Mercury 3.0L Carbureted Alpha manuals

Mercury 3.0L Carbureted Alpha Specifications (250 pages)

Brand: Mercury | Category: Engine | Size: 11.96 MB |

English

Table of contents

Table Of Contents

1

Produced

5

Old Cal New Cal

6

January 1, 2003

7

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10

Turn Key Start (TKS) System

12

Oil Pressure Switch

13

TKS Module

15

Project Objectives

17

• System Overview

18

• Installation Big Block

20

Big Block

21

Harnesses

25

• Service Diagnostic Tools

26

– CDS version 3.14 or higher

26

CARTRIDGE WILL BE AVAILABLE)

26

Gen III Cool Fuel System

27

System Overview

28

System Module Features:

29

System Overview:

30

Fuel Flow Through the System

31

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36

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36

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36

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37

Computer Diagnostic System

39

CDS Section Table of Contents

40

1 On The Water

42

Components

44

SmartComms Module

45

Break-Out Box

46

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49

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50

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50

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50

496/8.1 DTS changes and over

55

496/8.1 DTS/ Mech. 17 pin

72

Transom harness Part # 84

72

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72

865676a01

75

496/8.1 DTS engines

84

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88

Strategy Behind MerCruiser

94

Exhaust System Changes

94

Start of Dry Joint System

95

Dry Joint Design Changes

96

Dry Joint Gaskets

97

Restrictor Gasket

100

Full Flow Gasket

102

Block Off Gasket

104

Installation Reminder

106

Dry Joint 14

107

Exhaust Elbow

107

Dry Joint Service Manual

108

• Project Objectives

109

Exhaust Elbow Height

110

Exhaust Elbow Height 1.5”

111

Elbow Only

111

Exhaust Elbow Height 3.2”

112

Elbow, 1.7” Riser

112

Exhaust Elbow Height 4.5”

113

Elbow, 3” Riser

113

Exhaust Elbow Height 7.5”

114

Elbow, 6” Riser

114

Exhaust Elbow Height Summary

115

Intermediate Pipes

117

Product Update

123

Table of Contents

124

Quick Connects

125

Gear Lube Bottle Relocation

126

New Oil Reservoir

127

Power Trim Quick Connects

128

New Design

130

Power Steering Quick Connects

131

Transom Water Hose Fitting

133

• Project

134

• Benefits

134

• Impact

134

• Project Definition

135

• OEM Impact

135

MerCathode Assembly

136

MerCathode Quick Connects

137

Fuse change – Trim Pump

138

New Trim Pump Harness

139

New and Current Trim Pump

140

Control Harness to Trim Pump

141

Adapter Harnesses

141

Adapter Harness

142

Trim Pump Reservoir Cap

143

Oil Bottle Float Change

144

New Rear Engine Mount Design

145

Drive Changes – June 2003

146

Improved Engine Alignment

146

Old and New Style Mounts

147

Old Design Flywheel Housing

148

Inner Transom Plate

149

Flywheel Housing

149

Rear Mount (old)

149

Spring Washer

149

New Design Flywheel Housing

150

Rear Mount ( New)

151

Boat Stringer

153

Front Mount

153

New Mount Design Lowers

153

Engine To Height Specified

153

In Installation Drawings

153

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154

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154

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155

Cast in Switch Guide

159

Shift Plate Assemblies

160

Drive Initiatives – June 2003

162

Intermediate Shift Cable

162

Alpha / Bravo Shift Cables

163

New Alpha One Generation II

167

91-864497

168

Bravo Engine Couplers

171

Proposed New Design Bravo

172

Engine Coupler

172

Proposed Bravo Gas Engine

173

Coupler Design

173

Bravo Universal Joint Assy

174

Comparison of Rockwell to

175

GKN U-Joint Repair Parts

176

Alpha / Bravo Std

176

Rockwell U-Joint Assembly

177

Bravo Standard

178

GKN U-Joint Assembly

178

Bravo “X”

179

Bravo (X)

180

U-Joint Assemblies

180

Housing Chimney Bearing

190

91-90778 91-90777T1

193

Bravo III Changes for 2003

199

Propeller shaft Anode

200

Bravo III Bearing Carrier

201

Bravo Three Bearing Carrier

203

Damage / Propeller Defect

203

New Thrust Bearing

207

New Shaft Marking

208

Older Shaft Markings

208

Drive Initiatives – May 2004

210

Bravo Shift Lever Detent

211

Bravo Cone Clutch Redesign

214

Bravo Styling

216

Bravo Drive Shaft Housing

217

Introducing the New Bravo

219

Jan, 2004 Shimming process

219

Bearing Race and Chart

222

• Gear Tooth Count Gear Lash

223

New Shimming Tools Required

224

• Standard Bravo

225

• All Bravo X models

225

Gear Lash Flags for the new

226

Handle Fixture for checking

228

Gear Lash

228

Driven Gear Clamp Tool

229

New Shimming procedure for

230

Bravo Upper 2004

230

New Shimming procedure

231

CSI Info and FAQ

246

Frequently Asked Questions

247

CUSTOMER SATISFACTION SURVEY

249

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