Mercury 3.0L Carbureted Alpha Specifications Page 12
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Turn Key Start (TKS) System
x This system will be installed on all carbureted engines. Production start
will be during August through October of 2004.
x Basic Design:
- Additional fuel is required during engine starting and warm up.
- The new design began with the current casting and components similar
to carbureted outboard.
- The casting was modified adding an additional fuel flow path
for the TKS
module.
- The TKS flow path is normally open and closes using a heat expanding
device coupled to a needle/seat. This device closes the additional fuel
flow path after receiving 12 Vdc for 6-10 minutes.
- The engine will run at an elevated RPM (900 – 1,000) for the 6-10
minutes and then return to the normal idle speed.
Carburetor with TKS
x Operation:
- The new carburetor operates in a manner very similar to the previous
MerCarb units, but now has the added benefit of having an additional
amount of fuel automatically provided to the engine during cold starts.
Pumping the throttle twice before starting the engine is no longer
necessary. You just turn the key to start the engine.
- Table Of Contents 1
- Produced 5
- Old Cal New Cal 6
- January 1, 2003 7
- :DUUDQW\ 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
- :$51,1* 35
- (OHFWULFDO 36
- 581SRVLWLRQ 36
- &KHFNLQJ)XHO3UHVVXUH 36
- ,Q:DWHU7HVW 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
- 6HUYLFH%XOOHWLQ 49
- 0LQLPXP6\VWHP5HTXLUHPHQWV 50
- 2UGHULQJ,QIRUPDWLRQ 50
- $GDSWHU&DEOH+DUQHVVHV 50
- 496/8.1 DTS changes and over 55
- 496/8.1 DTS/ Mech. 17 pin 72
- Transom harness Part # 84 72
- 865677a01 72
- 865676a01 75
- 496/8.1 DTS engines 84
- 6HUYLFH%XOOHWLQ 88
- Strategy Behind MerCruiser 94
- Exhaust System Changes 94
- Start of Dry Joint System 95
- Dry Joint Design Changes 96
- Dry Joint Gaskets 97
- Restrictor Gasket 100
- Full Flow Gasket 102
- Block Off Gasket 104
- Installation Reminder 106
- Dry Joint 14 107
- Exhaust Elbow 107
- Dry Joint Service Manual 108
- • Project Objectives 109
- Exhaust Elbow Height 110
- Exhaust Elbow Height 1.5” 111
- Elbow Only 111
- Exhaust Elbow Height 3.2” 112
- Elbow, 1.7” Riser 112
- Exhaust Elbow Height 4.5” 113
- Elbow, 3” Riser 113
- Exhaust Elbow Height 7.5” 114
- Elbow, 6” Riser 114
- Exhaust Elbow Height Summary 115
- Intermediate Pipes 117
- Product Update 123
- Table of Contents 124
- Quick Connects 125
- Gear Lube Bottle Relocation 126
- New Oil Reservoir 127
- Power Trim Quick Connects 128
- New Design 130
- Power Steering Quick Connects 131
- Transom Water Hose Fitting 133
- • Project 134
- • Benefits 134
- • Impact 134
- • Project Definition 135
- • OEM Impact 135
- MerCathode Assembly 136
- MerCathode Quick Connects 137
- Fuse change – Trim Pump 138
- New Trim Pump Harness 139
- New and Current Trim Pump 140
- Control Harness to Trim Pump 141
- Adapter Harnesses 141
- Adapter Harness 142
- Trim Pump Reservoir Cap 143
- Oil Bottle Float Change 144
- New Rear Engine Mount Design 145
- Drive Changes – June 2003 146
- Improved Engine Alignment 146
- Old and New Style Mounts 147
- Old Design Flywheel Housing 148
- Inner Transom Plate 149
- Flywheel Housing 149
- Rear Mount (old) 149
- Spring Washer 149
- New Design Flywheel Housing 150
- Rear Mount ( New) 151
- Boat Stringer 153
- Front Mount 153
- New Mount Design Lowers 153
- Engine To Height Specified 153
- In Installation Drawings 153
- 0RGHOV$IIHFWHG 154
- 6LWXDWLRQ 154
- ,QVWDOODWLRQ 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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