Re: How to install a SMARTCRAFT system
Here is the text from the pdf instructions to install the trim conversion kit pn 889250K01 SMARTCRAFT SENSOR CONVERSION KIT
75/90/115 EFI 4-STROKE NOTICE After completing installation, place these instructions with the product for the owner's future use. NOTICE This document is written to aid our dealers, boatbuilders, and company service personnel in the proper installation or service of our products. Persons who are not familiar with these or similar products produced by Mercury Marine, and who have not been trained in the recommended servicing or installation procedures should have the work performed by an authorized Mercury Marine dealer technician. Improper installation or servicing of the Mercury product could result in damage to the product or personal injury to the installer or persons operating the product. Components Contained in Kit a b c d e f ghijk 21766 Ref. Qty. Description Part Number a 1 SmartCraft sensor harness assembly 84-889250T01 b 1 Water pressure sensor assembly 881879A20 c 1 Pitot sensor assembly 881879A16 d 4 Cable tie (8 in.) 54-816311T e 1 Tubing - 10 in. x 5/32 in. outer diameter 32-859785 71 f 1 Trim position sensor 896688001 g 1 Fitting assembly 22-896094A01 h 1 Elbow fitting 22-59351 i 1 Adapter fitting 22-859731 j 1 Female molded cap 13540 90-889250003 MAY 2010 ? 2010 Mercury Marine Page 1 / 8 SMARTCRAFT SENSOR CONVERSION KIT Ref. Qty. Description Part Number k 1 Connector clip 54-879962 SmartCraft Sensor Conversion Kit Installation 1. Remove the 8 pin digital input connector from the electrical plate, located on the rear starboard side of the engine below the relays. Remove the cap and mount clip from the connector. NOTE: Remove any remaining pieces of the mounting clip from the electrical plate. 21770 2. Attach the connector clip provided with the kit to the 8 pin SmartCraft harness connector. 3. Connect the SmartCraft harness to the 8 pin digital input connector on the engine harness. Mount the connectors to the electrical plate. a -SmartCraft harness connector b -Engine harness digital input connector 21772 4. Route the SmartCraft harness up the rear starboard side of the engine and cable tie the harness to the lower fuse breakout harness. ba Page 2 / 8 90-889250003 MAY 2010 SMARTCRAFT SENSOR CONVERSION KIT 5. Install the pitot sensor into the lower hole on the electrical plate above the starter solenoid. The pitot sensor has a blue dot, and is stamped with the number 881879-11. ab a -Cable tie securing SmartCraft harness to lower fuse breakout harness b - Pitot sensor assembly 21785 6. Install the block water pressure sensor into the upper hole on the electrical plate above the pitot sensor. The block water pressure sensor has a white dot, and is stamped with the number 881879-12. ab a -Pitot sensor assembly b -Block water pressure sensor 21790 7. Remove the connector caps from the two 3 pin connectors on the SmartCraft harness. Plug the 3 pin connector containing the white/green wire into the water pressure sensor, and the 3 pin connector containing the white/orange wire into the pitot sensor. 8. Pull the pitot tube out of the rigging grommet located at the front of the engine and route the tube down the starboard side of the engine. Cut off the pitot tube connector. 21867 90-889250003 MAY 2010 Page 3 / 8 SMARTCRAFT SENSOR CONVERSION KIT 9. Route the pitot tube under the oil filter and along the red power wires. Guide it through the loop of power wires that protrude from the starter solenoid. a -Pitot sensor b -Pitot tube c -Starter solenoid power wires cba 21797 10. Before inserting the adapter fitting into the pitot tube, ensure the pitot tube was cut short enough to avoid rubbing on the cylinder head. Insert the adapter fitting into the pitot tube. Connect the pitot tube to the pitot sensor. IMPORTANT: If the length of the pitot tube is too long, excessive wearing may occur. To avoid pitot tube failure, ensure the pitot tube does not rub against the side of the cylinder head. abc a -Pitot sensor assembly b -Pitot tube c -Hose rubbing against cylinder head 21837 Page 4 / 8 90-889250003 MAY 2010 SMARTCRAFT SENSOR CONVERSION KIT 11. Trim the motor up so the trim sensor is fully exposed and engage the tilt support lever. Remove the analog trim sensor. a -Analog trim sensor a 22076 12. Disconnect the trim position sensor brown/white wire bullet connectors located in front of the fuel system module (FSM) in front of the engine. Seal the engine brown/white wire bullet connector with the cap supplied with this kit. abc21860 a -Brown/white wire b -Air filter c -Fuel system module 13. Pull the trim position sensor brown/white wire out of the adapter plate grommet. 14. Remove the screw securing the wire retainers mounted on the starboard transom clamp bracket and pull out the trim position sensor lead. 21866 15. Install the digital trim position sensor. The wire leads must point down, and the rotating armature of the sensor must be properly aligned in the sensor mount. 16. Guide the trim position sensor wires through the hole in the starboard clamp bracket. Trim the engine up completely and pull the wires taunt. 90-889250003 MAY 2010 Page 5 / 8 SMARTCRAFT SENSOR CONVERSION KIT 17. Insert the trim position sensor wires into the wire retainers. Secure the wire retainers to the starboard transom clamp bracket with a screw. Tighten the screw securely. 21866 18. Push the trim position sensor bullet connectors through the adapter plate grommet. If the grommet should come loose, lubricate the grommet and push in until seated. 21868 Description Where Used Part No. 36P80 Rubber Lubricant Adapter plate grommet Obtain Locally 19. Disengage the tilt support lever. Trim the engine to its extremes and check for trim position sensor wire lead interference. Adjust the wire leads if necessary to avoid interference. 20. Run the sensor leads under the oil filter and up along the water hose that connects to the thermostat housing. 21. Remove the bullet connector plugs from the three bullet connectors located on the SmartCraft sensor harness. 22. Connect the trim position sensor bullet connectors to the SmartCraft sensor harness; black to black/orange, yellow to yellow, and light blue to purple/yellow. Secure the sensor leads and SmartCraft sensor harness to the existing engine harness. a a -Trim position sensor bullet connectors 21869 23. Use a 4 mm Allen wrench to remove the brass plug located under the starter motor on the engine block. NOTE: To aid in loosening the brass plug, tap on the end of the Allen wrench with a hammer. Page 6 / 8 90-889250003 MAY 2010 SMARTCRAFT SENSOR CONVERSION KIT 24. Separate the two pieces of the fitting assembly provided with the kit. Assemble the pieces to the elbow fitting as shown, and thread it into the block. aab a -Fitting assembly b -Elbow fitting 22101 25. Tighten the block water reservoir tap using a 16 mm (5/8 in.) and 14 mm (9/16 in.) wrench on the brass fittings. Use a 13 mm (1/2 in.) wrench to tighten down the stainless Legris fitting. 21871a a -Block water reservoir tap 26. Install the polyurethane tubing over the water hose, and into the block water pressure sensor and block water reservoir tap. IMPORTANT: Do not allow the polyurethane tubing to contact the cylinder head, as chaffing from the cylinder head may damage the tubing. abcde21875 a -Block water pressure sensor b -Pitot sensor c -Polyurethane tubing d -Block water reservoir tap e -Pitot tube 90-889250003 MAY 2010 Page 7 / 8 SMARTCRAFT SENSOR CONVERSION KIT Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Products of Mercury Marine Mercury Propellers, Mariner, Quicksilver, Alpha, Axius, Bravo One, Bravo Two, Bravo Three, K-Planes, W6250 Pioneer Road MerCathode, OptiMax, Precision Pilot, Pro Max, SeaCore, Skyhook, SmartCraft, Sport-Jet, Total Command, Verado, VesselView, Zero Effort, Zeus, #1 On The Water, M with Waves logo, Mercury with Fond du Lac, WI 54936-1939 Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. Page 8 / 8 90-889250003 MAY 2010
