Mercury 3.0L Carbureted Alpha Specifications Page 126
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Gear Lube Bottle Relocation
• Project Definition
– Relocate gear lube bottle to eliminate
interferences
– Add inline quick connection to lube line
• Benefits
– Eliminate improper connection
between hose and gimbal housing due
to space limitations
– Reduce installation time
– SN 0M640000 and up
• Start of Production
– March 10, 2003 - completed
Previous
Design
Released
Design
Inline Quick Connect
- 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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