiral Tooth Gear .013 -

New Shimming Tools Required to shim a Bravo Upper• U-Joint pinion gear shimming tool

U-Joint pinion gear shaft tools• Standard Bravo• All Bravo X models

Gear Lash Flags for the new shimming procedure

Holding Block and Rod assembly for the Dial Indicator• Dial Indicator holder rod and retaining nut.•Dial Indicator holding block.

Handle Fixture for checking Gear Lash• Handle fixture for checking gear lash.

Driven Gear Clamp Tool• Clamp tool to hold driven gear when checking gear lash.To order the Complete Tool Kit Including both sets of Shims required to

MEFI III to IV Conversion KitsBig Block

New Shimming procedure for Bravo Upper 2004• Step 1) Place the new U-Joint bearing pack on to the gear as you have in the past, by pressing the first

New Shimming procedure(continued)• Step 3) After the bearing preload is set remove the gear and bearing pack from the U-joint assembly along with the

New Shimming procedure(continued)• Step 4) In this step you will insert the original shim thickness that came out of the drive or a starting shim of

New Shimming procedure (continued)• Step 6) Insert Pinion gear shimming tool 91-865114 into the top of the driveshaft housing using the proper gear

New Shimming procedure (continued)• Step 7) Using a feeler gauge between the tool face and the gear teeth measure for the (0.64mm) .025 distance b

New Shimming procedure (continued)• Step 11) Place the thrust bearing on the top gear along with the shim race (thickness that was originally removed

New Shimming procedure (continued)• Step 13) Reinstall the U-joint gear and bearing pack with the stub shaft tool that you previously removed and reto

New Shimming procedure (continued)• Step 15) The next step will be to install the clamp block and handle assembly onto the end of the U-joint stub too

New Shimming procedure (continued)• Step 17) The next step will be to install the dial indicator holding block onto the holder rod.• Step 18) Install

New Shimming procedure (continued)• Step 19) Next align the Gear Lash Flag perfectly straight up and down on the bearing and pinion gear stub sha

MEFI III to IV Conversion Kits• Installation Small Block – Mount the MEFI IV ECM with existing hardware– Connect the J1 & J2 connections on the cr

New Shimming procedure (continued)• Step 22) Now tighten the clamp block on the stub shaft locking it tothe shaft.• Step 23) While holding the driven

New Shimming procedure (continued)• Step 25) In this step you will make the required shim race changes and redo the process, by first removing the di

New Shimming procedure (continued)• Step 29) After the gear lash process is complete and the drive is ready to reassemble for the final time, remove

2005 Product Update Section 6 Customer Satisfaction Index (CSI) 6

Notes:_______________________________________________________________________________________________________________________________________________

Table of Contents CSI Info and FAQ Customer Satisfaction Index (CSI) Frequently Asked Questions Sample of Card

CSI Info and FAQ Customer Satisfaction Index (CSI) Customer Satisfaction Index (CSI) Getting your finger on the pulse of your customer. People spend a

Frequently Asked Questions Why is CSI important? · CSI shows customers that we care about them. · They communicate whether our customers are happy

What is a “Hot Alert” and how is it generated? A Hot Alert is a faxed notification to a dealer that a consumer has returned a survey in which they in

90-821218 2-204CUSTOMER SATISFACTION SURVEYDear Valued Customer,We would like to ask you a few questions regarding your last Service visit to our De

MEFI III to IV Small Block Kit Harnesses

Dealers have found this card useful for several reasons: 1) The card allows you the opportunity to gain insight from each and every customer by way of

MEFI III to IV Conversion Kits• Service Diagnostic Tools– CDS version 3.14 or higher (Version 4.18 or higher for fuel pressure data stream correction)

Gen III Cool Fuel SystemSystem features:· Single Integrated Module- Filter, pumps, pressure regulator and cooler, all in one unit- Fuel flows through

This system will be standard on:· Small-Block MPI V8 Bravo· Small-Block MPI MIE· Big-Block MPI Sterndrive· Big-Block MPI MIEIt will not be availab

System Module Features:· Dual Pump Configuration- Improved Vapor Lock resistance compared to engines equipped with currentboost pumps· Corrosion Prot

2005Product UpdateSection 1 Fuel Systems 1

System Overview:Low pressurepumpHigh PressurePump1st stage relief(10 psi)Fuel pressureRegulatorFuel FilterHeat Exchanger(housing - casting)Water Outle

Fuel Flow Through the System"2-Story" Water Flow Path

Cool Fuel III System - Mounted on Small-Block Engine

Gen III Cool Fuel Module

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Digital Diagnostic Terminal (DDT) Cartridge - 1.31 VersionWHAT’S NEW FOR CARTRIDGE VERSION 1.31 –SMARTCRAFTPCM’S/ECM’S· Guardian Active Due To: – Fau

Mercury Marine has partnered with SPX Corporation to develop a PC-baseddiagnostic system called “Computer Diagnostic System” or “CDS”. This system isd

Table of Contents496 Mag & 8.1S Calibrations that Reduce the Amount of Soot ProducedMercury MerCruiser Engine Emission Regulations Changes Effecti

CDS Section Table of ContentsComputer Diagnostic System Announcement Letter CDS / DDT Comparison Matrix CDS FAQ's Computer Diagnostic System Comp

Dear Mercury Trade PartnerIn recent years, Mercury Marine has made significant enhancements to our outboard andMerCruiser engines. These changes were

1-800-345-2233CDS DDTView and Clear – Current and Historic Codes4 lines displayed•10 lines displayed•Read Data Stream ItemsMerCruiser555 PCM / ECM ••G

The Computer Diagnostic System (CDS) is Mercury Marine’s next generation diagnostic tool. The tool replaces the Quicksilver (DDT) Scan Tool currently

CDS - Computer Diagnostic System -ComponentsDell Latitude Laptop ComputerPanasonic Toughbook Laptop Computer

SmartComms ModulePin Probe Kit & Loaded Volts Lead

Break-Out BoxNew Digital Meter With Serial Connection for Conectingto Laptop

Various Kit Configurations Available

Computer Requirements for running the Mercury ComputerDiagnostic System (CDS) software and hardware:· 900 MHz Pentium Processor· USB port· Windows 2

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496 Mag & 8.1S Calibrations that Reduce the Amount of SootProducedThere have been complaints of MCM 496 MAG and MIE 8.1s units, both Baseand H.O.,

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2004Product UpdateSection 2 Electrical Systems 2

Table of Contents 2005 SmartCraft DTS Updates Service/Repair of Electrical Test Equipment

2005496/8.1 DTS changes and over view of the new 5.0 DTS

DTS 496 / 8.1 New Harness Plug Locations

2005

• A twin 496/8.1L HO in a 33 Foot Boat, after 15 minutes at WOT. Old Cal New Cal496/8.1 Engine Soot Update

Mercury MerCruiser Engine Emission Regulations Changes EffectiveJanuary 1, 2003.The changes that become effective January 1, 2003, regarding emission

5.0L MPI – BRAVO DTSEngine Block: GM 5.0LEngine Controller: PCM 03Fuel Injection: Sequential Fuel InjectionTBU: 80mm ElectricFlame Arrestor Flow:

496/8.1 DTS/ Mech. 17 pin Transom harness Part # 84-865677a01

8.1 MIE DTS 17 pin transmission harness, ZF Hurth part # 84-865676a01

8.1 MIE mech. 17pin transmission harness, part #84-865769a01

Over view of the 5.0 DTS engine

5.0 shift actuator same as 496

MerCruiser U.S. advertised engine power ratingAlso, effective January 1, 2003 MerCruiser U.S. advertised engine power rating will be based oncrankshaf

From left to right; 4 pin diagnostics, 6 pin paddle wheel /fuel tanks,17 pin transom harness and 2 pin clean power top of bracket 14 pin Deutsch

Termination Resistors Can 1 Yellow Can 2 new Blue

HVS Cam sensor location used on Small Block DTS

80 MM Electronic Throttle Body same as 496/8.1 DTS

PCM 03 controller uses box part number 885558 same as used on 496/8.1 DTS engines

5 Relays used from left to right Trim down /Trim up /Fuel pump Main Power/Start relay. Small block DTS are used with Bravo Transom assy, with 3 wire S

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2005Product UpdateSection 3Exhaust and Cooling Systems 3

Table Of Contents MerCruiser Dry Joint Exhaust and Cooling System - V6, V8 Small Block MCM Exhaust Elbow Height Change

MerCruiserMerCruiserDry JointDry JointExhaust and Cooling SystemExhaust and Cooling SystemV6, V8 Small BlockV6, V8 Small Block

Strategy Behind MerCruiser Exhaust System Changes• Prevent Coolant Leaks.• Eliminate Water from Leaking into ExhaustPassages.• Help Prevent Reversion.

Start of Dry Joint System• MCM V6 Models: S/N 0M615000-UP.• MCM V8 Models: S/N 0M600000-UP.• MIE V8 Models: S/N 0M0317000-UP.

Dry Joint Design Changes• New Exhaust Manifold.• New Exhaust Elbow.• New Gaskets.• New Risers.

Dry Joint Gaskets• Built-in Turbulator– Traps Condensation From Elbow– Traps Water Reversion– Increases Local Flow Velocity• Water & Exhaust Separ

Dry Joint Gaskets• New Materials– 18 gauge 316 ss Core.– Two Layer 5000oF GrafoilTM, Seals Exhaust Passage.– High Temp 4 Bead Silicone Seals Water Por

Dry Joint Gaskets• Coat Edge of All Water Ports with Perfect Seal.• If Bare Metal on Gasket Surface, use PerfectSeal.