Table Of Contents Section 1 - Fuel Systems Section 2 - Electrical Systems Section 3 - Exhaust and Cooling Systems Section 4 - Transom Assemblies Section 5 - Sterndrives Section 6 - Customer Satisfaction Index 2005_MerCruiser_Product_Update (0804)
1 2005 Product Update Section 1 Fuel Systems
Table of Contents 496 Mag & 8.1S Calibrations that Reduce the Amount of Soot Produced Mercury MerCruiser Engine Emission Regulations Changes Effective January 1, 2003. MerCruiser U.S. advertised engine power rating 2002 Built Carbureted Engines with Sealed Idle Mixture Screws. Electric Fuel Pump Troubleshooting Quad-Rings and O-Rings for Fuel Pressure Gauge Schrader Valve Adaptor Kit, P/N 91-803135.
496 Mag & 8.1S Calibrations that Reduce the Amount of Soot Produced There have been complaints of MCM 496 MAG and MIE 8.1s units, both Base and H.O., causing soot deposits on boats. A new calibration has been released that significantly reduces the amount of soot produced. These calibrations will be available through P&A in replacement PCM's. Whether, or not, a boat will develop soot deposits is very much dependent on the boat design, especially the exhaust locations and transom configuration.
496/8.1 Engine Soot Update • A twin 496/8.1L HO in a 33 Foot Boat, after 15 minutes at WOT.
Mercury MerCruiser Engine Emission Regulations Changes Effective January 1, 2003. The changes that become effective January 1, 2003, regarding emission regulations, pertain to all Mercury MerCruiser gas Sterndrives, Inboards and Tow Sports models, as well as the Scorpion 377 and HP500 EFI Racing Sterndrive (hereafter referred to as MerCruiser engines) certified to California emissions standards.
MerCruiser U.S. advertised engine power rating Also, effective January 1, 2003 MerCruiser U.S. advertised engine power rating will be based on crankshaft rather than propshaft measurement. We will continue to use the same SAE J1228/ISO 3046 rating protocol that we use now, which allows for either form of rating. The rated horsepower will not change from the current values since both methods of rating may yield similar values within the tolerances specified by the standard.
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Quad-Rings and O-Rings for Fuel Pressure Gauge Schrader Valve Adaptor Kit, P/N 91-803135. The following is a list of replacement sealing components for this Adaptor Kit. Qty. 1 1 Snap-On P/N 8-4814 8-4914 2 8-4614 Description Quad-Ring for GM style schrader valve adaptor. Quad-Ring for MC (Ford) style schrader valve adaptor. O-Ring, 1 ea. for GM and MerCruiser (Ford) style schrader valves. Mercury Parts does not stock these replacement quad-rings or o-rings.
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.
- TKS fuel path is in the normally open position. Electric power causes a wax expanding device to expand thus causing the needle to meet the seat and close the additional TKS fuel path. x Electric Paths: - There are two paths for electricity to get to the module: one via an additional oil pressure switch and one via an additional engine coolant switch. - Additional Oil Pressure Switch: An oil pressure switch is added to the system using a “T” fitting.
- Additional Coolant Temperature Switch: A second switch has been added to the system and it is located in a new thermostat housing on the 3.0L models and in the intake manifold coolant passage on V6 and Small Block V8 models. This switch is used to keep the TKS unit from opening (when the engine is warm), which prevents additional fuel from entering the engine under hot re-start conditions. One lead is wired to the circuit breaker (i.e.
x Troubleshooting and Repair: - The TKS system has very few repair parts: The TKS Module The oil pressure switch The coolant temperature switch and diode TKS Module - There are essentially three failure modes: Hard Starting – Cold In this mode, the TKS fuel path is closed. As the module is normally open, there are 3 possible root causes: - Continuous power is getting to the TKS module - Debris in the TKS fuel path - The TKS module has failed Hard Starting – Hot In this mode, the TKS fuel path is open.
x TKS Retro Fit Kit - Retro Fit Kits will be available for all engine lines, at the end of the year (2004): 3.0 L 4.3 L 5.0 L 5.7 L 1996 – 2004 1998 – 2004 1998 – 2004 1998 – 2004 - Anti-Dieseling Kits are not compatible with TKS carburetors or Retro Fit Kits.
MEFI III to IV Conversion Kits • Project Objectives – Provide long term resolution to availability issues with MEFI III ECM – Prioritize highest volume service ECMs for conversion – started in 2004 season
MEFI III to IV Conversion Kits • System Overview – MEFI IV ECM which physically appears the same as a MEFI III • Pin out locations are different • Coil driver is not internal – Calibrations have been directly converted into MEFI IV code
MEFI III to IV Conversion Kits • • Kit Components – MEFI IV ECM – Cross-Over harness – Secondary harnesses – Coil driver with heat sink – Coil driver bracket – Hardware – Instruction sheet Kit Models – 350 MPI & MIE 350 MPI FWC – 6.2 MPI – 7.4 MPI & MIE 7.4 MPI FWC – 454 MPI & MIE 454 MPI FWC – 502/8.2 MPI & MIE 8.2 MPI FWC – 4.3 EFI – 5.0 EFI – 5.
MEFI III to IV Conversion Kits • Installation Big Block – Mount the MEFI IV ECM with existing hardware – Connect the J1 & J2 connections on the crossover harness – Connect ground wire to flywheel housing bolt that has no other ground connection on it
MEFI III to IV Conversion Kits Big Block
MEFI III to IV Conversion Kits Big Block
MEFI III to IV Conversion Kits Big Block
MEFI III to IV Conversion Kits • Installation Small Block – Mount the MEFI IV ECM with existing hardware – Connect the J1 & J2 connections on the crossover harness – Mount coil driver/bracket to relay bracket • Alpha requires spacer and screw provided • Bravo remove and retain rear MerCathode and rear relay bracket screw for mounting – MPI models connect coil driver harness to crossover harness then to coil driver – EFI models connect coil driver Y harness to crossover harness then to coil driver • Route Y
MEFI III to IV Small Block Kit Harnesses
MEFI III to IV Conversion Kits • Service Diagnostic Tools – CDS version 3.14 or higher (Version 4.18 or higher for fuel pressure data stream correction) – MerCruiser Scan Tool version 4.
Gen III Cool Fuel System System features: · Single Integrated Module - Filter, pumps, pressure regulator and cooler, all in one unit - Fuel flows through filter before getting to lift pump · More Reliable - Fewer components - Fewer fuel paths · Better Accessibility · “Production-Friendly” - Eliminates installation of separate pre-filter at OEM · Re-usable, consumer serviceable filter element - Pull element, dump water, re-install, continue voyage
This system will be standard on: · Small-Block MPI V8 Bravo · Small-Block MPI MIE · Big-Block MPI Sterndrive · Big-Block MPI MIE It will not be available on: · V6 Sterndrive · Small-Block Ski · Small-Block Alpha System Overview · Water Separating Filter Element · 2 pumps – Lift & Pressure - Lift pump - Gerotor - Pressure pump – Turbine · Fuel Pressure Regulator - New 288 kpa (~42 psi) regulator - O-rings seal between OD on regulator and ID in cover, rather than a face seal and return hose
System Module Features: · Dual Pump Configuration - Improved Vapor Lock resistance compared to engines equipped with current boost pumps · Corrosion Protection - Strontium-coated Internal water passage (same as outboards) - External housing e-coated · Engine Installation - Low profile water connection, disconnect as required during engine installation - 3/8 NPTF thread inlet fuel connection · Service Access - Modules located above front engine mount brackets in all applications · Water Jacketed - P
System Overview: Heat Exchanger (housing - casting) Fuel pressure Regulator Water Outlet Low pressure pump Check Valve (in pump) Fuel Filter High Pressure Pump To Engine (Fuel Rail) Water Inlet 1st stage relief (10 psi) Pressure Regulator Water Separating Fuel Filter Water Jacket High Pressure Pump Lift Pump ( Boost Pump)
Fuel Flow Through the System "2-Story" Water Flow Path
Cool Fuel III System - Mounted on Small-Block Engine
Gen III Cool Fuel Module
NOTE: This is a preliminary copy and it is subject to change.
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Digital Diagnostic Terminal (DDT) Cartridge - 1.31 Version WHAT’S NEW FOR CARTRIDGE VERSION 1.
Computer Diagnostic System Mercury Marine has partnered with SPX Corporation to develop a PC-based diagnostic system called “Computer Diagnostic System” or “CDS”. This system is designed to aid the dealership technician by reducing the diagnostic times required to identify the root cause of electrical and electronic fuel controlled system problems.
CDS Section Table of Contents Computer Diagnostic System Announcement Letter CDS / DDT Comparison Matrix CDS FAQ's Computer Diagnostic System Components Computer Requirements for running the Mercury Computer Diagnostic System (CDS) software and hardware Computer Diagnostic System – Service Bulletin 2004-04
Dear Mercury Trade Partner In recent years, Mercury Marine has made significant enhancements to our outboard and MerCruiser engines. These changes were made to improve reliability, performance and increase customer satisfaction with our products. These same changes also made our engines more complex and sometimes more difficult to diagnose problems. Mercury Marine has expended considerable effort in developing a system that will simplify troubleshooting problems with these more complex engines.
CDS View and Clear – Current and Historic Codes 4 lines displayed 10 lines displayed Read Data Stream Items MerCruiser 555 PCM / ECM GM MEFI Thunderbolt V Outboard 555 PCM / ECM 2000 and prior DFI ECM 2.5L with 824003 ECU 3.0L Fuel ECM 3.0L Ignition ECM 2.
The Computer Diagnostic System (CDS) is Mercury Marine’s next generation diagnostic tool. The tool replaces the Quicksilver (DDT) Scan Tool currently used in Mercury Marine dealerships. Here is a list of frequently asked questions regarding CDS. 1. Why is the Quicksilver (DDT) Scan Tool being replaced? Two main reasons, first; the DDT is being phased out of production by the supplier. There are limited amounts of the DDT available at this time.
CDS - Computer Diagnostic System Components Dell Latitude Laptop Computer Panasonic Toughbook Laptop Computer
SmartComms Module Pin Probe Kit & Loaded Volts Lead
Break-Out Box New Digital Meter With Serial Connection for Conecting to Laptop
Various Kit Configurations Available
Computer Requirements for running the Mercury Computer Diagnostic System (CDS) software and hardware: · · · · · · · · · 900 MHz Pentium Processor USB port Windows 2000 (or XP backed down to 2000) 56K Modem PCMCIA slot 256 MB Ram DVD Drive 10 GB Hard Drive Serial Port
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2 2004 Product Update Section 2 Electrical Systems
Table of Contents 2005 SmartCraft DTS Updates Service/Repair of Electrical Test Equipment
2005 496/8.1 DTS changes and over view of the new 5.
DTS 496 / 8.
2005
5.0L MPI – BRAVO DTS Engine Block: GM 5.0L Engine Controller: PCM 03 Fuel Injection: Sequential Fuel Injection TBU: 80mm Electric Flame Arrestor Flow: 500 CFM @ 1 in Hg Manifold and 28” Hood Pressure Maximum Flame Arrestor Height From Crankshaft: 557 mm Rated Crankshaft HP: 260 Horsepower Rated WOT Speed: 4600-5000 RPM Transom Type: Bravo, Analog & Digital Sender, Magnum, Exhaust Tube Available Options Bravo 1: 1.65 (P), 1.50 (O) Bravo 2: 2.20 (P), 2.43 (H), 2.00 (O) Bravo 3: 2.20 (P), 2.43 (H), 2.
496/8.1 DTS/ Mech.
8.
8.1 MIE mech.
Over view of the 5.
5.
From left to right; 4 pin diagnostics, 6 pin paddle wheel /fuel tanks,17 pin transom harness and 2 pin clean power top of bracket 14 pin Deutsch
Termination Resistors Can 1 Yellow Can 2 new Blue
HVS Cam sensor location used on Small Block DTS
80 MM Electronic Throttle Body same as 496/8.
PCM 03 controller uses box part number 885558 same as used on 496/8.
5 Relays used from left to right Trim down /Trim up /Fuel pump Main Power/Start relay.
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3 2005 Product Update Section 3 Exhaust and Cooling Systems
Table Of Contents MerCruiser Dry Joint Exhaust and Cooling System - V6, V8 Small Block MCM Exhaust Elbow Height Change
MerCruiser Dry Joint Exhaust and Cooling System V6, V8 Small Block
Strategy Behind MerCruiser Exhaust System Changes • Prevent Coolant Leaks. • Eliminate Water from Leaking into Exhaust Passages. • Help Prevent Reversion. • Insure More Robust Exhaust Collection & Muffling System.
Start of Dry Joint System • MCM V6 Models: S/N 0M615000-UP. • MCM V8 Models: S/N 0M600000-UP. • MIE V8 Models: S/N 0M0317000-UP.
Dry Joint Design Changes • • • • New Exhaust Manifold. New Exhaust Elbow. New Gaskets. New Risers.
Dry Joint Gaskets • Built-in Turbulator – Traps Condensation From Elbow – Traps Water Reversion – Increases Local Flow Velocity • Water & Exhaust Separated – Better Sealing – No Leakage into Exhaust
Dry Joint Gaskets • New Materials – 18 gauge 316 ss Core. – Two Layer 5000o F GrafoilTM, Seals Exhaust Passage. – High Temp 4 Bead Silicone Seals Water Ports. – Perfect Seal Protects Manifold and Elbow.
Dry Joint Gaskets • Coat Edge of All Water Ports with Perfect Seal. • If Bare Metal on Gasket Surface, use Perfect Seal.
Restrictor Gasket Restrictor End of Gasket is Straight Open Restricted Open End of Gasket is Contoured
Restrictor Gasket • Used on All Raw Water Cooled Engines on the Manifold. • Restrictor Opening Goes Toward End That Bypass Water Comes From Thermostat Housing Into Exhaust Elbow. • Turbulator Points Upward.
Full Flow Gasket Open Open Both Ends of Gasket are Contoured
Full Flow Gasket • Used on All Engines with Risers. • Goes Between the Riser and Exhaust Elbow. • Turbulator Points Upward.
Block Off Gasket Closed Closed Both Ends of Gasket are Straight
Block Off Gasket • Used on All Closed Cooled Engines. • Goes Between the Exhaust Manifold and Riser. • Turbulator Points Upward.
Installation Reminder • Current MIE Inboard and Tow Sports V-Drive Requirements. – – – – – – – Test & Verify Exhaust System Designs 6.9-13.7 kPa (1-2 psi) Exhaust Back Pressure. Maintain Adequate Support of System Components. Use Exhaust Resonators if They Help. Use at Least Minimum Size Exhaust Hoses. Use Heat Resistant Exhaust Hose. Use at Least 2 Clamps per Connection.
Dry Joint 14o Exhaust Elbow
Dry Joint Service Manual • Nbr 37 V8 Service Manual Supplement. – 90-864260020 Oct 2002. • Section 6 Cooling System. – All Models. – Seawater System. – Closed Cooling System. • Section 7 Exhaust System. – Manifolds and Elbows. – Cold Riser Models. – Warm Riser Models. • Section 10 Color Diagrams. – Water Flow Diagrams.
MCM Exhaust Elbow Height Change • Project Objectives – Provide V-6 and S.B. V-8 MCM engines with increased elbow height – Increase exhaust elbow outlet angle – Create 1.
Exhaust Elbow Height • System Overview – Current MIE elbow will become standard on all V-6 & S.B. V-8 MCM’s except inline ski • Increases height by 1.5 inches over current MCM – Factory option for 1.
Exhaust Elbow Height 1.
Exhaust Elbow Height 3.2” Elbow, 1.
Exhaust Elbow Height 4.
Exhaust Elbow Height 7.
Exhaust Elbow Height Summary V6 MCM Models SB V8 MCM Models SB V8 Inboard Models (either rear or fwd facing exh) SB V8 Towsports Models w / Rear Facing Exhaust SB V8 Towsports Models w / Fwd Facing Exhaust 1.81 standard standard standard N/A standard 3.20 3.51 factory option factory option kit N/A kit 864591 (tall) Elbow + 3.00" Riser 4.50 4.81 factory option factory option factory option N/A N/A 864591 (tall) Elbow + 6.00" Riser 7.50 7.
Exhaust Elbow Height Turbulator will be removed from full flow gasket “New” PN 865786A01
Exhaust Elbow Height Intermediate Pipes New V6 New intermediate pipes will be labeled with model, riser size and pn.
Exhaust Elbow Height Intermediate Pipes
Exhaust Elbow Height • System Overview – Flow control valve installed on thermostat housing for RWC 350 MAG & MX 6.
Exhaust Elbow Height • New Service Kit’s – 1.
Exhaust Elbow Height • New Service Kit’s – Intermediate Elbow Kit’s (2 elbows per kit) • • • • • • 866000A01 V6 1.7” riser 866001A01 V6 3” riser 866002A01 V6 6” riser 866003A01 SB V8 1.
Exhaust Elbow Height • Service Kit’s – Several existing kits will be impacted • CC for MPI & Carb • 3 & 6 inch riser • Long block
2005 Product Update Section 4 Transom Assemblies 4
Table of Contents Quick Connects • Gear Lube Bottle Relocation • Oil Reservoir Hose • Power Trim Hoses • Power Steering Hoses • Bravo Transom Water Hose • Speedometer Hose • MerCathode Assembly Power Trim Pump Fuse Change New Trim Pump Harness Control Harness to Trim Pump Adaptor Harness Trim Pump Reservoir Cap Change Oil Bottle Float Change New Rear Engine Mount Design (Quick Mounts) Shift Plate Assembly Redesign Intermediate Shift Cable Redesign
Transom Plate Assembly Components Quick Connects Added For Reduced Installation Time and Secure Connections
Gear Lube Bottle Relocation Previous Design Released Design • 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 Inline Quick Connect
New Oil Reservoir Quick Connects There is a new quick connect fitting between the oil reservoir bottle and the current 90 degree quick connect fitting at the transom for easier removal and installation of the bottle for cleaning and or engine removal • 3/10/03 started with serial numbers 0M640000.
Drive Initiatives – January 2004 Power Trim Quick Connects Old Design • Project – Hydraulic quick connect fittings – Brass Construction – brass components shown in picture – In March 2004 the Male fittings on both the trim pump adapter and the trim line from the transom will change from brass to stainless steel – Affects Alpha and Bravo Drives • Benefits – Male / Female connections to insure correct connections • Impact New Design – SOP – January 12, 2004 – Hydraulic lines will be connected - no plugs t
Power Trim Quick Connects Trim Hose Up Pressure and Quick Connect Fitting Trim Pump Fitting Up Pressure at the Adapter 22-865410 22-865412 22-865411 22-865413 Quick Connect Fitting Trim Hose Down Pressure Trim Pump Fitting Down pressure at the Adapter
§ Power steering hose quick-connect fittings – Reduce installation time and opportunity for leaks • All Sterndrive models with power steering New Design Current Production
Drive Initiatives – January 2004 Power Steering Quick Connects • Project Definition – Quick connect fittings – Nickel Plated Brass Construction – Affects Alpha and Bravo Drives • Benefits – Eliminate cross threading on power steering cylinder – Reduce installation time – Male / Female connections to insure correct connections • Installation Clearance - .85” OEM Impact – Overall fitting height is 0.5” taller, requires .
Power Steering Quick Connects Power Steering High Pressure Hose 32-865387-053 = (1.3 m) 53in. 32-865387-060 = (1.5 m) 60 in. Power Steering Return Hose 32-865390-015 = (406 mm) 16 in. 32-865390-068 = (1.73 m) 68 in. 32-865390-085 = (2.2 m) 86 in. 32-865390-134 = (3.4 m) 135 in.
Drive Initiatives – January 2004 Transom Water Hose Fitting • Project OLD DESIGN 865470 – Redesign the inlet water fitting located on the transom. – Add quick connect fitting to inlet water hose – Minimize flow restriction through fitting.
Drive Initiatives – January 2004 Sea Pump Water Hose Quick Connect 22-865324 • Project – Provide easier installation for inlet hose via a quick connect junction in between transom and sea pump – Affects Bravo Drives Only • Benefits 22-865362 – Eliminates difficulty associated with removal of hose from inlet of sea pump • Impact – SOP – January 9th, 2004
Speedometer Quick Connect June 2003 Old Design • Project Definition – Quick connect fitting – Nickel Plated Brass / Plastic Construction – Affects Alpha and Bravo Drives New Quick Connect • Benefits – Male connector factory installed on gimbal housing – sealed when disconnected – SmartCraft steering / speedo kit will incorporate same fittings • OEM Impact – Female connector included in parts bag – SOP – June 16, 2003 – Single hand / blind installation
MerCathode Assembly • Project Definition – Add sealed connector in MerCathode harness to reduce installation time – Improve aesthetics on product Previous Design – SN 0M640000 and up (Bravo Applications) – Launched in conjunction with gear lube relocation and quick connect changes • Start of Production – March 10, 2003 completed Released Design
New MerCathode Quick Connect Feature MerCathode Quick Connects The service replacement MerCathode unit will come with the connector disassembled for ease in replacement through the hydraulic manifold New Quick Connect Design Old Design
Drive Initiatives – January 2004 Fuse change – Trim Pump • Project – Replace glass fuse assembly with flat blade style fuse • Benefits – Eliminate damage to fuse during disassembly of fuse holder – Automotive style fuse • Impact – SOP – January 12, 2004
New Trim Pump Harness Fuse and Holder New Three Pin Connector
New and Current Trim Pump Harness New Three Pin Packard Connector Current Three Blade Round Connector
Control Harness to Trim Pump Adapter Harnesses A02 A02
Control Harness to Trim Pump Adapter Harness
Trim Pump Reservoir Cap Change Problem: Trim Pump Cap Leaks • Trim pump purges oil through side vents in rough water applications. Root Cause: • Cap vents are large enough to allow sloshing oil to pass from reservoir to the exterior. Solution: • Provide a baffle in cap which allows air to vent but reduce the ability for liquid to migrate. New cap has a (yellow colored baffle and a rubber seal gasket) installed.
Oil Bottle Float Change The float in the oil reservoir bottle was improved to prevent it from sealing off the outlet when the bottle is filled from the top, causing the audio warning to sound even though the bottle was filled The new float went into production on 5/19/03 Starting S/N 0M653864
New Rear Engine Mount Design Note: New engines use a modified rear engine mount system (a). The bottom of the rear mount now has a knurled edge (b) [older version was smooth]. Alpha Shown - Bravo Similar The "double-wound" lockwasher (spring) is no longer used. The large fiber washer is still used.
Drive Changes – June 2003 Improved Engine Alignment • Project Definition – Address offset at nominal (detected by stack-up) at the rear engine mount / inner transom plate interface – additional material to be added to rear engine mounts – Minimize future potential for misalignment due to component stack-up in the following areas: • • • – – • Rear engine mounts / inner transom plate interface Engine coupler position / flywheel interface Engine coupler perpendicularity / flywheel interface Tied in wit
Old and New Style Mounts Old Engine Mount New Engine Mount
Old Design Flywheel Housing Mount Location
Old Style Rear Mount Installed Flywheel Housing Rear Mount (old) Spring Washer Inner Transom Plate
New Design Flywheel Housing Mount Location
New Style Rear Mount Installed Flywheel Housing Rear Mount ( New) Inner Transom Plate
Engine Placement When Using Old Style Rear Engine Mount Front Mount Boat Stringer Misalignment Clearance Caused when old mount was used.
Engine Placement Using New Design Rear Engine Mount Front Mount Boat Stringer New Mount Design Lowers Engine To Height Specified In Installation Drawings
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Shift Plate Assembly June 2003 • Project Definition – Redesign shift plate assembly to eliminate improper installation of shift interrupt and gear indicator switches – Affects Alpha and Bravo New Design • Benefits – Eliminate failure / claims due to improperly assembled shift plate assemblies (switch plunger engagement) – Repeatable and consistent shift events – Decrease adjustments to shift cables • Impact – Threaded stud/nuts replaced with stud and cotter pin – SOP June 17, 2003 – Original release i
Alpha Shift Plate – Exploded View Cast in Switch Guide Bosses
New Shift Levers for Alpha & Bravo Shift Plate Assemblies
Neutral Switch adjustment notch
Drive Initiatives – June 2003 Intermediate Shift Cable • Project Definition Black Teflon Coating – Alpha and Bravo intermediate shift cable redesign / resource to reduce friction and lost motion – Affects Alpha and Bravo • Benefits – Reduce required bend radius • Impact New Crimp method to prevent water leak – Installs exactly as the old style cable did – Went into production on June 17th 2003
Alpha / Bravo Shift Cables BRAVO Intermediate Shift Cable Part # 865437 A02 ALPHA Intermediate Shift Cable Part # 865436 A02
§ New internal “wig-wag” throttle and shift controls – – – – Allows more flexible control cable routing Reduced internal friction for smoother operation Use new SAE-style control cables Uses physically larger mechanism than previous generations
2005 Product Update Section 5 Sterndrives 5
Table of Contents New Alpha One Gen II Drive Shaft Housing Oil Seal Installation Tool Bravo Drive Updates and Changes x Bravo Engine Coupler Redesign x Bravo Universal Joint Assembly Changes x U-Joint Retainer Nut x Bravo Drive Shaft Housing Driven Gear Information x Bravo Gear Upgrade Components x Bravo Drive Shaft Housing Chimney Bearing Placement x Bravo Chimney Bearing Removal Tool x Bravo Lower Drive Shaft Comparison x Standard and High Performance Prop Shafts x Bravo Three Propeller Shaft and Oil Seal
New Alpha One Generation II Drive Shaft Housing Oil Seal Installation Tool 91-864497 New Integrated Oil Seal Installation Tool New Integrated Oil Seal Part Number 26-864319 91-817570T ( Two Seal Installation Tool) Old Style (Back to Back) Oil Seal Installation Part Number 26-66302
New Alpha One Generation II Drive Shaft Housing Oil Seal Installation Tool 91-864497
Drive Initiatives – January 2004 Improved Engine Coupler – Bravo Only • Project Definition Design to be finalized by the end of February 2004 – Change hub material from Aluminum to 12L14 Steel – Affects All V8 Bravo engine couplers only.
Bravo Engine Couplers Current Bravo Small Block Current Bravo Big Block
Proposed New Design Bravo Engine Coupler
Proposed Bravo Gas Engine Coupler Design •Shortened snout to provide installation clearance •Shielded for grease retention •Grease channel to direct lubrication to splines •Steel insert
Bravo Universal Joint Assy. • • • • • • • The Bravo U-Joint Assembly has changed from the Rockwell U-joint assembly to the GKN assembly. The Rockwell assembly is Gray in color, where as the GKN assembly is Black in color. The Rockwell assembly has the Cross & Bearing end caps retained with clips at the bottom of the cap inside of the yoke ear. The GKN assembly has the Cross & Bearing end caps retained with the clips above the cap on the outside of the yoke ear for Standard Bravo and Alpha.
Comparison of Rockwell to the GKN U-Joint Assy.
GKN U-Joint Repair Parts Alpha / Bravo Std. • ALPHA Universal Joint Assembly Stub Yoke Gear End Center Socket Splined Yoke Engine Coupler End Cross and Bearing Assembly 864281A 2 864282T 865503T 864281A01 865493A01 • BRAVO Std.
Rockwell U-Joint Assembly
Bravo Standard GKN U-Joint Assembly
Bravo “X” GKN U-Joint Assembly Repair parts for the GKN “X” Drive U-Joint Assembly such as the part numbers for all of the individual replacement parts are being worked on and will be brought out at a later date in 2004
Bravo (X) U-Joint Assemblies New L18 GKN U-Joint Assembly ( Bravo X Drives)
• Original style Driven gear (1999 & Prior)
• New style Replacement Gear for 1999 & prior as well as current Bravo Drives.
• Old Style Cone Clutch • with the number “7” New Upgrade cone clutch with the Top Groove
• Original Chimney bearing positioning for 1999 & prior Bravo Drives
• Proper positioning of the Top Cover and Drive Shaft Housing Chimney Bearing.
• 91-90773T • Original 91-864220 Upgrade 91-862530 2000 & up
Individual Replacement Puller Tool part Numbers for Bravo Service Tool 91-90244A 1 Bravo Service Tool 91-90244A 1 replacement part numbers. When you order part number 91-90777T1 puller Jaw, used to remove the sleeve bearing from the Top Cover Bearing Chimney or the Driveshaft Housing Bearing Chimney, you only receive one half of the tool. Part number 91-90778 puller jaw will also have to be ordered to make the puller tool complete.
• We have had some reports of Bravo Three propeller shaft oil seal leakage. • Samples of the production oil seal were placed on test in our engineering test cells to check for leakage. • The oil seals were also measured by our quality department to make sure that they were made to print. • After measuring oil seal samples that were taken from production, the seals were found to be out of print.
• The seal vendor was then contacted to set up a meeting on the quality and design issue of the oil seal. • The first thing that was done was to increase the ID of the Urethane retainer at the outside seal towards the propeller. • The next thing that was done was to have the vendor make the oil seals to print and air freight them to our facility for testing. • The new oil seals that were made to print were much better.
• New improved propshaft seals – Bravo Three – New lip design, material and spring tension – Greatly reduces potential for leakage and early failure
Bravo III Changes for 2003 Additional Anode added to Gear Case and Propeller Shaft on June 17, 2003 S/N 0M179452
Bravo III Anode Design Targets ¾Add 43% Anode Volume w/ Dual Gearcase and Propeller shaft Anode ¾Baseline -current 17.41 in³ (285.3 cm³) ¾Actual - added 4.52 in³ (74.07 cm³) – 25.9 % increase w/ propeller shaft anode ¾Actual – added 2.79 in³ (45.72 cm³) - 16 % increase w/ dual gearcase anode ¾Actual – total added 7.31 in³ (119.79 cm³)- 41.
Bravo III Bearing Carrier Threads machined after anodizing
• You may have also heard that the front propeller was hitting on the bearing carrier causing some surface rub damage. • It was found to be several issues. • 1) The ID of the front propeller is now opened up by an additional one hundred thousands per side to eliminate any possible rub. • 2) The propellers were not within the balance specifications of the print and were adding to the oil seal leaks as well as the hitting on the carrier.
Bravo Three Bearing Carrier Damage / Propeller Defect
Bravo Three Bearing Carrier Damage / Propeller Defect • • Heavy deposit on lower rib of propeller causing it to rub on the bearing carrier. Heavy Devcon Deposit on lower section of rib on inner propeller, causing it to rub on the bearing carrier.
Bravo Three Bearing Carrier Damage / Propeller Defect • Casting Flash on leading edge of propeller rib, Devcon across the face of the rib causing the propeller to Gaul on the bearing carrier.
Bravo Three Bearing Carrier Damage / Propeller Defect • • • The new version of the front propeller. Version One is the Machined current version using the letter (X) as an identifier. Version Two is the new Cast version using the letter (A) as an identifier.
Drive Initiatives – January 2004 New Thrust Bearing • Project Definition – Redesigned bearing to improve durability.
Drive Initiatives – January 2004 New and Old Outer Propeller Shaft New Shaft Marking Older Shaft Markings
Drive Initiatives – May 2004 • Project Definition – initiatives directed at improving the following: • NVH / Shift Effort – Bravo shift lever detent – Revised engine management during shift event ECM / PCM – Bravo Clutch Geometry • Bravo Styling – Ribbed Top Cover – Bravo (X) Only – Drive Shaft Housing, Top Cover & Rear Cover – Decals – Start of Production May 31, 2004 – End Model Number Change
Drive Initiatives – May 2004 Bravo Shift Lever Detent • Project Definition Baseline & Prototype Shift Handle Loads • Benefits 20 18 16 14 Load (lb.) – Modify Detent Shape – Smooth detent transition from forward into neutral and from reverse into neutral.
Bravo Shift Lever Detent Socket Current Bravo Shift Lever New Design Bravo Shift Lever
Bravo Shift Lever Detent Socket Used in all Bravo X and XR Stern Drives with High Bump Brass Sleeves Used in all Standard Bravo Stern Drives with Low Bump Brass Sleeves
Drive Initiatives – May 2004 Bravo Cone Clutch Redesign
Drive Initiatives – May 2004 Bravo Cone Clutch Redesign Current Bravo Cone Clutch New Design Bravo Cone Clutch
Drive Initiatives – May 2004 Bravo Styling • Project Definition – Restyling of • Upper Driveshaft Housing (DSH) • Rear Cover • Top Cover • Decals – No external changes to Bravo Drive since 1987 – Affects Bravo Drives only • Current Design Bravo New Design Bravo June 2004 Benefits – Enhanced aesthetics to identify the new and improved Bravo Drive • Impact – External Steering Suppliers may require changes to their components to match DSH changes – SOP – May 31, 2004
Bravo Drive Shaft Housing The “O” ring for the drive shaft housing shift shaft bore has been replaced with a new seal.
Bravo Drive Shaft Housing The “O” ring for the drive shaft housing shift shaft bore has been replaced with a new seal.
Introducing the New Bravo Jan, 2004 Shimming process • • • • • • • The Bravo drives for 2004 will have the gears in the drive shaft housing shimmed into position to improve on gear life. The Universal joint pinion gear will be shimmed for gear depth. The driven gears will be set by checking gear lash. There are new shims for the U-joint pinion gear bearing set as well as a new bearing pack to allow shimming to be done.
U-joint and Driven Gear Bearing Spacer Cup for all Bravo Drives • New U-joint shouldered bearing pack spacer cup and bearing.
U-joint and Driven Gear Shims and Chart • New U-joint shouldered bearing pack Chart and Shim.
Bravo 2004 Driven Gear Thrust Bearing Race and Chart
Gear Lash Specification Chart for Bravo 2004 • • • • • Gear Tooth Count 27 x 32 27 x 29 23 x 30 16 x 19 Spiral Tooth Gear Spiral Tooth Gear Spiral Tooth Gear Straight Tooth Gear Gear Lash .011 - .016 .013 - .018 .011 - .016 .010 - .
New Shimming Tools Required to shim a Bravo Upper • U-Joint pinion gear shimming tool
U-Joint pinion gear shaft tools • Standard Bravo • All Bravo X models
Gear Lash Flags for the new shimming procedure
Holding Block and Rod assembly for the Dial Indicator • Dial Indicator holder rod and retaining nut. •Dial Indicator holding block.
Handle Fixture for checking Gear Lash • Handle fixture for checking gear lash.
Driven Gear Clamp Tool • Clamp tool to hold driven gear when checking gear lash.
New Shimming procedure for Bravo Upper 2004 • • Step 1) Place the new U-Joint bearing pack on to the gear as you have in the past, by pressing the first bearing roller and cone assembly onto the gear until it bottoms on the gear. Next place the bearing cup for that bearing over the cone and roller assembly. Step 2) Place the center cup/spacer over the gear and press the second bearing onto the gear until a slight preload is felt.
New Shimming procedure (continued) • Step 3) After the bearing preload is set remove the gear and bearing pack from the U-joint assembly along with the large thrust support washer, place them over the stub shaft tool. 91865084 for the standard Bravo and 91-865083 for the (X) models and reinstall the pinion nut and washer, (DO NOT) over tighten the pinion nut, just tighten the nut and washer until it feels firmly seated against the gear.
New Shimming procedure (continued) • • Step 4) In this step you will insert the original shim thickness that came out of the drive or a starting shim of (.089mm) .035 and the U-joint bearing pack and pinion gear on the shaft tool into the housing bore. Step 5) Install the U-joint retainer nut and torque to (271Nm) 200 lb. ft. (use the reference chart for the actual torque that must be applied per the length of the torque wrench being used).
New Shimming procedure (continued) • Step 6) Insert Pinion gear shimming tool 91-865114 into the top of the driveshaft housing using the proper gear tooth count for the gear ratio of the unit being worked on.
New Shimming procedure (continued) • • • • Step 7) Using a feeler gauge between the tool face and the gear teeth measure for the (0.64mm) .025 distance between the gear teeth and the face of the shimming tool. If a change is required the shims come in (.0254mm) .001 increments. Make the changes and recheck for the (0.64mm) .025 distance between the gear teeth and the face of the tool.
New Shimming procedure (continued) • • Step 11) Place the thrust bearing on the top gear along with the shim race (thickness that was originally removed) or a (1.62mm) .064 starting point shim race, install the top cover and torque to (27Nm) 20 lb. ft. Step 12) Making sure that the gears are lined up (+) plus over (-) minus and the gears are in the proper position with the marks on the back of the driveshaft housing.
New Shimming procedure (continued) • • Step 13) Reinstall the U-joint gear and bearing pack with the stub shaft tool that you previously removed and retorque the retainer nut to (271 Nm) 200 lb. ft. Step 14) Next you will place the proper gear lash flag per the gear ratio of the drive, onto the stub of the shaft that you just installed with the U-joint pinion gear and bearing pack.
New Shimming procedure (continued) • Step 15) The next step will be to install the clamp block and handle assembly onto the end of the U-joint stub tool on the Pinion gear and bearing pack tightening it lightly at this point, just enough to keep the tool from coming off of the shaft. • Step 16) Now install the dial indicator holder rod into the top stud hole of the driveshaft housing and tighten the nut.
New Shimming procedure (continued) • Step 17) The next step will be to install the dial indicator holding block onto the holder rod. • Step 18) Install the dial indicator into the holding tool and lock it in place with the screw in the tool, using caution not to tighten the screw to tight causing it to bind the indicator movement.
New Shimming procedure (continued) • Step 19) Next align the Gear Lash Flag perfectly straight up and down on the bearing and pinion gear stub shaft. • Step 20) Move the dial indicator holding tool to align the dial indicator tip 90° perpendicular to the gear lash flag at the hash mark on the flag.
New Shimming procedure (continued) • • • Step 22) Now tighten the clamp block on the stub shaft locking it to the shaft. Step 23) While holding the driven gear in a locked position with the clamp tool, you will now check the amount of gear lash you have on this gear to the pinion gear, it must be from .000 to .
New Shimming procedure (continued) • • • • Step 25) In this step you will make the required shim race changes and redo the process, by first removing the dial indicator from the holding block, loosen the lash flag and remove it from the stub shaft, next remove the dial indicator rod to make room for the spanner wrench so you can remove the pinion gear and bearing pack from the housing. Taking care not to damage the pinion gear shims in the snout. Step 26) Remove the top cover.
New Shimming procedure (continued) • • Step 29) After the gear lash process is complete and the drive is ready to reassemble for the final time, remove the U-joint stub yoke shaft assembly and remove the pinion gear and bearing pack assembly.
2005 Product Update Section 6 Customer Satisfaction Index (CSI) 6
Notes:_________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ ________
Table of Contents CSI Info and FAQ Customer Satisfaction Index (CSI) Frequently Asked Questions Sample of Card
Notes CSI Info and FAQ _______________________ Customer Satisfaction Index (CSI) _______________________ Customer Satisfaction Index (CSI) Getting your finger on the pulse of your customer. People spend a lot of energy trying to make customers happy. Money spent for advertising, new and different merchandise, boat shows, open houses, training, and special programs. Staffing for peak customer traffic times or extending service department hours.
Frequently Asked Questions Notes _______________________ Why is CSI important? · CSI shows customers that we care about them. · They communicate whether our customers are happy with our products or services. · They tell us if we are providing the goods or services that they want. · The survey can provide us a valuable opportunity to correct an oversight or miscommunication with a customer. · They can indicate how profitable your dealership will be.
Notes _______________________ _______________________ _______________________ What is a “Hot Alert” and how is it generated? A Hot Alert is a faxed notification to a dealer that a consumer has returned a survey in which they indicated their engine problems / service issues were not resolved by the dealer and or their engine problems / service issues were not resolved to their satisfaction by the dealer.
CUSTOMER SATISFACTION SURVEY Dear Valued Customer, We would like to ask you a few questions regarding your last Service visit to our Dealership. We appreciate your business and your responses today will allow us to better serve your needs in the future. # .$* '' + ) $*' ()$' , ( $*' () %'$ (( $# ! # $*') $*( ' .$*' ( '+ ' &* () ( $"%! ) ( ) ( )$' !. ) ' ' % '( , ' $"%! ) , ' !! ' ! ) ' ( -%! # *!!.
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