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Mercury MerCruiser 3.0 MPI User Manual

Mercury MerCruiser 3.0 MPI
148 pages
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Page i © 2007 Mercury Marine 90-899883183 DECEMBER 2007
Mercury, 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 registered trademarks of Brunswick Corporation. Mercury Product Protection
logo is a registered service mark of Brunswick Corporation.
3.0 MPI
INSTALLATION MANUAL
Models Covered
Alpha
Models covered Serial Number
3.0 MPI 1A300000 and above
Notice
NOTICE
After completing installation, these instructions should be placed with the product for the owner's
future use.
NOTICE
Predelivery preparation instructions must be performed before delivering boat to the product owner.
Notice to Boat Manufacturer/Installer
Throughout this publication, dangers, warnings, cautions, and notices, (accompanied by
the International Hazard Symbol) are used to alert the manufacturer or installer to special
instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006
for product safety information in product manuals, instructions, and other collateral
materials. Observe Them Carefully!
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
!
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
!
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component
failure.

Table of Contents

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Mercury MerCruiser 3.0 MPI Specifications

General IconGeneral
Compression Ratio9.4:1
Cylinders4
Displacement3.0L / 181 CID
Fuel SystemMulti-Port Fuel Injection (MPI)
Ignition SystemElectronic
Fuel Type87 Octane
Full Throttle RPM4400-4800 RPM
Cooling SystemWater Cooled
ExhaustWater Cooled
Power Output135 HP @ 4800 RPM

Summary

SECTION 1 - IMPORTANT INFORMATION

Torque Specifications for 3.0 MPI

Specifies torque values for various fasteners to ensure secure installation.

Corrosion Protection

Details methods and products to protect the power package from galvanic corrosion.

Anti-fouling Paint

Provides precautions for applying anti-fouling paint to avoid warranty issues.

Emission Control Information Label

Describes the tamper-resistant label with engine emission and serial number data.

Owner Responsibility

Outlines operator duties for maintaining emission levels and engine specifications.

SECTION 2 - BOAT CONSTRUCTION

Transom Thickness and Surface

Specifies critical dimensions for transom thickness and flatness for sterndrive mounting.

Engine Bed

Details specifications for the engine mount alignment and placement.

SECTION 3 - EXHAUST SYSTEM

Carbon Monoxide Poisoning

Provides critical safety information regarding carbon monoxide hazards in boat exhaust.

Measuring Exhaust Elbow Height

Outlines the procedure to measure exhaust elbow height to prevent water intrusion.

Boat Requirements

Lists requirements for boats when performing exhaust elbow waterline height measurements.

Loading Requirements

Details how to load the boat to simulate conditions for waterline height measurements.

SECTION 4 - FUEL SYSTEM

California Regulations for 2007—Low‑Permeation Fuel Hose

Specifies requirements for using low-permeation fuel hose for California compliance.

Fuel Delivery System

Provides guidelines for designing a safe and efficient fuel delivery system.

SECTION 5 - COOLING SYSTEM

Specifications

Lists specifications for sterndrive seawater pump output based on gear ratio.

3.0 MPI Water Flow Diagrams

Illustrates water flow paths for models with seawater cooling systems.

Models with Closed Cooling

Shows water flow diagrams for models equipped with a closed cooling system.

SECTION 6 - DRIVE SYSTEM AND ENGINE INSTALLATION

Transom Cutout

Details procedures for cutting the transom to accommodate the drive unit.

Finding The Crankshaft Centerline

Provides methods for locating the engine's vertical crankshaft centerline.

90 DEGREE TOOL METHOD

Explains using a 90-degree tool to determine the crankshaft horizontal center line.

Installing Gimbal Housing

Guides the installation of the gimbal housing onto the transom assembly.

Connecting Speedometer Pickup

Details how to connect the speedometer pickup hose to the drive unit.

Power Trim Electrical Connection

Provides instructions for connecting the power trim pump's electrical system.

Shift Cable Installation

Explains the procedure for installing and adjusting the sterndrive shift cable.

Alpha Sterndrive Installation

Covers the final steps for installing the Alpha sterndrive unit.

SECTION 7 - STARTING AND ELECTRICAL

Battery

Provides guidelines and specifications for selecting and installing a marine battery.

Electrical System Precautions

Outlines essential precautions to avoid damage when working with the electrical system.

Boat Harness Installation Guidelines—MPI Sterndrive

Guides the selection and installation of boat harnesses for MPI sterndrive engines.

KEY SWITCH CONNECTOR

Details the connection and function of the key switch assembly.

LANYARD STOP SWITCH

Explains the function and connection of the lanyard stop switch for engine shutdown.

ACCESSORY RELAY CONNECTION

Describes how to connect an accessory relay for increased power supply.

Analog Gauge Interface (AGI) Installation

Covers the installation of the Analog Gauge Interface for analog or SmartCraft gauges.

Configuring Analog/Digital Tachometer Signal through PCM

Explains how to configure the PCM for analog or digital tachometer signals.

SECTION 8 - REMOTE CONTROLS

Steering Helm and Cable

Provides information and warnings regarding the installation of steering helm and cable.

Steering Cable Specifications

Details critical dimensions and specifications for steering cables.

Checking Alpha Shift Cable Installation and Adjustment

Guides the installer through checking and adjusting the Alpha sterndrive shift cable.

Troubleshooting Shift Problems

Offers solutions for common hard shifting or chucking/ratcheting issues.

SECTION 9 - PREDELIVERY PREPARATION AND STORAGE

Predelivery Preparation

Outlines final steps to prepare the power package for customer delivery.

Engine Oil

Details procedures for checking and filling engine oil levels.

Power Steering Fluid

Provides instructions for checking and filling the power steering fluid reservoir.

Power Trim Pump

Covers procedures for checking and purging air from the power trim pump system.

Flushing the Power Package

Explains the procedure for flushing the engine's cooling system with fresh water.

STERNDRIVE WATER PICKUPS

Details the use of flushing attachments for sterndrive water pickups.

Cold Weather or Extended Storage

Recommends procedures for preparing the engine for cold weather or storage.

Draining the Seawater System

Provides instructions for draining the engine's seawater cooling system.

Predelivery Inspection

A checklist of items to inspect and test before delivering the boat.

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