Mercury INSTALLATION MANUAL D7.3L D-TRONIC Bedienungsanleitung

90-861 180990 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. INST ALLA TION MANUAL D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS NOTICE to INST ALLER After Completing Inst[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 2 of 90 General Information Notice to Installer Throughout this publication, “W arnings” and “Cautions” (accompanied by the International Hazard Symbol ! ) are used to alert the installer to special instructions concerning a partic- ular service or operation that may be hazardous if perform[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 3 of 90 W ARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOA TS EQUIPPED WITH THESE EN- GINES, UNLESS PROVISIONS HA VE BEEN MADE TO EXCLUDE GASOLINE V A- PORS FROM ENGINE COMP ARTMENT (REF: 33 CFR). Failure to comply could[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 4 of 90 Multiple Sterndrive Steering Tie Bar Arrangements With multiple sterndrives it is important to consider which of several possible steering sys- tems should be selected. CAUTION Failure to observe the recommended Tie Bar Arrangements as presented in this section could result in serious damag[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 5 of 90 Quicksilver Products ACCESSORIES Quicksilver remote controls, steering systems, propellers, etc. are available for this product. Refer to “Quicksilver Accessories Guide” for complete listing. This “Guide” is available from: Attn: Parts Department Mercury Marine W6250 W . Pioneer Roa[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 6 of 90 T orque Specifications DESCRIPTION TORQUE DESCRIPTION lb-in. lb-ft Nm Speedometer Pickup Barb Fitting 10-15 1.2-1.6 Exhaust Pipe or Block-off Plate 20-25 27-34 Power Steering Hydraulic Hose Fittings 20-25 27-34 Power T rim Pump Hose Fittings 100-150 1 1-16 Propeller Nut (Bravo One and T wo)[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 7 of 90 Antifouling Paint IMPORT ANT : Corrosion damage that results from the improper application of anti- fouling paint will not be covered by the limited warranty . Painting Boat Hull or Boat T ransom: Antifouling paint may be applied to boat hull and boat transom but you must observe the follow[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 8 of 90 Installation Requirements Boat Construction TRANSOM 22170 22033 b c f a d e e a- T ransom Thickness - 2 in. (51mm) Minimum to 2-1/4 in.(57mm) Maximum b- Inner Surface of T ransom Must Be Parallel Within 1/8 in. (3mm) in Area Covered by T ransom Plate (e) and Remain Within T ransom Thickness[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 9 of 90 ENGINE COMP ARTMENT W ARNING Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad- hered to when constructing the engine compartment. Care must be exercised in the design and construction of the engine compartment. Seams must be located so that any rain water , which [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 10 of 90 Multiplying the engine air flow (cfm) by 0.1 will generally determine the combustion air vent size requirement (per engine) . Therefore: Engine Combustion Air Flow (cfm) X 0.1 = Combustion Air V ent Area Per Engine (Square Inches) OR Engine Combustion Air Flow (m 3 /min.) X 22.8 = Combusti[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 1 1 of 90 Exhaust System IMPORT ANT : It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install the exhaust system. Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine. Dam[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 12 of 90 Some engines may be equipped with a factory installed exhaust riser . V erify that the riser provides the required dimension “c”, or a distance greater than “c”, as indicated. Model (c) = (a) Minus (b) All Models (c) Must Be 13 in. (330 mm) or More merCruiser a c d b 76076 T ypical[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 13 of 90 4. Th e tank breather pipe must have an inner diameter of at least 1/2 in. (13mm) and must be fitted with a swan neck to prevent water from entering the tank. It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to preve[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 14 of 90 Battery IMPORT ANT : Boating industry standards (BIA, ABYC, etc.) federal standards and Coast Guard regulations must be adhered to when installing battery . Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accor[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 15 of 90 EDI Electrical System Precautions NOTE: The following precautions apply to all EDI model Engines. CAUTION A void damage to the Electronic Direct Injection (EDI) electrical system and compo- nents. Refer to the following precautions when working on or around the EDI electri- cal harness or [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 16 of 90 76010 a c b D7.3L D-T ronic Shown - All Similar a- Engine Harness Connector b- Extension Harness Connector (From Instruments) c- Electrical Bracket T ACHOMETER SPECIAL INFORMA TION IMPORT ANT : If using a tachometer from another manufacturer , do not use the mag- netic tachometer pickup (o[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 17 of 90 Propeller Selection GENERAL INFORMA TION IMPORT ANT : Installed propeller must allow engine to run at its specified maximum wide-open-throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 18 of 90 Hot W ater Heater Installation Recommendation IMPORT ANT : When connecting a cabin heater or hot water heater , certain require- ments must be met, including, but not limited to the following: • Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 19 of 90 RETURN HOSE CONNECTION 76023 a a- Location on W ater Circulation Pump for Hot W ater Return (Bayonet Fitting Replaces Plug) Seawater Connections D7.3L D-T ronic and D7.3L D-T ronic LD models must be equipped with a through hull or through transom water supply to ensure sufficient water flo[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 20 of 90 SEA W A TER STRAINER Strainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling the engine. Seawater Strainer Minimum Flow Rate 1 All Models 40 (150) 1 Amount listed is in gallons per minute and (liters per minute). Install seawater s[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 21 of 90 Steering Helm and Cable T ransom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification hand- book. The steering cable coupler nut must also have a means of locking it to the guide t[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 22 of 90 CAUTION POWER STEERING EQUIPPED UNITS ONL Y : If steering cable with improper dimen- sions is installed, severe damage to transom assembly and/or steering system may result. 1. Steering cable must be the correct length, particularly when installed in larger boats. 2. Avoid sharp bends, kin[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 23 of 90 T ransom Cutout NOTICE to INST ALLER Before Starting Installation Read “General Information” and “Installation Requirements” Sections Completely . IMPORT ANT : The following instructions will provide a sterndrive unit mounting loca- tion that is suitable for most boats. Best mounti[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 24 of 90 Finding Crankshaft V ertical Centerline SINGLE ENGINE Locate and mark vertical centerline on transom. 71620 a a- V ertical Centerline DUAL ENGINE 1. Locate and mark boat vertical centerline (a) on transom. 71620 a a- V ertical Centerline 2. Locate and mark crankshaft vertical centerlines ([...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 25 of 90 Finding Crankshaft Horizontal Centerline (“X” Dimension) “X ” Dimension can be measured b y the “90 ° T ool Method” or by the “T ape Measure Method.” 90 ° TOOL METHOD 1. Construct 90 ° tool. 71621 90 ° b a a- Dimension from Chart Below b- Measurement: 4 ft. (1.2 m) T o [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 26 of 90 T APE MEASURE METHOD T ransom angle must be known, then measure “X” Dimension with tape measure. 1. Determine “X” Dimension from the following chart. T ape Measure Method Chart Model Bravo One / T wo / Three T ransom Angle This dimension should only be raised or lowered after prope[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 27 of 90 Cutting T ransom T ransom cutout can be made by either using the T emplate [shipped with transom assembly] or the T ransom Drilling Fixture Kit (purchased separately). Follow instructions indicated on template or provided with drilling fixture. IMPORT ANT : Read and observe the following i[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 28 of 90 Checking T ransom Thickness Ensure transom surface thickness and flatness conform to minimums specified in “Installa- tion Requirements” listed previously . NOTE: T ransom must be between 2” (51 mm) and 2-1/4” (57 mm) a distance of 8” (203 mm) to either side of the vertical cente[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 29 of 90 Installing T ransom Assembly Gimbal Housing 1. Carefully remove transom assembly from shipping carton. 2. Remove and read all tags which are attached to transom assembly . IMPORT ANT : Read and observe the following regarding your engine and the thru- propeller exhaust system: • With any[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 30 of 90 Inner T ransom Plate 1. Insert wires, hoses and shift cable through appropriate openings in inner transom plate. 2. Position gimbal housing on transom and hold in place. NOTE: When tightening transom assembly fasteners in the following step, start in the center and, using a circular patter[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 31 of 90 Power T rim Pump 1. Mount pump in desired location. IMPORT ANT : Make hydraulic connections as quickly as possible to prevent oil from leaking out of system. Be careful not to cross-thread or overtighten hose fittings. 75126 50630 75127 50632 a c d e f g b a- Black Hose (UP Circuit) b- Gra[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 32 of 90 Steering System NOTE: For Dual Installations, Power steering unit can be mounted on port or starboard transom assembly . Measure exact distance between power package centerlines. Select a ti e bar from Quicksilver Accessory Guide. Refer to tie bar installation instructions before pro- ceed[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 33 of 90 4. T orque pivot bolts to 25 lb-ft (34 Nm). Bend washer tabs against corresponding flats on bolt heads. CAUTION MOVING THE CONTROL V AL VE RAM with the hoses disconnected will expel fluid from the ports. Wear eye protection. 5. T he cylinder ram may be stiff and difficult to move when you [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 34 of 90 7. Connect steering cable as follows: a. Remove shipping cap from both ends of steering cable guide tube. b. Coat steering cable end with a liberal amount of Special Lubricant 101. c. Install steering cable and secure with hardware as shown. 71901 71906 71903 g h f e d a b c 73901 d a- Ste[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 35 of 90 Speedometer Pickup IMPORT ANT : Do not disturb plug at speedometer fitting if no speedometer is to be fitted, or if an alternate speedometer pickup will be used. 1. Remove plug from speedometer pickup tube fitting. 70037 a b a- Fitting Plug b- Speedometer Pickup T ube Fitting 2. Apply Perf[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 36 of 90 3. Route hose to monitor bottle mounted on engine and cut off excess hose. IMPORT ANT : A void using excessive hose when routing to gear lube monitor . Hose should be routed directly , in as straight a line as possible, to avoid low spots (traps) in the system. 75313 74235 75874 a d c b a-[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 37 of 90 Drive Unit Seawater Routing Seawater for engine cooling is supplied through a separate seawater pickup, not through the drive unit. Therefore, it is necessary to block the drive unit seawater passage and to cut th e water hose that is located between the bell housing and the gimbal housing[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 38 of 90 SEA W A TER HOSE NOTE: The trim limit switch wires and speedometer hose are attached to the water hose. Prior to cutting the hose, move the wires and speedometer hose to avoid cutting them when cutting water hose. The existing sta-strap and clip can be reused if they are moved out of the w[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 39 of 90 Engine Installation Engine Preparation 1. Remove and read all tags attached to engine. 2. Remove all hardware that secures engine to shipping container . 3. Loosen fasteners and remove exhaust pipe and exhaust hose from pallet. 4. Connect battery cables to engine. Be sure to observe the fo[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 40 of 90 T ransom Preparation IMPORT ANT : Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches, and O-ring must be properly seated in groove, or water and exhaust may leak into boat. 22059 a b a- Gimbal Housing Mating Surface b- O-ring 1. Install exhaust pi[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 41 of 90 Installing Engine / Alignment 1. Attach a suitable sling to lifting eyes on engine and adjust 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 ou[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 42 of 90 3. Align rear engine mounts with inner transom plate mounts. Set engine onto front mounts and inner transom plate mounts, while simultaneously aligning exhaust elbow with ex- haust tube. (Do not relieve hoist tension.) nd IMPORT ANT : Engine attaching hardware must be installed in sequence[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 43 of 90 7. Attach chain and hooks from suitable engine sling to starboard front lifting eye and port mounted Engine Lifting Eye T ool. 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[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 44 of 90 CAUTION DO NOT use an alignment tool from another manufacturer . Alignment tools other than Quicksilver Alignment T ool may cause improper alignment and damage to gimbal bearing and/or engine coupler . CAUTION T o avoid damage to gimbal bearing, engine coupler , or alignment tool:  DO N[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 45 of 90 IMPORT ANT : Finished boat stringer must position engine so that a minimum mount adjustment exists after front mount is adjusted down to stringer . This allows for fu- ture adjustments. 9. Adjust front mount assembly until it touches stringer . 10. Recheck alignment with alignment tool. T [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 46 of 90 Engine Connections Quicksilver Seawater Pickup and Seacock 1. Drill a 2 in. (50mm) hole thru hull in appropriate location (Refer to “Installation Require- ments.”). 2. Apply m arine caulking (sealer) to mounting surface on seawater pickup (thru-hull fitting) where hull contact will occ[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 47 of 90 Seawater Strainer When using a seawater strainer other than Quicksilver Seawater Filter (Part Number 35-801763739) refer to manufacturer ’s instructions for installation, operation and mainte- nance. Refer to the following when installing and connecting Quicksilver seawater strainer . IM[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 48 of 90 Closed Cooling Recovery Bottle 1. Connect plastic tubing (from kit) to bayonet fitting on heat exchanger . Secure with tubing clamp provided. 2. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: a. Within limits of clear plastic tu[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 49 of 90 Fuel Lines 1. Connect flexible fuel line to fuel supply fitting. Secure with hose clamp. 2. Connect flexible fuel line to fuel return fitting. Secure with hose clamp. 76027 a b a- Fuel Supply Fitting b- Fuel Return Fitting Power Steering Hydraulic Hoses CAUTION Route hoses exactly as shown[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 50 of 90 Exhaust System 1. T ighten exhaust tube hose clamps securely . 76106 d c b a T ypical a- Elbow b- T ube c- Hose Clamps (4) d- Pipe Electrical Connections CONTINUITY CIRCUIT 1. Connect continuity circuit wire (supplied with engine package) from engine to transom assembly . T ighten inner tr[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 51 of 90 INSTRUMENTS AND EXTENSION HARNESSES NOTE: If using other than Quicksilver instrumentation and harnesses, refer to manufactur- ers’ instructions. 1. Follow the appropriate instructions “a”, “b” and/or “c”, depending upon boat configura- tion: a. Prepare dash openings and/or mo[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 52 of 90 3. Refer to Quicksilver Instrumentation Wiring Diagram. Using screws provided, connect the listed color coded wires to numbered switch terminals as shown. D7.3L D-T ronic Harness Wire (Color Code) Connect T o: T erminal Number 16C BLACK (BLK)  2 40A YELLOW (YEL)  1 L T1 BLUE (BLU) ?[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 53 of 90 NEUTRAL SAFETY SWITCH CONNECTION 1. Connect neutral safety switch wires at instrument panel and remote control. Refer to ap- propriate wiring diagram. Secure connections as shown and coat with Liquid Neoprene. Slide rubber sleeve over connections. YEL/RED YEL/RED RED 36BC2 PUR 36BC3 PUR 36[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 54 of 90 Shift Cable Installation and Adjustment NOTE: Shift Cable Adjustment T ool (91-12427) allows the shift cables to be installed and adjusted, with or without the sterndrive attached. IMPORT ANT : The direction of propeller rotation (RH or LH) for this drive unit is deter- mined by the follow[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 55 of 90 4. Install drive unit shift cable. 23345 a b c a- W ashers (2) b- Lock Nut - T ighten Until Contact, Then Back Of f 1/2 T urn c- Cotter Pin - Insert from T op and Spread Both Ends 5. Place adjustment tool over drive unit shift cable, as shown. Hold tool in place, using a piece of tape over[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 56 of 90 7. Adjust remote control shift cable as follows: a. T emporarily install shift cable end guide into shift lever , and insert anchor pin. b. Adjust shift cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of co[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 57 of 90 10. Shift remote control lever into full forward position. Place end of adjustment tool in barrel retainer . RH ROT A TION BRA VO ONE, TWO, THREE AND BLACKHA WK MODEL: Rear slot in tool should fit over shift lever stud. LH ROT A TION BRA VO ONE AND TWO: Forward slot in tool should fit over[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 58 of 90 T roubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into forward gear . 1. When installing the control box in the side panel of the boat, make sure that the[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 59 of 90 4. D o not strap or clamp the control cables to any other cables or rigid structure within three feet of the control box. 5. Be sure the cable is not permanently kinked. 6. Make sure there is proper clearance for cable movement when the control box is installed in the side panel. The cable[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 60 of 90 Throttle Cable Installation and Adjustment IMPORT ANT : When installing throttle cables, be sure that cables are routed in such a way as to avoid sharp bends and/or avoid contact with moving parts. DO NOT fasten any items to throttle cables. 1. Place remote control lever(s) in neutral/idle[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 61 of 90 76025 a b c d Single Cable Shown (Dual Similar) a- Accelerator Position Sensor (APS/IVS) b- APS/IVS Anchor Stud c- Cable Barrel End Bracket d- Cable Barrel Anchor Stud b c d d a c e e a- Throttle Cable End Guide b- Cable Barrel c- Anchor Stud d- Flat W asher and Locknut e- Spacer - With Du[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO 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 b a- Gear Lube Monitor b- Cap 3. Push in on dribble valve until gear lube appears. 72471 a a- Dribbl[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO 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 T ypical a- Splines b- O-rings[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 64 of 90 9. Check drive shaft bellows for cleanliness and absence of debris. 72472 a a- Driveshaft Bellows 10. Lubricate O-ring seals with 2-4-C Marine Lubricant. 72183 a a- O-Ring Seals 1 1. Pull out shift linkage as far as it moves. “Jaws” will open, as shown. 72460 a a- Shift Linkage IMPORT [...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 65 of 90 12. Place Remote Control in neutral position. NOTE: A s bell housing shift cable enters the shift linkage assembly , it pushes the assembly back into the sterndrive housing, and the “jaw” closes, securing the cable, as shown in steps “A”, “B” and “C”. 72467 C B A IMPORT ANT[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 66 of 90 14. Secure drive unit to bell housing with 5 flat washers and 6 locknuts. T orque to 50 Ib. ft. (68 N ⋅ m). 71244 b a a- Do Not Install Flat W asher Here b- Elastic Stop Nuts (6) and Flat W ashers (5) IMPORT ANT : On Bravo One, T wo and Three Models, the “T rim-In Limit Pin Insert” m[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 67 of 90 IMPORT ANT : The position of the T rim-In Limit Pin on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested. Refer to statement at the front of this manual entitled; “Bravo Three Notice: T rim-In Limit Pin”. IMPORT ANT : T o aid in installing r[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 68 of 90 18. On All Drive Units - Perform steps 19 through 21. 19. Raise drive to gain access to area 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[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 69 of 90 Predelivery Preparation NOTICE Before starting Predelivery read “General Information” and “Installation Requirements” completely . Battery Connection IMPORT ANT : Engine electrical system is negative (–) ground. 1. Connect engine positive (+) battery cable (usually RED) to positi[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 70 of 90 22031 a a- Fill Neck 3. Check all trim line connection points for leaks. If fluid is visible at fittings, tighten fitting(s). T orque fitting(s) to 100-150 lb-in. (1 1-16 Nm). T rim Position Sender Adjustment 1. Loosen both trim position sender attaching screws. 71220 a b a- Attaching Scre[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 71 of 90 4. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown. 71671 a a- T rim Gauge Needle 5. T ighten retaining screws and turn ignition key to the “OFF” position. 71220 a b a- Retaining Screws b- T rim Position Sender[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 72 of 90 Power Steering Fluid IMPORT ANT : Use only Quicksilver Power T rim and Steering Fluid, or Dexron III auto- matic transmission fluid (A TF), in power steering system. CAUTION DO NOT RUN POWER STEERING DR Y , or pump will be damaged. 1. Position drive unit so that it is straight back. 2. Rem[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 73 of 90 1. With drive in full down position, remove oil vent screw . CAUTION Failure to fill drive unit to level of vent hole will result in a low drive oil level. Gear lube monitor only MAINT AINS drive oil level and will not correct an improperly filled drive unit. 2. Fill gear lube monitor with[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 74 of 90 2. Install propeller with attaching hardware as shown. T ighten nut a minimum of 55 lb-ft (75 Nm), then continue to tighten until 3 tabs on the 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-T[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 75 of 90 BRA VO THREE IMPORT ANT : Correct rotation propeller MUST match direction of rotation of propeller shaft. W ARNING Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller . W ARNING Place a block of wood between the anti-vent[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 76 of 90 T est Running Engine W ARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOA TS EQUIPPED WITH THESE EN- GINES, UNLESS PROVISIONS HA VE BEEN MADE TO EXCLUDE GASOLINE V A- PORS FROM ENGINE COMP ARTMENT (REF: 33 CFR). F[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 77 of 90 8. Refer to “Operation and Maintenance Manual” and start engine. Run at idle rpm until water temperature is normal. 9. W atch all gauges for normal readings. 10 . Tur n steering wheel starboard, then port, and check to ensure drive unit turns the correct way . 1 1. Inspect engine compa[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 78 of 90 14. Restart engine and observe drive unit. If drive unit creeps, an external tension may exist on steering cable. Ensure that there 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 i[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 79 of 90 Boat-In-The-W ater T ests IMPORT ANT : Engine alignment MUST BE CHECKED with boat in the water , fuel tanks filled, and with a normal load onboard. IMPORT ANT : DO NOT perform the following with boat in a test tank or tied to dock. ENGINE INITIAL BREAK-IN PROCEDURE It is especially importa[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 80 of 90 IMPORT ANT : T o run engine at maximum rpm before the Engine 20-Hour Break-In Pe- riod is complete, follow this procedure only after the Engine Initial Break-in Proce- dure has been completed: 1. Complete Engine Initial Break-In Procedures if not already accomplished. 2. Start engine and r[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 81 of 90 Cold Weather or Extended Storage Draining Instructions CAUTION If Power Package will not be used for an extended period of time or will be exposed to freezing temperatures, drain water from seawater section of cooling system. W ater MUST BE drained to prevent corrosion and freeze damage to[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 82 of 90 1. Close seacock, if so equipped, or disconnect and plug seawater inlet hose, if boat is to remain in the water . 2. Remove and drain the following: a. T h e end covers from both the port and starboard sides of heat exchanger . Drain tank completely . IMPORT ANT : Use compressed air to blo[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 83 of 90 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. 4. Remove seawater pump outlet hose from top of seawater pump and drain. 76107 b a a- Seawater Pump b- Outlet Hose CAUTION A void water entering boat. Do not unplug or disconnect seawat[...]

73962 BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRA Y GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TA N = TA N WHT = WHITE YEL = YELLOW L T OR LIT = LIGHT DRK = DARK b c d e f g h a D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 84 of 90 Power T rim System Wiring Diagram a- 20 Amp Fuse b- Ground Bolt (Floor Mount) c- “UP” Solen[...]

BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRA Y GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TA N = TA N WHT = WHITE YEL = YELLOW L T OR LIT=LIGHT DRK = DARK 73596 a b c D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 85 of 90 MerCathode System Wiring Diagram a- Controller b- 20 Amp Fuse c- Electrode[...]

BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red T A N=T a n WHT = White YEL = Y ellow 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 - BRA VO MODELS Page 86 of 90 Quicksilver Instrumentation Wiring[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 87 of 90 1- V oltmeter Gauge 2- T achometer Gauge 3- W ater T emperature Gauge 4- Oil Pressure Gauge 5- T rim Gauge 6- Engine System Monitor Panel a - Check Engine Light b - Engine Coolant High T emperature / Low Gear Lube Monitor Light c - Oil Pressure W arning Light d - Charge Indicator Light e -[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO 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[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 89 of 90 SEA W A TER COOLING CIRCUIT (RA W W A TER) 1 - Seawater Inlet 2 - Seawater Strainer 3 - Seawater Pump 4 - Aftercooler 5 - Engine Oil Cooler 6 - Heat Exchanger (Seawater Circuit) 7 - Power Steering Fluid Cooler 8 - Exhaust Pipe W ater Jacket 9 - Seawater Outlet (Exhaust) 10- Seawater Outlet[...]

D7.3L D-TRONIC DIESEL ENGINES - BRA VO MODELS Page 90 of 90 Predelivery Inspection Not Check/ Applicable Adjust Not Check/ Applicable Adjust CHECK BEFORE RUNNING ON THE W A TER TEST Drain plug in and petcocks Engine alignment (Inboards only) closed Seawater inlet valve open Starter neutral safety switch operation Engine mounts tight W ater pump ope[...]