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3.0L Carbureted Alpha
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Mercury 3.0L Carbureted Alpha Specifications Page 55
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2005
496/8.1 DTS changes and over
view of th
e
new 5.0 DTS
1
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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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