DIESEL ENGINE JETDRIVE INSTALLATION Pro Max, … · Mercury, Mercury Marine, MerCruiser, Mercury...

Page i © 2005 Mercury Marine 90-866353050 NOVEMBER 2005

Cummins MerCruiser DieselMercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registeredtrademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

1.7L MJ, 2.8L EJ, AND 4.2L EJDIESEL ENGINE JETDRIVE INSTALLATIONMANUALModels CoveredJetdrive

Models Covered Serial Number Or Year

1.7L MJ, 2.8L EJ, and 4.2L EJ Diesels All Jetdrives

NoticeNOTICE

After completing installation, place these instructions with the product for the owner's future use.

NOTICE

Predelivery preparation procedures must be performed before delivering the boat to the product owner.

Notice to Boat Manufacturer/InstallerThis publication uses warnings and cautions (accompanied by the international hazardsymbol) to alert the manufacturer or installer about special instructions concerning aparticular service or operation that may be hazardous if it is performed incorrectly orcarelessly. Observe Them Carefully!These safety alerts alone cannot eliminate the hazards that they signal. Complying withthese safety alerts must also be accompanied by the exercise of common sense to preventaccidents.

! WARNINGWARNING—indicates a potentially hazardous situation that, if not avoided, could resultin death or serious injury.

! CAUTIONCAUTION—indicates a potentially hazardous situation that, if not avoided, may result inminor or moderate injury or property damage. It may also be used to alert against unsafepractices.

IMPORTANT: Indicates information or instructions that are necessary for properinstallation or operation.NOTE: Refer to the appropriate Cummins MerCruiser Diesel applications manual forapplication recommendations.This installation manual has been written and published by Cummins MerCruiser Diesel toaid the boat manufacturer (OEM) in the installation of the products described herein.

Page ii

This manual assumes that OEM personnel are familiar with marine product installation andare familiar with, if not trained in, the recommended installation procedures of CumminsMerCruiser Diesel products.We cannot anticipate all conceivable installations and their possible hazards or results.Therefore, the OEM is responsible for any installation that does not fulfill the requirementsof this manual.It is the responsibility of the boat manufacturer to select the appropriateengine‑transom‑drive package (including the correct gear ratio and propeller) for a givenboat. Cummins MerCruiser Diesel recommends that any new or unique hull–powerpackage combination be thoroughly water‑tested before sale to verify that the boatperforms as desired and that the engine operates at rated rpm at wide‑open throttle (WOT).For assistance in the United States, contact a Cummins MerCruiser Diesel distributor. Forassistance outside the United States, contact the local Cummins Mercruiser Diesel officeor authorized distributor.All information, illustrations, and specifications contained in this manual are based on thelatest product information available at time of publication. Cummins Mercruiser Dieselreserves the right to make changes at any time without obligation. As required, revisionsto this manual will be sent to all OEM boat companies.

Page iii

Manual Outline

1 - Important Information

2 - Boat Construction

3 - Exhaust System

4 - Fuel System

5 - Cooling System

6 - Drive System and Engine Mounting

7 - Starting and Electrical

8 - Remote Controls

9 - Predelivery Preparation and Storage

Important Information 1Boat Construction 2Exhaust System 3Fuel System 4Cooling System 5Drive System and Engine Mounting 6Starting and Electrical 7Remote Controls 8Predelivery Preparation andStorage 9

Page iv

SECTION - 1 IMPORTANT INFORMATION

NOVEMBER 2005 Page 1 / 7

SECTION 1 - IMPORTANT INFORMATIONTable of ContentsSerial Number Location........................................................................................................................................... 2General Information................................................................................................................................................. 2

Sales and Technical Assistance ...................................................................................................................... 2Torque Specifications.............................................................................................................................................. 2Special Tools........................................................................................................................................................... 3Quicksilver Products—Accessories......................................................................................................................... 4Corrosion Protection................................................................................................................................................ 5

Antifouling Paint ............................................................................................................................................... 5Emission Information for Jetdrives.......................................................................................................................... 6

Noise Emissions ............................................................................................................................................... 6Dual (Twin) Jetdrive Installation.............................................................................................................................. 6

Internal Tie Bar Only ........................................................................................................................................ 7

1

IMPORTANT INFORMATION SECTION - 1

Page 2 / 7 NOVEMBER 2005

Serial Number LocationThe serial numbers are the manufacturer's keys to numerous engineering details, which apply toyour Cummins MerCruiser Diesel Package. When contacting MerCruiser or Cummins MerCruiserDiesel, (CMD®) about service, always specify model and serial numbers.

a

aI D 0 0 0 7 7

17776

Jetdrive Serial Number Locationa - Jetdrive model, gear ratio, and serial number

General InformationSales and Technical Assistance

Cummins MerCruiser Diesel (CMD) distributor network is trained to assist you with any sales ortechnical issues. This includes application engineering and service.If you have an issue with the application of our product that cannot resolved, contact your CMDdistributor application engineer. All requests for assistance should be directed to your local CMDdistributor. The distributor for your area can be found by using the service locator on the Cumminswebsite (www.cmdmarine.com) or by contacting 1‑800‑DIESELS (1‑800‑343‑7357). For furthertechnical assistance, contact us at our email address: [email protected].

Torque Specifications1.7L MJ Jetdrive

Description Nm lb. in. lb. ft.

Rear engine mounting bolts 47 35

Locknut, front mounts 80 59

Trunnion clamping bolts 57 42

Two stage damping coupler to flywheel M10 socket head 44 33

Flywheel housing bolt M10 50 37

Shaft coupling 54 40

Jet to hull attachment 27 20

Exhaust elbow riser clamp 10 88

Seawater pump flange nuts 20 177

Lower water pump bracket bolts 24 212

Water pump bracket bolts 37 27

Engine mount bolts 80 59



2.8L EJ Jetdrive


Coupler bolts 50 37



Coupler to flywheel M10 socket head 44 33






4.2L EJ Jetdrive


Coupler bolts 50 37



Trunnion clamping bolts 57 42

Coupler to flywheel 10 mm sockethead 44 33






Special ToolsEngine Lifting Eye Tool (1.7L Diesel Only)

6603

Lifts front of engine while adjusting motor mounts during alignment procedure.Do not use this to lift the rear of the engine. 91‑863678



Universal Protractor

8889

Used to align engine tojetdrive. Must be calibratedto read 0.5° or better

Snap‑On tool numberYA328A

Mold Insert

b

a

c 6885

Creates proper opening infiberglass (GRP) hulls 887317

Mount Plate Kit

Provides a mounting face for Aluminum hulls 887448

Quicksilver Products—AccessoriesQuicksilver remote controls, steering systems, and other accessories are available for this product.Refer to the Diesel Parts And Accessories Guide (90‑892645005) for complete listing.This Guide is available from:Mercury MarineAttn: Parts DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939USAOutside of U.S.A., order through distribution center, or distributor.



Corrosion ProtectionCummins MerCruiser Diesel power packages are equipped with anodes, to help protect them fromgalvanic corrosion under moderate conditions. However, for severe conditions, it is recommendedthat a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed (somemodels have a MerCathode System as standard equipment). A MerCathode Monitor also isavailable to allow the operator to check the operation of the MerCathode System with the push ofa button. Refer to the Diesel Parts And Accessories Guide (90‑892645005) for part numbers.Boats which are connected to AC shore power, require additional protection to prevent destructivelow voltage galvanic currents from passing through the shore power ground wire. A QuicksilverGalvanic Isolator can be installed to block the passage of these currents while still providing a pathto ground for dangerous fault (shock) currents. Refer to the Diesel Parts And Accessories Guide(90‑892645005) for part number.IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System andanodes may be unable to handle the increased galvanic corrosion potential.

Antifouling PaintIMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paintwill not be covered by the limited warranty.Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transombut you must observe the following precautions:IMPORTANT: Do not paint anodes or MerCathode system reference electrode and anode, as thiswill render them ineffective as galvanic corrosion inhibitors.IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper or tin basepaints, if not prohibited by law, can be used. If using copper or tin based anti‑fouling paints, observethe following:• Avoid an electrical interconnection between the Cummins MerCruiser Diesel Product, anodic

blocks, or MerCathode system and the paint by allowing a minimum of 40 mm (1.5 in.)UNPAINTED area on transom of the boat around these items.

7192

a b

a - Painted boat transom b - Minimum 40 mm (1.5 in.) UNPAINTEDarea around transom assembly

NOTE: The jetdrive assembly can be painted with a good quality marine paint or an anti‑foulingpaint that does not contain copper or any other material that could conduct electrical current. Donot paint drain holes, anodes, MerCathode system, and items specified by boat manufacturer.



Emission Information for JetdrivesNoise Emissions

CMD stern drive engines will be certified for the European Recreational Craft Directive (RCD) foremissions and noise that will go into effect on January 1, 2006. These engines will have a "CE"sticker to indicate their compliance. When these engines are used in the jet application, theemissions certification still applies, but the noise certification does not because the entire exhaustsystem is not provided as part of the jet package. The boat manufacturer is responsible for doingthe noise certification on the exhaust system of their design. The "CE" sticker should be removedfrom the engine when used in all jet applications. The jetdrive power package will be includedunder the boats "CE" certification sticker only after all RCD requirements have been met by theboat builderIMPORTANT: If a certified exhaust system has not been installed, remove the "CE" sticker fromthe engine.

Dual (Twin) Jetdrive InstallationIMPORTANT: Multiple jetdrive installations can only be used in vessels with 15º of deadrise orless without modification to the jetdrive steering system. Vessels with deadrise greater than 15ºwill require modifications to the jetdrive steering system. Contact your Cummins MerCruiser DieselDistributor or Dealer for jetdrive steering modification information.When installing the jetdrive in a dual engine installation in vessels with any deadrise, the rearengine mount must be adjusted to allow the engine to stay at 0º port to starboard.1. Place the vessel at 0º from port to starboard.2. Loosen the rear mount plate locking bolts.

19024

a

a

b

a - Rear mount plate locking bolt b - Rear mount plate

3. Rotate the Rear mount plate until it is at 0º from port to starboard.4. Torque the rear mount plate locking bolts.


Rear mount plate locking bolts 60 44

The area in front of the jetdrive intake on the vessel must be flat and free of any type of obstructionssuch as water inlets, transducers, or boat hull designs features such as steps and strakes.



Internal Tie Bar OnlyFor jetdrive dual engine installation, the internal tie bar kits can be used for vessels having up to15º deadrise. Please refer to the Diesel Parts and Accessories Guide 90‑892645005 to orderMerCruiser tie bars. External tie bars can not be used on jetdrives. Contact your CumminsMerCruiser Diesel Distributor or Dealer for boats with a deadrise greater than 15º.


NOTES:


SECTION - 2 BOAT CONSTRUCTION


SECTION 2 - BOAT CONSTRUCTIONTable of ContentsBoat Construction.................................................................................................................................................... 2Hull Preparation....................................................................................................................................................... 2

Fiberglass Boats................................................................................................................................................2Aluminum Boats................................................................................................................................................4

Cut Out Dimensions for the Jetdrive....................................................................................................................... 8Transom Cut Out Dimensions (Fiberglass and Aluminum) .............................................................................. 8Cut Out Detail ................................................................................................................................................ 10

2

BOAT CONSTRUCTION SECTION - 2


Boat Construction! WARNING

Avoid serious injury or death and property damage due to improper boat design and construction.Always adhere to all applicable Marine Regulations (United States Coast Guard [USCG],European Union ‑ Recreational Craft Directive [EU‑RCD], and so on) and the standards theyreference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE],International Standards Organization [ISO], and so on) when designing and constructing theboat and the boat components, such as the engine compartment, fuel delivery system andexhaust system.

For additional boat construction information refer to the Cummins MerCruiser Applications Manual(90‑865067020) and the Engine Sterndrive Installation Manual provided with your power package.For dual jetdrive installation in a vee hull vessel greater than 15º, refer to Dual Jetdrive Installationinformation located in section 1 of this manualIf you have an issue with the application of our product that cannot be resolved, contact your CMDdistributor application engineer. All requests for assistance should be directed to your local CMDdistributor. The distributor for your area can be found by using the service locator on the Cumminswebsite (www.cmdmarine.com) or by contacting 1‑800‑DIESELS (1‑800‑343‑7357). If furthertechnical assistance is needed, contact us at our email address: [email protected].

Hull PreparationFiberglass Boats

For fiberglass (Glass Reinforced Plastic or "GRP") hulls, the integrated jet recess and mountingface is formed using the fiberglass mold insert, part number 887317. The fiberglass mold insertcan be used on an existing fiberglass female mold to provide a form to fiberglass over, thus creatingthe correct intake tunnel dimensions. The fiberglass mold insert is removed after lamination andcan be re‑used.This method applies to single and twin installations in ‘vee’ bottom vessels and catamarans.

b

a

c 6885

Mold insert before modifications Part Number 887317a - Mounting faceb - Transom recess

c - Jetdrive recess mounting surface

This method of installation provides some flexibility of position and allows the Cummins MerCruiserDiesel Jetdrive to be installed in almost all hull types, whether new or existing, independent ofdeadrise and transom angles.



1. Trim fiberglass mold insert to suit hull deadrise. For the fiberglass mold insert to sit neatly inthe hull mold, the corner of the mount face needs to be notched so that the insert can sitsquarely on the vessel bottom. This applies for single jetdrive installations only.

2. Trim away the shaded part of the fiberglass mold insert as shown.

ab

cc

c

7154

Trimming shaded areas to match deadrisea - Material to be removedb - Centerline of boat (Single jetdrive

applications only)

c - Angle of deadrise

3. For the fiberglass mold insert to sit neatly in the hull mold, trim the aft section to match thetransom angle, so that the fiberglass mold insert can sit squarely against the vessel transom.

4. Trim away the shaded part, "c" of the drawing below. (If the transom is at 90°to the keel, thenremove the entire side.)

a

b

cc

d

d

e

7188

Material to removea - Isometric viewb - Side viewc - Material to be removed

d - Reference pointe - Transom angle



5. Ensure that the fiberglass mold insert is placed in the hull mold with the jetdrive recessmounting surface parallel to the vessel keel, or baseline. This is imperative to align the jet unitwith the engine.

b

a

c d

e

6894

Profile Viewa - Transomb - Jet transom platec - Mount plate

d - Delta plane angle, maximum 7°e - Delta plane length

6. Ensure the jet intake is gently flared from the ‘vee’ to the flat of the mould insert.IMPORTANT: A transition triangle, called a delta plane, is required. It is the transition from thepointed edge of the keel to the leading edge of the jetdrive intake. It provides a transition area forthe water to adjust. This is typically done with a single piece of aluminum. The dimensions of thedelta plane are predetermined by the deadrise of the hull and the maximum recommended angleof transition, which is less than 7°. This delta plane is shown in the Isometric View below. Minimumdelta plane lengths are given in the Delta plane table below (from 10° to 25° deadrise).7. Prepare the hull for lay‑up.8. Place the fiberglass mold insert into the female hull mold.9. Secure the fiberglass mold insert temporarily into the female hull mold.10. Coat the surface with mold release to ensure removal after laminating.IMPORTANT: Laminate thickness in the jet mounting area must be 8‑10mm thickness (to suitbolts).11. Laminate schedule as per instructions.

Aluminum BoatsFor aluminum hulls, the integrated jetdrive recess and mounting face is formed using the MountPlate Kit 887448 welded into place.



IMPORTANT: The angle of this plate at the transom must be 90 degrees, with the bottom of theplate parallel with the keel to ensure a watertight seal.

a

6904

Plate Anglea - This angle is 90°

The plate angle for the jet recess must be a 90° angle. The areas around this plate can beconstructed as necessary.This method of installation provides some flexibility of position and allows the Cummins MerCruiserDiesel Jetdrive to be installed in almost all hull types, whether new or existing, independent ofdeadrise and transom angles.1. Weld mount plate kit to hull on the sides and back, cutting away and adding material as

necessary to fit. Use adequate materials for this area.2. Angle section for the jetdrive mount must conform to the following dimensions after installation.

8283

Measurements are in millimeters



3. Ensure that the mount plate kit is mounted with the jet recess mounting surface parallel to thevessel keel, or baseline. This is imperative to align the jet unit with the engine.

b

a

c

e

d

9602

Profile Viewa - Transomb - Jet Transom Platec - Mount Plate Kit 887448

d - Delta plane angle maximum 7°e - Delta plane length

4. Ensure the jet intake is gently flared from the ‘vee’ to the flat of the mould insert.IMPORTANT: A transition triangle, called a delta plane, is required. It is the transition from thepointed edge of the keel to the leading edge of the jetdrive intake. It provides a transition area forthe water to adjust. This is typically done with a single piece of aluminum. The dimensions of thedelta plane are predetermined by the deadrise of the hull and the maximum recommended angleof transition, which is less than 7°. This delta plane is shown in the Isometric View below. Minimumdelta plane lengths are given in the Delta plane table below (from 10° to 25° deadrise).



5. Determine the dimensions of the delta plane. They are predetermined by the deadrise of thehull and the maximum recommended angle of transition, which is less than 7°. Minimum deltaplane lengths are provided in the following table (from 10° to 25° deadrise).

a

b

6903

Isometric Viewa - Mount Plate Kit 8874482 b - Delta plane

The following picture shows the typical deadrise.

a

6883

Transom view showing typical deadrisea - Deadrise at transom, measured in degrees from horizontal



Minimum Delta Plane Based on Deadrise

Vessel Deadrise at Transom Minimum Length of Delta Plane

10° 250 mm (9 37/32 in)

11° 278 mm (10 15/16 in)

12° 307 mm (12 5/64 in)

13° 336 mm (13 15/64 in)

14° 365 mm (14 3/8 in)

15° 394 mm (15 1/2 in)

16° 422 mm (16 5/8)

17° 450 mm (17 23/32 in)

18° 478 mm (18 53/64 in)

19° 507 mm (19 31/31 in)

20° 536 mm (213/32 in)

21° 565 mm (22 1/4 in)

22° 595 mm (23 7/16 in)

23° 625 mm (24 19/64 in)

24° 654 mm (25 3/4 in)

25° 683 mm (26 7/8 in)

Cut Out Dimensions for the JetdriveTransom Cut Out Dimensions (Fiberglass and Aluminum)

Use a ruler and a marker pen to construct the area to be cutout.1. Draw a line on the jet mounting face and the jet recess showing the real vessel centerline.



2. Mark the area to be cut out using the dimensions below.

133 mm(5.24 in.)

285 mm(11.22 in.)

148 mm(5.83 in.)

b

a

19870

View of transom from rear of boata - Radius 20 mm (0.75 in.), both sides b - 300 mm (11.81 in.) from transom to jet

recess face



3. Make sure the lines match in the corner of the transom and the hull.

150 mm(5.90 in.)

50mm(1.97 in.)

10mm(0.39 in.)

148 mm(5.83 in.)

148 mm(5.83 in.)

c

ba

a

19871

View underneath hulla - Radius 5 mm (0.20 in.) both sidesb - 412 mm (16.22) from transom face to

end of opening

c - Transom edge

Cut Out Detail1. After the cutout has been marked out, use a 40 mm (1.5 inch) diameter hole saw to create

the top corners.



2. Finish the remainder of the cutting and trimming, creating a hole that looks like this:

7053

a

Transom and hull cutouta - 40 mm (1.5 inch) diameter holes


NOTES:


SECTION - 3 EXHAUST SYSTEM


SECTION 3 - EXHAUST SYSTEMTable of ContentsJetdrive Exhaust System Requirements................................................................................................................. 2

Specifications ................................................................................................................................................... 2External Flappers ............................................................................................................................................. 2Thru-Transom Fittings ...................................................................................................................................... 2Fasteners ......................................................................................................................................................... 2

Exhaust Elbow Height............................................................................................................................................. 2Installing the Exhaust ....................................................................................................................................... 3

Rotate the 1.7L Exhaust Elbow (If required) .............................................................................................. 3Locating And Installing The Through-Hull Exhaust System.................................................................................... 4

Additional Information ...................................................................................................................................... 5Exhaust System Hose / Tube Connections ...................................................................................................... 6

3

EXHAUST SYSTEM SECTION - 3


Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

9 Loctite 567 PST Pipe Sealant Pipe plugs and fittings 92-809822

Jetdrive Exhaust System Requirements! CAUTION

Improper exhaust system installation may allow water to enter the exhaust manifolds andcombustion chambers, damaging the engine. The boat manufacturer or the installing dealer isresponsible for proper installation of the engine and exhaust system. Damage caused from wateringestion is not covered by the Cummins Mercruiser Diesel Limited Warranty unless the damageis the result of defective Cummins Mercruiser Diesel components.

SpecificationsRefer to NMMA, ABYC, and U.S. Coast Guard boating standards and regulations for completeguidelines.• The exhaust system must be thoroughly tested to make sure that water is not being ingested

into the engine. Damage caused from water ingestion is not covered by the MercuryMerCruiser or Cummins MerCruiser Diesel Limited Warranty.

• Exhaust tail pipes and exhaust tips must not be higher than the exhaust elbows at any point.• The tailpipe must have a minimum downward slope of 2.5°, or a 13 mm (0.5 in.) drop per

305 mm (12 in.) downward pitch, from the exhaust elbow to the outlet in the transom.• The exhaust outlet must be slightly above the water line and the distance from the top of the

exhaust header to the water line must be a minimum of 28 cm (11 in.) with the boat at rest inthe water and loaded to its maximum user weight.

External FlappersNo internal flappers are used in the diesel's exhaust system risers. Each outlet can use an externalexhaust flapper.

Thru‑Transom FittingsAll through‑transom fittings must have the same internal dimensions (I.D.) as the hoses they areconnected to.

FastenersRefer to NMMA, ABYC, and U.S. Coast Guard boating standards and regulations for completeguidelines.All fasteners must be corrosion resistant and not cause galvanic or electro‑chemical reactionsbetween the mating surfaces.

Exhaust Elbow Height! CAUTION

It is the responsibility of the boat manufacturer or installing dealer to properly locate the engineand install the exhaust system. Improper installation may allow water to enter the exhaustmanifolds and combustion chambers and severely damage the engine. Damaged caused by thewater in the engine will not be covered by the Cummins MerCruiser Diesel Warranty, unless thisdamage is the result of defective parts.

Refer to the Mercury MerCruiser or Cummins MerCruiser Diesel Engine Installation Manualprovided with your power package or the Cummins MerCruiser Diesel Application Manual todetermine proper elbow height.



Installing the ExhaustThe exhaust outlet must be through the transom or hull side so that exhaust gasses are directedaway from the vessel, engine room ventilation, and personnel.

ROTATE THE 1.7L EXHAUST ELBOW (IF REQUIRED)NOTE: The exhaust elbow rotates only on the 1.7L engine.Rotate exhaust elbow before installing the exhaust pipe.1. Disconnect the water overboard hose from the exhaust elbow fitting.2. Remove the plug and the water overboard fitting. Clean any old sealant from the threads.3. Apply sealant to the threads of the plug and the fitting.

Tube Ref No. Description Where Used Part No.

9 Loctite 567 PST Pipe Sealant Pipe plugs and fittings 92-809822

4. Install the water overboard fitting where the plug was installed. Tighten securely.5. Install the plug where the water overboard fitting was installed. Tighten securely.6. Loosen the exhaust elbow clamp.7. Rotate the exhaust elbow approximately 180º. Temporarily do not tighten clamp.

a

b

8257

Exhaust elbowa - Water overboard fitting b - Plug

! CAUTIONAvoid damage or injury. The turbocharger is a part of the exhaust system and can be HOT.Ensure that cables, hoses and lines are routed and secured away from the turbocharger.



8. Ensure that sufficient clearance exists between the turbocharger, thermal blanket, and thermalblanket retaining spring and the exhaust elbow with bellows to prevent heat damage. Theexhaust bellows must not compress or lay against the turbocharger, thermal blanket, orthermal blanket retaining spring.

17820

a

6608

b

a

Typical 1.7L exhaust setup, elbow facing rearward Typical 1.7L exhaust setup, elbow facing forwarda - Exhaust elbow

9. If rotating elbow, exhaust elbow clamp must be retorqued.


Exhaust elbow riser clamp 10 88

Locating And Installing The Through‑Hull Exhaust SystemIMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to properly locatethe engine and install the exhaust system. Improper installation may allow water to enter theexhaust manifolds and combustion chambers and severely damage the engine. Damage causedby water in the engine will not be covered by Cummins MerCruiser Diesel Warranty, unless thisdamage is the result of defective part(s).Determine if an exhaust riser kit or a water lift muffler kit is required, by taking measurements aand b, with boat at rest in the water and maximum load aboard. Subtract b from a to find c. If c isless than specified in chart, an exhaust riser kit or a water lift muffler kit must be installed.



Models c=a minus b

All models c Must be 279 mm (11 in.) or more

6808

a

b

cd

Typical Jetdrive Enginea - From waterline to top of transomb - From highest point on exhaust elbow

to top of transom

c - From "a" minus "b"d - Waterline at rest

Additional Information1. If an exhaust riser or a water lift muffler kit is not required: The exhaust outlet (for routing

exhaust to outside of boat) must be located so that a minimum of 13 mm (1/2 in.) per305 mm (12 in.) downward pitch (drop) exists in the exhaust hose or pipe from the engineexhaust elbow to the outlet.• The exhaust outlet (for routing exhaust to outside of boat) must be located so that a

minimum of 13 mm (1/2 in.) per 305 mm (12 in.) downward pitch (drop) exists in theexhaust hose or pipe from the engine exhaust elbow to the outlet.

• A minimum drop of 100 mm (4 in.) overall is required, as specified by the American Boatand Yacht Council. The drop must be constant so that a low spot does not exist at anypoint in the exhaust hose or pipe.

2. The exhaust outlet must be slightly above the water line with the boat at rest in the water andwith a full load aboard.

3. We also recommend the use of an exhaust flapper on each outlet.



4. The exhaust system must not cause excessive back pressure when measured at exhaustelbow outlets. Back pressure must not exceed a 1000 mm (39‑1/2 in.) water column, or76 mm (3 in.) of mercury when measured with a mercury manometer [approximately10.3 kPa (1‑1/2 psi) ]. The 2.8L and 4.2 engines accomodate an exhaust hose size of102 mm (4 in.). The 1.7L exhaust elbow outlet is sized to fit 82.6 mm ( 3 1/4inches)+,although 102 mm (4 in.) can be used with an adapter.

a

b

cde

f

g13787

Typical continuously sloping exhaust line (Not to scale)a - Exhaust elbowb - Measurement ‑ 379 mm (11 in.)

minimumc - Exhaust hose or pipe (slope to

specifications)d - Muffler

e - Exhaust outlet internal shutterf - Exhaust flapper valveg - Waterline

ab

cd

e

f

g

18110

Typical Waterlift Muffler Exhaust System (Not to scale)a - Vent line [6 mm (1/4 in.)]b - Transomc - Waterlined - Exhaust hose

e - Drain valvef - Waterlift mufflerg - Exhaust elbow

Exhaust System Hose / Tube ConnectionsWe recommend fitting an exhaust muffler to reduce noise levels. This should be in the exhaustpipe between the riser and outlet.1. Ensure that connections do not restrict the flow of discharge water from the exhaust elbow.



! CAUTIONAvoid exhaust hose failure which could cause exhaust or discharge water to enter the boat.Discharge water from the exhaust elbow must flow without restriction around the entire insidediameter of the exhaust hose to avoid causing hot spots, which could eventually burn throughthe exhaust hose. Connect the exhaust hoses and tubes to the exhaust elbows so that they donot restrict the flow of discharge water from the exhaust elbows.

6543 6799

Correct Connection Incorrect Connection2. Secure exhaust hoses and tubes at each connection with at least 2 hose clamps.


NOTES:


SECTION - 4 FUEL SYSTEM


SECTION 4 - FUEL SYSTEMTable of ContentsFuel System - Jetdrive............................................................................................................................................. 2

4

FUEL SYSTEM SECTION - 4


Fuel System ‑ JetdriveFor information regarding fuel system requirements, connections, and fuel filters, refer to Section4 of the Sterndrive Installation Manual provided with your power package.

SECTION - 5 COOLING SYSTEM


SECTION 5 - COOLING SYSTEMTable of ContentsCooling System - Jetdrive........................................................................................................................................ 2

5

COOLING SYSTEM SECTION - 5


Cooling System ‑ JetdriveThere are no cooling system components on the Jetdrive unit.For information regarding the seawater specification, hot water heater installation, and water flowdiagrams, refer to Section 5 of the Sterndrive Installation Manual provided with your powerpackage.

SECTION - 6 DRIVE SYSTEM AND ENGINE MOUNTING


SECTION 6 - DRIVE SYSTEM AND ENGINEMOUNTING

Table of ContentsInstalling the Jetdrive............................................................................................................................................... 2

Trial Fit With Jetdrive ........................................................................................................................................ 2Prepare the Engine................................................................................................................................................. 6

Engine Preparation - 1.7L MJ Diesel ................................................................................................................6Prepare Engine .......................................................................................................................................... 6Change Coupler ......................................................................................................................................... 7

Removal of Coupler ............................................................................................................................. 7Installation of Inertia-Damping Coupler ............................................................................................... 9

Engine Idle Speed Adjustment Screw - 1.7 MJ ....................................................................................... 11Install Water Pump Kit - 1.7L Diesel only........................................................................................................12Engine Preparation - 2.8L EJ and 4.2L EJ......................................................................................................14

Prepare Engine ........................................................................................................................................ 14Change Coupler ....................................................................................................................................... 15

Removal of Standard Coupler ........................................................................................................... 15Installation of Coupler ........................................................................................................................ 16

Prepare the Jetdrive.............................................................................................................................................. 17Jetdrive Preparation—1.7L..............................................................................................................................17Jetdrive Preparation—2.8L and 4.2L...............................................................................................................19

Installing the Engine.............................................................................................................................................. 191.7L Engine.....................................................................................................................................................19

Engine to Jetdrive Mount Bolt Arrangement ............................................................................................ 21Install the 2.8L and 4.2L Engines....................................................................................................................22

Engine to Jetdrive Mounting Bolt Arrangement ....................................................................................... 25Aligning the Engine to the Jetdrive........................................................................................................................ 26

Support the Engine ........................................................................................................................................ 26Alignment ...................................................................................................................................................... 27Protractor Alignment Method ......................................................................................................................... 28

Horizontal Alignment Method ................................................................................................................... 28Vertical Alignment .................................................................................................................................... 30

Secure Front Mounts and Final Check ........................................................................................................... 32Jetdrive Gear Lube Monitor................................................................................................................................... 33

6

DRIVE SYSTEM AND ENGINE MOUNTING SECTION - 6



Sikaflex 291 Transom and hullStainless steel bolts Obtain Locally

7 Loctite 271 Threadlocker Sterndrive coupler or inboard drive platebolt 92-809819

86 Loctite 262 Coupler Fasteners Obtain Locally

87 High Performance Gear Lubricant Gear Lube MonitorJetdrive rear bearing 92-802854A1

91 Engine Coupler Spline Grease Gear shaft couplerEngine coupler 92-802869A1

95 2-4-C with TeflonShift bracket mounting surfaces, bolt

threadsGrease fitting on coupler shaft

92-802859A1

Installing the JetdriveTrial Fit With Jetdrive

IMPORTANT: It is important that the cutout be within specifications to ensure proper fitting and awatertight seal around drive unit. Refer to Section 2—Boat Construction.1. With the jetdrive on a trolley jack, move the unit up into cutout.2. When the unit is fully raised, push it forward into place.

1

2

7118

1 - Raise unit into position 2 - Push unit forward

3. Make any necessary adjustments in the cutout at this time, being careful not to exceed thespecifications.

4. Push the jetdrive forward to contact the face of the transom. Ensure that there is no gap in the90º corner (the lowest, most aft section of the hull).



5. Use a scribe to accurately mark the 26 bolt holes on the hull.

6731

a

Marking the bolt holes on the hulla - Bolt holes used to mark location of holes to be drilled

6. Remove the jetdrive.7. Carefully drill through the hull at locations marked using an 11 mm drill bit. Make sure holes

are perpendicular. A drilling jig (obtain locally) can be used if needed.

6730

a

Drilling holes with jetdrive removeda - 11 mm holes

IMPORTANT: Do not use the jetdrive unit as a drilling jig. Drill bits in the bolt holes could causedamage to the jetdrive, and potentially excessive corrosion could occur around the bolt holes,allowing leaks.8. Deburr the holes and edges of the cutout.



9. Before final installation with sealant, install the jetdrive unit with a trolley jack and check thealignment of the bolt holes. Correct as necessary.

6731

a

Final alignment checka - View drilled holes through bolt holes

10. Remove the jetdrive unit from hull and apply sealant only to the transom and hull.

6733

a

a - Sealant bead


Sikaflex 291 Transom and hull Obtain Locally

! CAUTIONUse care when applying sealant to the hull and bolts to ensure a watertight seal. Failure to createa watertight seal can result in leaks, damage to the equipment, or the sinking of the boat.



11. To ensure watertight integrity, follow the cut‑away illustration of the jetdrive unit and hull andapply sealant to the mating surfaces and to all bolt shanks and heads to seal the jetdrive unitto the hull .

cab

d

e d

f

17832

c

Cutaway Sectiona - Washerb - Locknutc - M10 Socket head cap screw

d - Sikaflexe - Jet unit bodyf - Boat hull or transom

12. Using a trolley jack, position the jetdrive in the hull.13. Insert all cap screws and bolts, applying sealant on the shank and head of the bolt to ensure

a good seal.14. Place a small amount of stainless steel anti‑seize compound on the threads. Place a flat

washer and a locknut on each fastener and follow the following torque sequence to ensurethe unit seals evenly on both surfaces.


Stainless Steel Anti-SiezeCompound Stainless steel bolts Obtain Locally

15. Hand tighten all the bolts in the sequence given below.



16. Torque all bolts in the sequence given to ensure a watertight seal.

1210

8

6

2

1

5

7

9

11

3

21

19

17

23

24

18

20

22

4

26

25

15

13

14

16

6888

Torque Sequence


Bolts 27 20

Prepare the EngineEngine Preparation ‑ 1.7L MJ DieselPREPARE ENGINE

1. Remove and read all tags attached to the engine.2. Remove all hardware that secures the engine to shipping container.3. Remove and discard the gear lube bottle.



4. Remove the shift plate by removing the three 8 mm bolts. Discard the shift plate, it is notrequired for jet installation.

6924

a

a - Shift plate

CHANGE COUPLERREMOVAL OF COUPLER

1. Remove and save the shift bracket bolts.NOTE: The shift bracket must be moved to the remove bell housing. The bracket is connected tothe engine by wires to the overload protection circuit. Use care not to break or kink the wires orthe connector.

6925

a

a - Shift bracket bolts



2. Support the engine and remove the seven 10 mm and the two 12 mm flywheel housing bolts.Remove the flywheel housing. Bolts are different sizes and thread pitches. Note locations forre‑assembly.

6926

a

a - Flywheel housing bolts.

3. Remove the six engine coupler bolts and remove coupler.

6927

aa

b

a - Coupler bolts b - Coupler



INSTALLATION OF INERTIA-DAMPING COUPLER1. An inertia‑damping coupler must be fitted to the engine flywheel in place of the standard

sterndrive flywheel coupler. Install the new coupler assembly. Apply sealant to theinertia‑damping coupler bolts and torque to specifications.

6928

a b

a - Coupler b - Coupler bolts


86 Loctite 262 Coupler Fasteners Obtain Locally


Inertia coupler bolts 44 32.5

2. Hold the flywheel and remove the four bolts holding the coupler gear shaft from the coupler.

a b

8797

a - Bolts b - Coupler gear shaft

3. Reinstall the flywheel housing and the shift bracket, paying attention to the location of thespecific bolts, as marked previously.



NOTE: Different thread patterns and fastener combinations are used to hold the coupler andflywheel cover. Ensure the proper placement of each. Be sure to note the position and orientationof any electrical harness wires.

6882

gf

g

cd b

d e

h

j i

a

a - Flywheel housingb - Bolt, washers and nut ‑ M10 X 1.5 X

60c - Bolt and washers‑ M10X 1.5 X 30d - Bolt and washers ‑ M12X1.25 X 55e - Bolt and washers ‑ M12X1.75 X 55

f - Bolt and washers ‑ M12X1.75 X 35g - Bolt and washers ‑ M12X1.75 X 30h - Flat washeri - Lock washerj - Flywheel Coupler


M10 Socket Head Bolts 44.1 33

M12 Socket Head Bolts 86 64

4. Apply a light coat of 2‑4‑C Marine Lubricant with Teflon to shift bracket mounting surfaces andfasteners prior to installation.


95 2-4-C with Teflon Shift bracket mountingsurfaces, bolt threads 92-802859A1



5. Install shift bracket front two bolts. Torque bolts.

6925

a

a - Front bolts for shift bracket


Bolt, shift and electricalbracket

M10 x 1.25 38 28

M8 x 1.25 19 168 28

ENGINE IDLE SPEED ADJUSTMENT SCREW - 1.7 MJSome engines require adjustment to the idle for use with the jetdrive. Refer to appropriateprocedure below for your power package, if listed.NOTE: This procedure is for the 1.7L Diesel engine connected to the jetdrive only. Follow theinstructions in the appropriate Cummins MerCruiser Diesel Engine Installation Manual to adjustthe idle speed on all other engines, if necessary.

! CAUTIONThe wide open throttle (WOT) stop screw next to the injector pump lever adjusts the enginespeed governor, and is set and sealed at the factory. Do not readjust this setting. Readjustingthe governed speed and operating above the specified rpm will cause extensive engine damageor failure. Removal of the seal or readjustment of the WOT stop screw is considered misuse ofan engine and the resulting damages will not be covered by the limited warranty

IMPORTANT: Setting the idle speed requires an accurate tachometer, usually available only at aservice facility. Do not set the idle with the on‑board tachometer which is probably not accurateenough to accomplish this process adequately. Improper adjustment can result in dangeroussituations or poor engine performance.Idle speed must be 850 RPM at normal operating temperature. If necessary, proceed with thefollowing readjustment.



1. The idle adjusting screw is on the front side of the fuel injector pump, and is secured by ajam‑nut. Using a 10mm wrench, loosen the jam‑nut and remove both the jam‑nut and the idleadjustment screw.

ab

c

d

6709

a - Idle adjusting screwb - Injection pump lever

c - Injection pump lever stopd - Jam‑nut

2. Remove the jam‑nut from the idle adjustment screw.3. Screw the jam‑nut onto new, longer idle adjustment screw supplied with engine kit.4. Install new idle adjustment screw into idle adjustment screw hole until it just touches the

injection pump lever stop, being careful to leave the end of the screw with the screwdriver slotfacing out.

NOTE: Engine idle adjustment for the 1.7L must take place in the water. Refer to Boat in the WaterTests in Section 9 Predelivery Preparation and Storage

Install Water Pump Kit ‑ 1.7L Diesel only1. Loosen the lower fasteners that hold the adjusting brace for the power shift pump .2. Remove the screw and washers attaching the upper adjusting brace holding the power shift

pump. Discard the fasteners and drive belt.

8699

a

b

d

c

a - New bracket fastener locationb - Upper power shift pump adjusting

brace attaching screw and washers

c - Bracketd - Drive belt

3. Align the small hole in the seawater pump flange with the damper pulley pin.



4. Ensure that the seawater pump flange is seated on the damper pulley pin. Install the nuts withlockwashers. Torque the seawater pump flange nuts.



5. Install drive belt on pulley and power shift pump.6. Install the lower bracket bolt with lockwasher. Torque the lower bracket bolt.

6937

a

b c

d

e

a - Lower bracket bolt and lockwasherb - Nuts and lockwashersc - Damper pulley pin

d - Seawater pump outlet hosee - Seawater pump inlet hose


Lower bracket bolt 24 212

7. Attach water pump bracket to engine block with two bolts provided. Torque the bolts.


Water pump bracket bolts 37 27



8. Reattach brace to location shown in step 2 using the fastener provided. Adjust belt to propertension. Check tension by depressing the upper strand of the drive belt with light thumbpressure (approximately 5 kgf (11 lbf), at point shown. Belt should move no more than5 mm (3/16 in.) either way. Secure the fasteners.

a7204

Check tension at Arrowa - Power steering pump belt

9. Connect the seawater pump outlet hose to the seawater pump. Tighten the hose clamp.10. Connect other end of the seawater pump outlet hose to the seawater inlet at rear of engine.

Tighten the hose clamp.11. To avoid hoses rubbing or kinking, install clips and tighten.

7143

a

b

cc

d

Seawater hose from pump to intakea - Seawater pumpb - Seawater pump outlet hose

c - Clipsd - Seawater inlet

Engine Preparation ‑ 2.8L EJ and 4.2L EJPREPARE ENGINE

1. Remove and read all tags attached to engine.2. Remove all hardware that secures engine to shipping container.3. Remove and discard gear lube bottle.4. Remove shift plate by removing the three 8 mm bolts. Discard the shift plate, it is not required

for jet installation.



CHANGE COUPLERREMOVAL OF STANDARD COUPLER

1. Remove the starter.2. Remove the two flange screws retaining the engine harness connector bracket, and

MerCathode controller if equipped, to the flywheel housing.3. Remove the two turbocharger support bracket screws.

a

b

cd

10376

Sterndrive modela - Engine harness connector bracketb - Engine harness connector bracket

screw

c - Turbocharger support bracketd - Turbocharger support bracket screw

4. Remove the engine RPM speed sensor (magnetic tachometer pickup).

a

b

11649

a - Engine RPM speed sensor b - Screw

5. Remove the flywheel housing cover.



6. Remove the standard coupler.

a

b

cd

10301

a - Coupler boltsb - Standard Coupler

c - Adapter plate bolts (On early modelsonly)

d - Adapter plate (On early models only)

INSTALLATION OF COUPLER1. Apply sealant to bolt threads and install the sterndrive snubnose coupler.

ab

18285d

c

e

fa - Flywheel coverb - Standard coupler (supplied with

engine)c - Flywheel

d - Coupler (supplied with jetdrivepackage)

e - Coupler boltsf - Flywheel housing bolts


7 Loctite 271 Threadlocker Sterndrive coupler or inboarddrive plate bolt 92-809819



2. Torque the coupler bolts.

18287

a

b

a - Coupler bolts b - Coupler


Sterndrive coupler bolt 47.1 34

3. Install the flywheel housing cover. Connect the ground (–) wires, if equipped. Torque theflywheel cover bolts.

18289

a

b

c

Couplera - Flywheel coverb - Ground (–) wires

c - Flywheel cover bolt


SAE 5 Sterndrive flywheel housing cover bolt (with adapter plate) 47.1 34

4. Install all other components removed.

Prepare the JetdriveJetdrive Preparation—1.7L

1. Remove the jetdrive input shaft coupling from the engine coupling by removing the fourmounting bolts. The seal and snap ring are pre‑installed on the spline end of the input shaftcoupling.



! CAUTIONDo not use torn or damaged seals. Torn or damaged seals can allow lubricating fluids to leakout, possibly causing damage to internal parts. If the seal is damaged during assembly, replacewith a new seal.

2. Lubricate the gear shaft splines on the gear shaft coupler and insert the gear shaft couplerinto the jetdrive.


91 Engine Coupler Spline Grease Gear shaft coupler 92-802869A1

3. Insert the seal into the jetdrive with the coupler in place.4. Install the snap ring to secure the seal using the correct snap ring pliers.

7133

a

Gear shaft coupler attached to jet drivea - Gear shaft coupler

5. Ensure that the snap ring is secured in the groove.

6932

b

c

a

a - Sealb - Snap ring

c - Gear shaft coupler



6. Lubricate the gear shaft coupler with engine coupler spline grease through the grease fitting.


91 Engine Coupler Spline Grease Engine coupler 92-802869A1

Jetdrive Preparation—2.8L and 4.2L1. Remove the jetdrive splined input shaft from the jetdrive by removing the large snap ring and

seal. The seal and snap ring are pre‑installed on the spline end of the input shaft couplingwithout snap ring spline grease.

! CAUTIONTorn or damaged seals can allow lubricating fluids to leak out or water to enter the gearbox,possibly causing damage to the internal parts. If the seal is damaged during assembly, replacewith a new seal.

2. Lubricate the gear shaft splines on the gear shaft coupler and insert the gear shaft couplerinto the jetdrive.


91 Engine Coupler Spline Grease Gear shaft coupler 92-802869A1

3. Insert the seal into the jetdrive with the coupler in place.4. Install the snap ring to secure the seal using the correct snap ring pliers.5. Ensure that the snap ring is secured in the groove.6. Lubricate the splined input shaft coupler with engine coupler spline grease.


91 Engine Coupler Spline Grease Engine coupler 92-802869A1

Installing the Engine1.7L Engine

! CAUTIONAvoid product damage caused by improper engine to jetdrive alignment. Improper enginealignment can be caused by mismatched flywheel housing mounts and engine mount platemounting hardware, or by inaccurate alignment. Ensure that the flywheel housing mounts andthe engine mount plate mounting hardware, port and starboard, are the correct parts and matchbefore installing the engine, and that the engine is within 0.5 degrees of parallel. Failure toproperly align engine with the jetdrive will result in coupler damage and failure.

Refer to the appropriate Cummins MerCruiser Engine Installation Manual provided with yourpower package or Cummins MerCruiser Diesel Application Manual for details regarding yourspecific engine.

! CAUTIONEngine MUST be lifted with a lifting arm or damage to engine components could occur.

1. Attach a suitable sling and lifting arm to the engine lifting eyes and adjust so that the engineis level when suspended. Refer to the Engine Installation Manual that came with your powerpackage for details.

2. Remove all hardware that secures the engine to the shipping container.



3. Lift the engine into position in the boat using an overhead hoist. Refer to the Engine InstallationManual that came with your power package for details.

! CAUTIONWhen lowering engine into position do not set engine on shift cable. Shift cable outer casing canbe crushed causing difficult or improper shifting.

4. Align the rear engine mounts with the jetdrive engine mount while simultaneously aligning theengine coupler to the coupler on the jetdrive. Do not relieve hoist tension.

a

b 6526

Typicala - Rear engine mount b - Jetdrive mount

IMPORTANT: Engine attaching hardware must be installed in sequence shown.



ENGINE TO JETDRIVE MOUNT BOLT ARRANGEMENT

8055

Jetdrive Serial Numbers 1D000001through 1D000124

8055

Jetdrive Serial Numbers 1D000125and Above

a

cb

d

hg

f

6911

e

a - Boltb - Large washerc - Spacerd - Rear engine mounte - Shim washer DJ1023B

(0.065" thick)f - Fiber washerg - Engine mount plate,

(jetdrive)h - Nyloc nut

a

bc

d

fg

h6912

e

a - Boltb - Large washerc - Spacerd - Rear engine mounte - Mount to rest directly on

engine mount platef - Fiber washerg - Engine mount plate,


NOTE: Refer to the appropriate Mercury MerCruiser or Cummins MerCruiser Diesel EngineInstallation Manual provided with the power package for details regarding this procedure.1. Torque both rear engine mounting bolts.IMPORTANT: The finished boat stringer must position the front engine mount so that a minimumof 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer(structure) height to obtain the 6 mm (1/4 in.) dimension.2. Adjust the front engine mounts until they rest on the boat stringer.3. Set the engine on the stringers.4. Relieve the hoist tension and disconnect the sling from the engine lifting eyes.IMPORTANT: Complete the alignment process "Aligning the Engine to the Jetdrive" beforepreceding with the next steps.5. Line up the alignment marks on the coupler for easier bolt assembly



6. Connect the engine coupler to the jetdrive gear shaft coupler using the bolts previouslyremoved from the coupler.

a

17023

b

High inertia couplera - High‑inertia damper ring b - Gear shaft coupler bolts

NOTE: Some engines with early couplers will also be equipped with a separate high‑inertia ring,similar to in the photo above. The higher inertia is required to keep the units from clattering atengine speeds below 1300 RPM.7. Grease coupling with 2‑4‑C lubricant using the grease fitting on the coupler shaft.


95 2-4-C with Teflon Grease fitting on coupler shaft 92-802859A1

Install the 2.8L and 4.2L Engines


Refer to the appropriate Cummins MerCruiser Engine Installation Manual provided with yourpower package or Cummins MerCruiser Diesel Application Manual for details regarding yourspecific engine.

! CAUTIONEngine MUST be lifted with a lifting arm or damage to engine components could occur.



1. Attach a suitable sling and lifting arm to the engine lifting eyes and adjust it so that the engineis level when suspended.

13959

a

b

c

2.8L shown, typicala - Front lifting eyeb - Rear lifting eye

c - Suitable sling

2. Remove all hardware that secures the engine to the shipping container.3. Lift the engine into position in the boat using an overhead hoist. Refer to specific engine

manual for your engine for details.



4. Align the rear engine mounts with the Jetdrive engine mount while simultaneously aligning theengine coupler to the coupler shaft on the jetdrive. Do not relieve hoist tension.

11161

a

b

d

c

4.2L Diesel showna - Rear engine mountb - Jetdrive engine mount

c - Engine couplerd - Jetdrive coupler shaft

5. Move the engine back onto jetdrive input shaft until bolt holes on the mounts are aligned.6. Determine the jetdrive serial number and use the appropriate fastener combination from the

following tables in Engine to Jetdrive Mount Bolt Arrangement.IMPORTANT: Engine attaching hardware must be installed in sequence shown.



ENGINE TO JETDRIVE MOUNTING BOLT ARRANGEMENT

8055

Jetdrive Serial Numbers 1D000001through 1D000124

8055

Jetdrive Serial Numbers 1D000125and Above

a

cb

d

hg

f

6911

e

a - Boltb - Large washerc - Spacerd - Rear engine mounte - Shim washer DJ1023B

(0.065" thick)f - Fiber washerg - Engine mount plate,


a

bc

d

fg

h6912

e

a - Boltb - Large washerc - Spacerd - Rear engine mounte - Mount to rest directly on

engine mount platef - Fiber washerg - Engine mount plate,




1. Torque both rear engine mounting bolts with hardware as described above.

11162

a

a

4.2L Diesel showna - Rear engine mounting bolts

Description Nm lb‑in. lb‑ft


IMPORTANT: The finished boat stringer must position the front engine mount so that a minimumof 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer(structure) height to obtain the 6 mm (1/4 in.) dimension.2. Adjust the front engine mounts until they rest on the boat stringer.3. Set the engine on the stringers4. Relieve hoist tension.5. Disconnect the sling from the engine lifting eyes.

Aligning the Engine to the JetdriveThe alignment process is done with all engines. The alignment must be within 0.5º of parallel inboth horizontal and vertical planes.


Support the EngineThere are different systems for each engine to support the engine for engine to jetdrive alignment.1. Support the engine with a suitable hoist, distributing the weight of the engine just enough to

remove pressure from mounts, but not enough to actually lift engine.• The 1.7L engine has a center lifting eye that is purchased and installed on the engine.



! CAUTIONCenter lifting eye is used for engine alignment only. Do not use to lift entire engine.

16872

a

a - Center lifting eye

• The 2.8L engine has no lifting arrangement, but can be slid into position on its mounts.• The 4.2L engine has two lifting eyes that are mounted on the engine at all times. Attach

hoist chains with a leveler attachment, and level the engine so that the weight is evenlydistributed among the mounts with the engine in the proper position.

AlignmentAlignment is complete when the centerline of the jet drive is within 0.5° from parallel with thecenterline of the engine crankshaft in any direction. This is accomplished by moving the engine inits mounts as described in the Protractor Alignment Method and Horizontal Alignment Method,which follow.

7376

a

b

c

Typical vertical alignmenta - Engine centerlineb - Jetdrive centerline

c - Within 0.5° from parallel



Protractor Alignment MethodThe principal method for establishing the engine to jetdrive alignment is to use a universalprotractor to measure the angular relationship of the engine to the jetdrive (e.g. Snap‑on tool no.YA328A). Any protractor that is used must be calibrated to read to 0.5º degrees or better. Referto your specific engine service manual for details on aligning the engine.

! CAUTIONIt is very important that the vessel is kept at the same inclination and position for this alignmentprocedure. Any movement of the vessel during this procedure may cause incorrect alignment.

HORIZONTAL ALIGNMENT METHOD1. Prepare engine for alignment:

a. On the 1.7L MJ: Using the center lifting eye tool with chain sling, take up the tension inthe hoist so that it only just starts to take the weight of the engine and allows the engineto move freely left to right within the front mounts. Refer to the engine installation manualprovided with this power package for details.

b. On the 2.8L EJ: To move the engine left or right: Loosen the locknuts on the mounts.Move the engine as necessary in the slotted mount. Refer to the engine installationmanual provided with this power package for details.

c. On the 4.2L EJ:Using the hoist with a leveler attachment, take up the tension in the hoistso that it only just starts to take the weight of the engine and allows the engine to movefreely left to right within the front mounts. Refer to the engine installation manual providedwith this power package for details.

2. Take measurements from the aft face of the water jet mount plate across any symmetricalreference points on the engine bell housing or the bell housing mount bolts themselves.

a

b

c

d

e

f

7214

Typical horizontal alignmenta - Left measurement pointb - Right measurement pointc - Symmetric reference point on rear of

engine bell housing

d - Centerline of jet mainshafte - Centerline of engine crankshaftf - Within 0.5° degrees from parallel

IMPORTANT: On engines equipped with trunnions, the large diameter of mount trunnion must notextend over 30 mm (1‑5/32 in.) from the edge of the mount bracket to the centerline of the mountstud on the trunnion‑equipped engines.



3. Move the engine left or right until measurements are within 2 mm (0.079 in.) of being equal.

7939

b

c

a

Port front mount, (Starboard similar) 2.8L, Left and right adjustmenta - Locknutb - Adjusting nut

c - Large diameter of mount trunnion

4. Torque the trunnion clamp bolts, if equipped.

c

8798

a

b

c

Front mount 1.7L, 4.2L similara - Trunnion clamp boltb - Mount trunnion maximum

extension ‑ 30 mm (1‑5/32 in.)

c - Mount bracket


Trunnion clamp bolt 57 42

5. Release the hoist tension to allow the front engine mounts to take the full weight of the engine.



VERTICAL ALIGNMENT1. Attach the protractor to either the reverse shaft or the steering shaft on the outboard part of

the jet unit.

7340

a

Jetdrive alignment surfacea - Steering shaft

2. Accurately read and record the measurement (in degrees) from the protractor.

! CAUTIONIt is very important that the vessel is kept at the same inclination and position for this alignmentprocedure. Any movement of the vessel during this procedure may cause incorrect alignment.

3. Reposition the protractor to a suitable machined reference surface on the engine. This surfacemust be accurately machined so as to be known to be parallel to the engine crankshaft.

7341

a

1.7L MJ alignment referencea - Heat exchanger



a

b

18306

2.8L EJ alignment referencea - Protractor b - Front of crankshaft pulley

18307

a

b

4.2L MJ alignment referencea - Protractor b - Top of crankshaft pulley

4. Loosen both of the locknuts on the front mounts.IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in the directionrequired to align the engine to maintain equal weight on the mounts.



5. Turn the adjusting nuts as required to raise or lower the front of the engine so that the engineangle is within 0.5º to the angle measured from the jetdrive.

6876

a

ba

b

1.7L Front mount, 4.2L similara - Locknut b - Tab washer

7938

a

b

2.8L Front mounta - Locknut b - Adjusting nut

6. Torque all engine mount locknuts.


Engine mount locknut 80 59

! CAUTIONEngine alignment procedure is to be repeated / checked at 100 hours or first service interval,which ever occurs first.

Secure Front Mounts and Final Check1. Secure front mounts to the engine bed with appropriate fasteners.2. Re‑check all dimensions again to ensure that the vertical alignment is within specifications.3. If the vertical alignment is no longer within specification, repeat both the vertical and horizontal

alignment procedures until correct.



4. Bend the tab washer down flat on the adjusting nut.

6876

a

ba

b

Typicala - Locknut b - Tab washer

Jetdrive Gear Lube Monitor1. Ensure that the jetdrive gear lube monitor bottle is installed and secured with a rubber strap.2. Ensure that the hose is attached from the gear drive to a gear lube monitor bottle.

7966

a

b

c

d

a - Gear lube monitorb - Rubber strap

c - Hose barb on gear lube monitor bottled - Hose barb on gear case

NOTE: If gear lube monitor is empty, refer to the Jetdrive Service Manual for filling instructions.Observe occasionally for leaks.3. Fill to the operating range (full) line with specified fluid, if needed.


87 High Performance GearLubricant Gear Lube Monitor 92-802854A1

4. Replace the gear lube monitor cap.5. Inspect the rear bearing for the proper amount of fluid.

a. Put the reverse gate in the forward position.



b. Using a flat blade screwdriver, remove the top vent screw.

9072

a

a - Top vent hole

c. Lubricant is added through the top vent hole until it reaches this level and flows out. Therear bearing requires 370 ml of Premium Gear Lube when empty.


87 High Performance GearLubricant Jetdrive rear bearing 92-802854A1

d. Inspect the condition of the vent screw washer and replace if required.e. Install the vent screw.

SECTION - 7 STARTING AND ELECTRICAL


SECTION 7 - STARTING AND ELECTRICALTable of ContentsStarting and Electrical - Jetdrive.............................................................................................................................. 2

7

STARTING AND ELECTRICAL SECTION - 7


Starting and Electrical ‑ JetdriveThere are no electrical or starting components on the Jetdrive unit.For information regarding the starting battery, battery cables, instrumentation, and wiringdiagrams, refer to the Sterndrive Installation Manual provided with your power package for yourappropriate engine.For installation information on the electrical portion of the optional Trim System, refer to theinstruction sheet that comes with the optional Trim System.

SECTION - 8 REMOTE CONTROLS


SECTION 8 - REMOTE CONTROLSTable of ContentsPower Trim System (If equipped)............................................................................................................................ 2Steering Helm and Cable........................................................................................................................................ 2Forward and Reverse Operation—Remote Control and Cables............................................................................. 6

Jetdrive Reverse Bucket Hydraulic Hose Installation—1.7L Only.....................................................................6Jetdrive Reverse Bucket Hydraulic Hose Replacement—2.8L and 4.2L Only..................................................7

Removal ..................................................................................................................................................... 7Installation .................................................................................................................................................. 8

Forward and Reverse Operation—Jetdrive.......................................................................................................9Direction of Jet Flow ................................................................................................................................ 10Separate Forward and Reverse Operation and Throttle Controls ........................................................... 10Forward and Reverse Operating Cable Installation And Adjustment ...................................................... 10

Bleeding Procedure for Reverse Bucket Pump...............................................................................................11Adjust Reverse Bucket Controls......................................................................................................................12

Preparation .............................................................................................................................................. 12Adjustment ............................................................................................................................................... 13

Checking Forward and Reverse Operating Cable Adjustment........................................................................19Checking Forward and Reverse Operating Cable Installation and Adjustment ....................................... 19

Throttle Cable Installation and Adjustment......................................................................................................22

8

REMOTE CONTROLS SECTION - 8



114 Power Trim and Steering Fluid Power steering pump 92-802880A1

131 Loctite 5920 Ultra Copper Hi Temp RTV Silicone Reverse shaft ball joint nut Obtain Locally

Power Trim System (If equipped)The optional Power Trim System can be used with any of the Quicksilver panel or in‑handle trimcontrols (that are specified for use with MerCruiser sterndrives) that are equipped with either thebullet or the pig nose connectors. Install trim control in accordance with instructions thataccompany it.

Steering Helm and CableJetdrive assembly is equipped with a steering lever that will accommodate attachment pointsdesigned for cables with end dimensions that comply with ABYC standards as outlined in theNMMA certification handbook. Neither the steering attachment point nor the cable mountingbracket is supplied with the jetdrive. The bracket and the attachment point can be purchasedseparately with the steering cable. The steering cable coupler nut must also have a means oflocking it to the guide tube as specified in ABYC requirements.

! WARNINGFailure to use a steering cable locking device could cause loss of steering, causing possibledamage to the boat or injury.

All current production Quicksilver RideGuide steering cables have a self‑locking coupler nut anddo not require an external locking device. (Other cable manufacturers also make cables withself‑locking coupler nut.)

7255

a

a - Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove)



If using a steering cable that does not have a self‑locking coupler nut, an external locking devicemust be used.

a

b

c

d

e

f

7256

a - Steering cableb - Grease fittingc - Cotter pin

d - Locking sleeve (must be orderedseparately if required)

e - Cable coupler nutf - Cable guide tube

! CAUTIONMANUAL STEERING UNITS ONLY: Do not attempt to adjust cable guide tube on pivot block,as guide tube and locknut have been torqued with Loctite at the factory. An attempt to loosennut or tube may result in damage to tube.

1. Ensure that the steering cable is the correct length, particularly when installed in larger boats.2. Avoid sharp bends, kinks, or loops when routing the cable.



3. Fully extended steering cable end dimension must be as shown in the following.

CL

ab

c

de

fg

hi

jk

l

7254

a - Coupler nut —7/8‑14 UNF‑28 threadb - 298 mm (11‑3/4 in.) minimumc - Interface pointd - 12.7 mm (1/2 in.) maximume - 10.7 mm (27/64 in.) minimum flatf - 3.1 mm (7/64 in.) minimum radius

g - 15.9 mm (5/8 in.) maximum diameterend fitting

h - 9.5 mm (3/8 in.)i - 9.8 mm (3/8 in.) diameter through hole

(chamfered each side)j - 34.9 mm (1‑3/8 in.) maximumk - 15.9 mm (5/8 in.) diameter tubel - Cable travel, see Cable Travel table for

measurements

Cable Travel Measurements

Mid‑travel position 429 mm (16‑7/8 in.)

Total travelminimum 203 mm (8 in.)

maximum 228 mm (9 in.)

Travel each side of mid‑travel positionminimum 102 mm (4 in.)

maximum 114 mm (4‑1/2 in.)

4. Center the steering wheel at the helm.5. With the jet nozzle centered, adjust the steering cable housing on the bracket until the end is

aligned with attachment point.



6. Connect the end of the steering cable to the attachment point.

a

b

7392

c

a - Attachment pointb - Bracket to hold the steering cable

housing

c - Steering cable

7. Verify that the steering wheel and jet nozzle are still centered.8. Secure the steering cable housing to the bracket.

a

7391

a - Bracket



9. Test the system by turning the steering wheel left and right, with corresponding movementfrom the jetdrive nozzle.

7393

a

b

7388

a - Cable fully extended for left turn b - Cable fully retracted for right turn

10. If binding occurs, or if the jetdrive nozzle can not fully turn left or right, adjust as necessary.

Forward and Reverse Operation—Remote Control and CablesJetdrive Reverse Bucket Hydraulic Hose Installation—1.7L Only

! CAUTIONAvoid injury or property damage. Extreme heat will lower the burst pressure or melt the hydraulichoses of the steering system. Stress on hose fittings or kinks in the hoses may cause hosefailure. Loss of directional control may occur. Route the hydraulic hoses to avoid kinks, extremeheat, and stress on the hose fittings.

1. Connect the high pressure hose fitting to the reverse bucket control valve. Ensure that thequick connect fitting is securely engaged.



2. Connect the low pressure hose fitting to the reverse bucket control valve. Ensure that the quickconnect fitting is securely engaged.

18226

a

b

a - Low pressure hose fitting b - High pressure hose fitting

3. Secure the hoses to the engine and jetdrive with tie straps if necessary.4. Fill and air‑bleed the system.

Jetdrive Reverse Bucket Hydraulic Hose Replacement—2.8L and 4.2L OnlyNOTE: The hydraulic hoses that are supplied with the engine are too short for use with the jetdrive.They will need to be removed and replaced with the longer hoses provided with the jetdrive.NOTE: Catch fluid that drains from from hose, cooler and pump in a suitable container.

REMOVAL1. Remove and discard the high pressure hose with pump fitting and O‑ring from the reverse

bucket pump.

a

b

c

18224

a - Pump fittingb - High pressure hose outlet

c - O‑ring



2. Remove and discard the low pressure hose from the fluid cooler.

a

b

c

18225

a - Fluid coolerb - Low pressure hose

c - Supply hose from reservoir (do notremove)

INSTALLATION

! CAUTIONAvoid injury or property damage. Extreme heat will lower the burst pressure or melt the hydraulichoses of the steering system. Stress on hose fittings or kinks in the hoses may cause hosefailure. Loss of directional control may occur. Route the hydraulic hoses to avoid kinks, extremeheat, and stress on the hose fittings.

IMPORTANT: Be careful to not cross thread or overtighten hose fittings.1. Connect the high pressure hose fitting to the reverse bucket control valve. Ensure that the

quick connect fitting is securely engaged.2. Connect the low pressure hose fitting to the reverse bucket control valve. Ensure that the quick

connect fitting is securely engaged.

18226

a

b

a - Low pressure hose fitting b - High pressure hose fitting

3. Route the low pressure hose to the connection on the fluid cooler.4. Cut the hose to length.

Engine Low Pressure Hose Length

2.8L EJ 105 cm (41 in.)



Engine Low Pressure Hose Length

4.2L EJ 125 cm (49 in.)

a

b

c

18225

a - Fluid coolerb - Low—pressure hose reverse bucket

control valve

c - Low—pressure hose from reservoir

5. Attach the hose and tighten hose clamp securely.6. Ensure that there is a new O‑ring on the high pressure hose pump fitting.7. Route the high—pressure hose to the reverse bucket pump.8. Thread the high—pressure hose pump fitting into the reverse bucket pump. Torque the pump

fitting.

a

b

c

18224

a - Pump fittingb - High pressure hose outlet

c - O‑ring


Pump fitting at pump 31 23

9. Secure the hoses to the engine and jetdrive with tie straps if necessary.10. Fill and air‑bleed the system.

Forward and Reverse Operation—JetdriveTo ensure proper shift and throttle operation, we recommend the use of a Cummins MerCruiserDiesel (or CMD) control box and control cables only. Refer to the Diesel Parts And AccessoriesGuide (CMD‑4081891 / 90‑892645004) for selection. However, if a control other than CumminsMerCruiser Diesel is to be used, control must provide the following:



Description Cable Travel At Shift Plate End with 6.8–9 kg 15–20 lb. LoadApplied

Forward and Reverse Operation Cable 73 mm to 80 mm (2‑7/8 in. to 3‑1/8 in.)

Throttle Cable 70 mm to 80 mm (2.75 to 3.125 in.)

DIRECTION OF JET FLOWIMPORTANT: Jet flow is determined by the position of the bucket controlled by the Forward andReverse Operation cable installation in the remote control.IMPORTANT: When installing Forward and Reverse Operation and throttle cables, be sure thatcables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do notfasten any items to Forward and Reverse Operation cables.

SEPARATE FORWARD AND REVERSE OPERATION AND THROTTLE CONTROLSIMPORTANT: Forward and Reverse Operating Cable must be connected at the remote controlfor the appropriate position of the bucket as explained in the following:

Forward or Bucket upThe control cable will have to be installed in the remote control so that cableend will move in direction "A" when the remote control handle is placed inthe forward position.

Neutral or Bucket at midpoint When cable is at the midpoint mark, the bucket should be in the midpoint orneutral position.

Reverse or Bucket downControl cable will have to be installed in remote control so that cable end willmove in direction "B" when the remote control handle is placed in the reverseposition.

B

A

6614

Arrows indicating direction of motion

FORWARD AND REVERSE OPERATING CABLE INSTALLATION AND ADJUSTMENT1. Locate center of remote control and control cable play (backlash).



IMPORTANT: Be sure to keep center mark "c" aligned with control cable end guide edge whenmaking the following adjustment.1. Put shift handle or forward and reverse operation remote control in the neutral position.2. Push in on control cable end with enough pressure to remove play and mark position "a" on

tube.3. Pull out on control cable end with enough pressure to remove play and mark position "b" on

tube.4. Measure distance between marks "a" and "b" and mark position "c" half‑way between marks

"a" and "b."

ab

c

6617

Finding neutral on the cable2. Temporarily install the control cable end guide into the forward and reverse operation lever

and insert the clevis pin.

Bleeding Procedure for Reverse Bucket Pump

! CAUTIONOperating the reverse bucket under power before it has been adjusted can result in damage tothe jetdrive or to the pump. Do not operate the reverse gate of the jetdrive until the reverse buckethas been adjusted.

IMPORTANT: All air must be purged to prevent the fluid in the pump from foaming and overflowingfrom the pump reservoir. Air in the power steering fluid causes power steering system to becomeless responsive, resulting in poor boat control.IMPORTANT: Use only Power Trim and Steering Fluid or automatic transmission fluid (ATF),Dexron, or Dexron II in the power steering system.1. With the engine off, position the reverse bucket so that it is in the neutral position. Remove

the fill cap and dipstick from the power steering pump. Add Power Trim and Steering Fluid,automatic transmission fluid (ATF), or Dexron II, as required, to bring level up to "FULL COLD"mark on the dipstick.


114 Power Trim and Steering Fluid Power steering pump 92-802880A1

2. Move the remote control back and forth to end of travel in each direction several times, andthen re‑check fluid level and add fluid, if necessary.

3. Install vented fill cap.

! CAUTIONDo not operate the engine without water flowing through the seawater pickup pump and thejetdrive intake, as damage to the seawater pickup pump impeller and jetdrive main seals couldoccur, causing subsequent overheating damage to the engine or seal damage to the jetdriveunit, or both.



4. Start the engine and run at fast idle (1000–1500 RPM) until procedure is complete. During thistime, move remote control back and forth to end of travel in each direction several times. Referto Operation, Maintenance, Warranty Manual provided with this power package for details onrunning your power package out of water.

5. Position the bucket so that it is in the neutral position and stop engine. Remove the fill capfrom pump. Allow any foam in pump reservoir to disperse, and then check fluid level and addfluid, as required, to bring level up to "FULL HOT" mark on the dipstick. Do not overfill.Re‑install the fill cap securely.

IMPORTANT: Reverse bucket must be positioned in the neutral position and power steering fluidmust be hot for an accurate reading of the fluid level.6. If the fluid remains foamy, repeat steps four and five until all the air in the fluid is purged and

the fluid level remains constant.

Adjust Reverse Bucket Controls

! WARNINGAvoid injury or death and power package damage from electrical shock, fire, or explosion. Alwaysdisconnect both battery cables from the battery before servicing the power package.

NOTE: Perform this procedure on all new installations before any water tests, as well as afterservice work that disturbs any adjusted settings, or required disassembly of the reverse gate,reverse gate operating mechanism, or both.

PREPARATION1. Disconnect the battery cables from battery.2. Lower the reverse bucket to its reverse position. You can do this while the engine is off by

moving the hand control to the full reverse position and then pushing down on the reversebucket to cause it to move to the reverse position.

7290

Reverse



8597

Pushing bucket down3. Disconnect the operating cable from the reverse mechanism by removing the two bolts that

attach it to the plunger shaft assembly and the lower feedback linkage respectively.

7293

a

b

a - Lower feedback linkage b - Plunger shaft assembly

ADJUSTMENT1. With the operating cable disconnected, place the hand control in the Neutral position.

7305



2. With the control lever in the Neutral position, adjust the operating cable anchor point alongthe cable set to 187 mm (7.375 in.) between the centers of the eyelets.

187mm

7.375

8598

Measure from centers of eyelets3. The tie rod assembly that connects the reverse tiller to the reverse gate must now be adjusted

to the lowered reverse gate which is resting against the lower stop. Support the reverse bucketand remove the tie rod bolt on the reverse bucket .

7298

a

a - Tie rod attachment point

4. Allow the reverse bucket to rest against the stop on the jetdrive.



5. Ensure that the power cylinder is in its fully retracted position. Push down on the lever armextension to allow hydraulic fluid to pass through the valve, and allow the piston to move.

7296

a

b

a - Cylinder end b - Lever arm extension

6. Attempt to re‑install the tie rod bolt of the reverse bucket through the ball joint back into thebucket arm. If it does not thread in directly, the tie rod assembly requires adjustment.



7. If adjustment is required, loosen the lower locknut and screw the rod end onto or off thethreaded rod to correct the alignment so that the bolt can now be installed.

7299

a

7300

b

a - Lower locknut b - Rod end

! WARNINGIt is most important that when making any adjustments that the reverse gate is caused to onlyjust touch the permanent stops or is held slightly away from the stop in this position. DO NOTadjust the ball joint to cause the reverse gate to be hard against this stop with the power cylindernot in its fully retracted position.

8. Ensure that the two washer spacers are in place either side of the ball joint.NOTE: Washer spacers are required to be used with the ball joint and these must be correctlyreinstalled for correct function.



9. With the operating tie rod adjusted, install the bolt securing the operating tie rod to the reverseshaft and tiller.

7298

a

a - Operating tie rod

10. Apply sealant to the threads of the ball joint bolt. Install and torque the ball joint nut.

7301

a

a - Upper ball joint nut


Reverse shaft and tiller ball joint nut 85 63


131 Loctite 5920 Ultra Copper HiTemp RTV Silicone Reverse shaft ball joint nut Obtain Locally

11. With this step completed ensure that the cylinder is in the fully retracted position with thereverse gate in the full down reverse position before proceeding.



12. Move the remote control lever to the full throttle reverse position to make it easier to attachthe cable anchor to the mechanism.

7302

13. Refit the free end of the operating cable to the plunger shaft clevis.

7285

a

a - Clevis



14. Connect the cable anchor point on the lower feedback linkage. Make sure that the cable ispositioned below the cable anchor pivot, as shown. If the cable is installed over the pivot, itwill bind the mechanism.

a b

8599

Cable below anchor pointa - Cable b - Anchor pivot

NOTE: Ensure that the 187 mm (7.375 in.) centers are maintained. Do not adjust the cable anchorfrom this setting during connection.15. Test and check function.

Checking Forward and Reverse Operating Cable AdjustmentCHECKING FORWARD AND REVERSE OPERATING CABLE INSTALLATION AND ADJUSTMENT

! WARNINGThis jetdrive has an internal rotating impeller that could cause injury if contact is made with hands,clothing, or tools. To avoid injury, keep hands and clothing away from the inlet and outlet of thejetdrive, regardless of whether the boat is in the water. Secure tools and loose items to avoidbeing struck by projectiles as a result of contact with the rotating impeller and to prevent damageto the impeller.

! WARNINGDo not put hands or feet on or in a running engine. Moving parts can cause injury. Keep clearof running engines during testing, and close hatch or cover when in use.

The engine must be running to perform the following tests. Refer to Section 9, Engine OperationTests, Boat Out Of The Water for more information.

! CAUTIONOverheating from insufficient cooling water will cause engine and drive system damage. Ensurethat there is sufficient water always available at water inlet holes during operation.

1. Ensure adequate water is available to the water inlet holes to avoid damaging the engine.2. Verify the remote control travel for forward.IMPORTANT: Do not use excessive force when holding pressure on the drive unit forward andreverse operating cable.



a. Place the remote control in forward position, past detent, into WOT position.

F N R

6636

b. Check that the bucket is in the full upright and forward position.

7266

Bucket in full upright and forward position3. Verify remote control travel for reverse.‑

a. Place the remote control in reverse position, past detent, into the WOT position.

F N R

7269

F N R



b. Check that the bucket is in the full down and reverse position.

7267

Bucket in full down and reverse position4. Verify remote control travel for Neutral‑

a. Place the remote control in the neutral detent and position.

F N R

7321

FN

R

b. Check that the bucket is in the neutral position, with the bucket covering about 75% ofthe nozzle.

7267

Neutral position (75% down)5. If any of these positions are not achieved, refer back to Install and Adjust Reverse Bucket

Controls.



IMPORTANT: An additional adjustment may be needed because:• An extra long remote control forward and reverse operating cable is used.• The remote control has inadequate output travel.• A large number of bends in remote control forward and reverse operating cable.

Throttle Cable Installation and AdjustmentRefer to the appropriate Cummins MerCruiser Diesel Engine Installation Manual provided withyour power package.NOTE: The 1.7L engine requires significant throttle adjustment that must be done in the water forthis application. Refer to Boat in the Water Tests in this manual for details.

SECTION - 9 PREDELIVERY PREPARATION AND STORAGE


SECTION 9 - PREDELIVERY PREPARATION ANDSTORAGE

Table of ContentsOther Fluids Used.................................................................................................................................................... 2Predelivery Preparation........................................................................................................................................... 2

Coolant Recovery—1.7L and 4.2L ................................................................................................................... 2Coolant Level - 2.8L EJ .................................................................................................................................... 3Power Shift Assist Pump .................................................................................................................................. 4Battery Connection ........................................................................................................................................... 5Drive Unit Gear Lube Monitor ........................................................................................................................... 5

Engine Operation Tests........................................................................................................................................... 5Boat Out of the Water ....................................................................................................................................... 6Boat In the Water ............................................................................................................................................. 6Testing Preparation .......................................................................................................................................... 6Testing .............................................................................................................................................................. 7Checking Shift Operation ................................................................................................................................. 8Boat In The Water Tests .................................................................................................................................. 8

1.7 MJ Engine Idle Speed Adjustment ....................................................................................................... 8Replace Idle Adjustment Screw (if not already changed) .......................................................................... 9Maximum RPM Test - All Models .............................................................................................................. 9

Jet Trim Kit Installation (If equipped)..................................................................................................................... 10Predelivery Inspection Checklist........................................................................................................................... 11

9

PREDELIVERY PREPARATION AND STORAGE SECTION - 9



Dexron III Automatic Transmission Fluid Power shift assist pump Obtain Locally

34 Special Lubricant 101 Steering cable and clevis 92-802865A1

87 High Performance Gear Lubricant Gear lube monitor 92-802854A1

114 Power Trim and Steering Fluid Power shift assist pump 92-802880A1

123 Marine Engine Coolant Coolant recovery bottleClosed cooling system 92-813054A2

Other Fluids UsedDescription Where Used Part Number

Fleetguard Compleat withDCA4 Closed cooling system Fleetguard Part Number: CC2825

Obtain Locally

Predelivery PreparationNOTICE

Before starting Predelivery, read General Information and Installation Requirements completely.

Take the following final steps to prepare power package for delivery to the customer after thepower package installation is complete. It is the boat manufacturer's responsibility to perform theseprocedures or to have the dealer to complete these procedures.

Coolant Recovery—1.7L and 4.2L1. Remove the cap from the coolant recovery reservoir and fill to full mark with coolant solution.

Reinstall the cap.2. Recheck the coolant level after the first WOT boat test and add coolant, if necessary.3. Maintain the coolant level in the coolant recovery reservoir between add and full marks with

the engine at normal operating temperature.

a

b

6704

1.7L MJa - Cap b - Full mark



6102

4.2L EJ


123 Marine Engine Coolant Coolant recovery bottle 92-813054A2

Coolant Level ‑ 2.8L EJ

! CAUTIONAvoid serious injury from burns. Do not remove the coolant cap when the engine is hot. Coolantmay discharge violently.

IMPORTANT: Check engine coolant before starting the engine.1. Allow the engine to cool if it is warm or hot.2. Remove the pressure cap from the coolant expansion tank.3. The coolant level in the coolant expansion tank should be within 25 mm (1 in.) of the bottom

of the filler neck or between the upper and lower marks, if marked.

16605

b

a

c

a - Coolant expansion tankb - Pressure cap

c - Bottom of filler neck

IMPORTANT: When installing the pressure cap, be sure to tighten it securely to prevent coolantloss.4. Add the specified coolant as necessary to bring the level to within 25 mm (1 in.) of the bottom

of the filler neck or between the upper and lower marks, if marked.




123 Closed cooling system 92-813054A2

Description Where Used Part Number

Fleetguard Compleat withDCA4

Closed cooling system

Fleetguard Part Number: CC2825Obtain locally

Marine engine coolant 92‑813054A2Europe only

5. Install the pressure cap. Tighten securely.6. With the engine at normal operating temperature, check the coolant level in the coolant

expansion tank. Protect your hand from the scalding coolant and carefully turn the pressurecap to allow any pressure to escape slowly. Then remove the cap.

Power Shift Assist PumpIMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatictransmission fluid (ATF) in power shift assist system.

! CAUTIONDo not operate the power shift assist without fluid. Otherwise the pump will be damaged.

1. With the engine off, position the jetdrive reverse bucket so that it is in the full upright andforward position.

2. Remove the cap and dipstick from the power shift assist fluid reservoir, and check the fluidlevel. Fill to the minimum mark. Do not overfill.

a

b

d

6707

c

a - Power shift assist fluid reservoirb - Cap and dipstick

c - Full hot markd - Minimum mark


114 Power Trim and Steering Fluid Power shift assist pump 92-802880A1

Dexron III AutomaticTransmission Fluid Power shift assist pump Obtain Locally



Battery ConnectionIMPORTANT: Engine electrical system is negative (–) ground1. Place the battery as close to the engine as possible2. Connect the engine positive (+) battery cable (usually red) to positive (+) battery terminal.3. Connect the engine negative (–) battery cable (usually black) to negative (–) battery terminal.4. Ensure that all battery terminal connections are tight.5. Spray the terminals with a battery connection sealant to retard corrosion.

Drive Unit Gear Lube MonitorIMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always checkoil level when drive is cool and engine is shut down.1. Remove the gear lube monitor cap.2. Fill the gear lube monitor to the operating range (full) line.

b a

6540

Typicala - Gear lube monitor cap b - Operating range (full) line


87 High Performance GearLubricant Gear lube monitor 92-802854A1

3. Ensure that the rubber gasket is inside the gear lube monitor cap.4. Install the gear lube monitor cap. Do not overtighten.5. Recheck the level of the gear lube after first use.

Engine Operation Tests! CAUTION

Water must be sprayed into the jet intake to keep ceramic seals cooled and lubricated whentesting the engine out of the water. Failure to keep the seals cool and lubricated will result intheir early failure and subsequent drive damage. Spray sufficient amounts of water into the jetintake to keep the shaft and seals cooled and lubricated.

Refer to the appropriate Cummins MerCruiser Diesel Jetdrive Owners Manual for the testingprocedures for your engine.The following conditions are unique to the jetdrive:• The jetdrive impeller is directly driven by the engine. The impeller is turning whenever the

engine is cranking or running. Keep hands clothing, and tools away from the jetdrive inlet andoutlet when the engine is running.

• The jetdrive mainshaft has a ceramic seal that must be kept wet and cool whenever the engineand jetdrive are running. Always provide sufficient water to the seals when operating the boatout of water.



Boat Out of the WaterIMPORTANT: Because of the potential difficulty of spraying adequate water into the inlet of thejetdrive and the risks involved, we strongly recommend that all engine operation tests be performedwith the boat in the water.The following information is for engine operation tests with the boat out of the water:

! WARNINGThis jetdrive has an internal rotating impeller that could cause injury if contact is made with hands,clothing, or tools. To avoid injury, keep hands and clothing away from the inlet and outlet of thejetdrive, regardless of whether the boat is in the water. Secure tools and loose items to avoidbeing struck by projectiles as a result of contact with the rotating impeller and to prevent damageto the impeller.

IMPORTANT: If using an adapter and a water hose to supply water to the engine seawater supplyinlet, do not use full water source pressure to the engine.1. Connect a hose between the adapter and a water source. Refer to the appropriate Cummins

MerCruiser Diesel Jetdrive Owners Manual provided with the power package.

! CAUTIONOverheating from insufficient cooling water will cause engine and drive system damage. Ensurethat there is sufficient water always available at water inlet holes during operation.

2. Spray sufficient amounts of water into jet intake to keep ceramic seals cooled and lubricated.3. Quickly check the following:

• basic engine function• reverse bucket operation• steering operation• gauge function.

Boat In the WaterThe following information is for engine operation tests with the boat in the water:IMPORTANT: If using a test tank ensure that the water level is above the seawater inlet holes onthe jetdrive.

7241

a

ba - Minimum water level b - Seawater intake

Testing PreparationIMPORTANT: During operation ensure that the engine seawater pump suction does not collapsethe hose to the water source causing the engine water supply to stop.1. Ensure that there is a sufficient supply of cooling water to the seawater inlet holes.



NOTE: Refer to the Operation, Maintenance and Warranty Manual provided with the product foroperating specifications and fluid capacities.IMPORTANT: The jetdrive unit oil level in the gear lube monitor will rise and fall during jetdriveoperation. Always check the oil level in the monitor when the jetdrive is cool and the engine is shutdown.2. Check the jetdrive unit oil level in the gear lube monitor.3. Test the audio warning system, if equipped, by moving the Panel Lights and Audio Test Switch

to the Test position.

Testing

! WARNINGDo not leave the helm unattended when performing tests with the boat in the water.

1. Ensure that the cooling system drain plugs and hoses are installed and tight.NOTE: Refer to the Operation, Maintenance and Warranty Manual provided with your powerpackage for operating specifications and fluid capacities.

! CAUTIONAvoid damage or injury. The turbocharger is a part of the exhaust system and can be HOT.Ensure that cables, hoses and lines are routed and secured away from the turbocharger.

2. Ensure cables, hoses and lines are routed a minimum of 102 mm (4 in.) from the turbocharger.3. Check the closed cooling system fluid level.

! CAUTIONAvoid possible injury or damage to the oil dipstick and internal engine components. Do notremove the oil dipstick when the engine is running. Stop the engine completely before removingor inserting the dipstick.

4. Check the engine oil level.5. Check the jetdrive oil level in the gear lube monitor.6. Check the drive belt tension.IMPORTANT: Avoid overheating the starter in the following step. Do not engage the starter formore than 15 seconds. Allow at least 1 minute of cool‑down time before engaging the starter foranother 15 seconds.7. On engines with a mechanical fuel injection pump: Pre‑lubricate the turbocharger and engine

by holding the stop switch engaged while you simultaneously turn the key switch to the startposition for 15 seconds. These actions turn the engine without starting it. Repeat the processas needed. Pre‑lubrication is complete when the indicator lamp shows the oil pressure.

8. Refer to Operation, Maintenance and Warranty Manual and start engine. Operate at a fastidle RPM until the engine reaches normal operating temperature.

IMPORTANT: On some diesel engines: The initial heating of the thermal insulating blanket on theturbocharger may result in some white smoke and burning smell in the area of the turbocharger,which is usually normal and occurs mostly during the first hour of engine operation.9. Watch all gauges for normal readings.10. Set the engine throttle to idle.11. Inspect the engine compartment for water, oil, fuel and exhaust leaks.12. Turn the steering wheel to starboard, and then to port to verify that the jetdrive nozzle turns

the correct way.13. Check the steering cable for smooth operation.14. Check for obstructions between all steering and shift components that move.



15. On the 1.7L MJ–stop the engine and turn the key switch off. On the 2.8L EJ and 4.2L EJ–stopthe engine by turning off the key switch.

16. Lubricate the steering cable and clevis.IMPORTANT: Ensure that the cable end that connects to the steering arm is heavily lubricatedwith Special Lubricant 101.

a

b

7390

a - Steering cable end b - Steering lever


34 Special Lubricant 101 Steering cable and clevis 92-802865A1

17. Position the jetdrive nozzle so that it is straight back.18. Remove the dipstick from the power shift assist fluid reservoir and observe the fluid level. The

fluid level should be between the full hot and add marks on dipstick.

Checking Shift OperationWith the engine operating, ensure that the jetdrive shifts properly, as explained in the following:1. Shift into forward and reverse, making sure that the bucket is in the selected position before

the engine begins to accelerate.2. If the proper results are not achieved in the previous steps, readjust the shift cables.3. When shifting from forward and reverse to neutral ensure that the jetdrive bucket is in neutral

before the remote control shift lever comes to the neutral detent position. Perform this checkusing various shifting rates to ensure that the jetdrive shifts the same whether shifting quicklyor slowly.

Boat In The Water TestsIMPORTANT: Do not perform the following with boat in a test tank or tied to dock.

1.7 MJ ENGINE IDLE SPEED ADJUSTMENTNOTE: This procedure is for the 1.7L Diesel engine connected to the jetdrive only. Follow theinstructions in the appropriate Cummins MerCruiser Diesel Engine Installation Manual to adjustthe idle speed on all other engines, if necessary.

! CAUTIONThe wide open throttle (WOT) stop screw next to the injector pump lever adjusts the enginespeed governor, and is set and sealed at the factory. Do not readjust this setting. Readjustingthe governed speed and operating above the specified rpm will cause extensive engine damageor failure. Removal of the seal or readjustment of the WOT stop screw is considered misuse ofan engine and the resulting damages will not be covered by the limited warranty



IMPORTANT: Setting the idle speed requires an accurate tachometer, usually available only at aservice facility. Do not set the idle with the on‑board tachometer because it is not accurate enough.Improper adjustment can result in poor engine performance.Idle speed must be 850 RPM at normal operating temperature. If necessary, proceed with thefollowing:

REPLACE IDLE ADJUSTMENT SCREW (IF NOT ALREADY CHANGED)1. The idle adjustment screw should have been changed during the installation of the engine. If

it has not been changed yet, proceed as indicated:a. The idle adjusting screw is on the front side of the fuel injector pump, and is secured by

a jam‑nut. Using a 10mm wrench, loosen the jam‑nut and remove both the jam‑nut andthe idle adjustment screw.

ab

c

d

6709

a - Idle adjusting screwb - Injection pump lever

c - Injection pump lever stopd - Jam‑nut

b. Remove the jam‑nut from the idle adjustment screw.c. Screw the jam‑nut onto new, longer idle adjustment screw supplied with engine kit.d. Install new idle adjustment screw into idle adjustment screw hole until it just touches the

injection pump lever stop, being careful to leave the end of the screw with the screwdriverslot facing out.

2. Using an accurate tachometer, adjust the idle speed to 850 RPM, as follows:a. To lower the idle speed–—turn the idle adjusting screw counterclockwise (left) until the

correct idle RPM is reached. Ensure that the idle adjusting screw is touching the injectionpump lever stop.

b. To increase the idle speed—turn the idle adjusting screw clockwise (right) until idle RPMis reached. Ensure that the idle adjusting screw is touching the injection pump lever stop.

c. Tighten the jam‑nut while preventing the idle adjusting screw from turning.MAXIMUM RPM TEST - ALL MODELS

IMPORTANT: All Cummins MerCruiser Diesel engines require an initial engine break‑in beforeperforming this test. Refer to the Owners manual that is provided with your power package for theappropriate procedure for your engine.1. Operate the boat at WOT with the boat loaded as specified. Adjust the power trim, if equipped,

to achieve maximum speed.NOTE: Use an accurate service tachometer to verify RPM.IMPORTANT: To operate the engine at maximum RPM before the engine 20‑hour break‑in periodis complete, follow this procedure only after the Engine Initial Break‑In Procedure has beencompleted:



2. If you have not already done so, complete the Engine Initial Break‑In Procedures Refer to theCummins MerCruiser Diesel Engine Owners Manual provided with the power package forbreak‑in procedure.

3. Start the engine and operate at a fast idle RPM until the engine reaches normal operatingtemperature.

4. Run the boat up on plane.IMPORTANT: Do not operate at maximum RPM for more than 2 minutes.5. Advance the engine RPM (in 200 RPM increments) until the engine reaches its maximum

rated RPM. Do not operate at maximum RPM for more than 2 minutes. If the engine cannotreach its maximum rated RPM, check the adjustment of the throttle cable and verify that thecorrect gear ratio for the engine is installed in the jetdrive.

Jet Trim Kit Installation (If equipped)If your power package is to be equipped with a Mercruiser Jet DJ10P Trim Kit , refer to theMercruiser Jet DJ10P Trim Kit installation instructions.



Predelivery Inspection ChecklistNotApplicable

Check orAdjust CHECK BEFORE RUNNING Not

ApplicableCheck orAdjust ON THE WATER TEST

Drain plug in and petcocks closed Engine alignment

Seawater inlet valve open Starter neutral safety switch operation

Engine mounts tight Water pump operation

Engine alignment Instruments) operation

Jetdrive unit fasteners torqued Fuel leaks

Power trim cylinders fastenerstight, if equipped Oil leaks

Battery fully charged and secured Water leaks

All electrical connections tight Exhaust leaks

Exhaust system hose clampstight

Idle 850 RPM, within specifications (1.7LMJ Only)

All fuel connections tight Forward, neutral, and reverse gearoperation

Throttle, shift and steering systemfasteners tightened properly Steering operation throughout range

Throttle cable moves throughrange of motion completely Acceleration from idle RPM

Crankcase oil levelWOT RPM within specifications (inFORWARD gear) Refer to curves anddata information at www.cmdmarine.com

Power trim oil level, if equipped Power trim operation, if equipped

Jetdrive unit oil level Boat handling

Power shift assist fluid level

Lube engine coupler greasefitting

Closed cooling level AFTER ON WATER TEST

Alternator belt tension Fuel, oil, coolant, water and fluid leaks

Seawater pickup pump belttension Oil and fluid levels

Power steering pump belt tension Apply Quicksilver Corrosion Guard to theengine package

Audio warning system operation


NOTES:


DIESEL ENGINE JETDRIVE INSTALLATION Pro Max, … · Mercury, Mercury Marine, MerCruiser, Mercury...

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Transcript of DIESEL ENGINE JETDRIVE INSTALLATION Pro Max, … · Mercury, Mercury Marine, MerCruiser, Mercury...