Mercury MerCruiser 3.0 MPI

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BOAT CONSTRUCTION SECTION - 2

NOTES:

Page 4 / 4 90-899883183 DECEMBER 2007

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Table of Contents5
Torque Specifications for 3.0 MPI6
Quicksilver Products6
Accessories6
Serial Number Decal Placement6
Corrosion Protection7
Anti-Fouling Paint7
Emission Control Information Label8
Owner Responsibility9
Emission Certification Star Label9
Hang Tag11
Important Information18
Carbon Monoxide Poisoning18
Good Ventilation18
Poor Ventilation19
Measuring Exhaust Elbow Height19
General Information19
Boat Requirements20
Loading Requirements20
Loading the Boat with a Capacity Plate21
Example22
Loading the Boat-Without a Capacity Plate23
Example24
Clear Hose Measurement Method26
Clear Hose Measurement Method from Seacock or Muffler Drain27
General Information30
California Regulations for 2007-Low-Permeation Fuel Hose30
Special Information about Electric Fuel Pumps30
Fuel Delivery and Specifications30
Fuel Delivery System31
Special Information about Electric Fuel Pumps32
Fuel Lines and Fittings32
Specifications36
Seawater Pickup36
3.0 MPI Water Flow Diagrams37
Models with Seawater Cooling37
Models with Closed Cooling38
Transom Cutout41
Finding the Crankshaft Centerline41
Single Engine41
Dual Engine42
Finding Crankshaft Horizontal Center Line (X-Dimension)42
90 Degree Tool Method43
Tape Measure Method43
Cutting out the Transom44
Checking the Transom Thickness46
Transom Connections46
Installing Gimbal Housing46
Installing the Alpha Inner Transom Plate46
Connecting Speedometer Pickup47
Alpha Gear Lube Monitor Connection at Gimbal Housing48
Alternative Mounting of Gear Lube Monitor on Transom49
Power Trim Pump49
Power Trim Pump Connections and Filling50
Trim Limit Switch Connection51
Transom Harness51
Installing Steering System for the Alpha Drive52
Hydraulic (Helm) Steering52
Manual Steering Installation52
Power Steering Instalation54
Engine Installation59
Transom Preparation for the Alpha Drive59
3.0 MPI Engine Preparation60
Fuel Inlet Fitting61
3.0 MPI Installation62
Initial Engine Alignment66
Exhaust Connections68
Engine Harness Connections68
Continuity Wire Connection69
Electrical Connections69
Instrumentation Connections69
Audio Warning System Connections, if Equipped70
Power Trim Electrical Connection71
Power Trim Pump Connections71
Fluid Connections72
Gear Lube Monitor Connection72
Power Steering Hoses72
Seawater Pickup73
Coolant Recovery System73
Cable Installation74
Shift Cable Installation74
Alpha Models74
Shift Cable Travel74
Separate Shift and Throttle Controls75
Installation76
Throttle Cable Installation and Adjustment79
Alpha Sterndrive Installation80
Trim Cylinder Installation85
Speedometer Connection85
Alpha Notice: Increased Trim-In Range Capability86
Alpha Trim Cylinder Spacer Removal86
Alpha Trim Cylinder Disassembly88
Alpha Trim Cylinder Reassembly89
Alpha Trim Cylinder Installation90
Information and Check List - Installation Using 14 Pin Connection94
Battery94
Battery Cables94
Power Harness95
Electrical System Precautions95
Boat Harness and Installation Connections96
Engine Harness and Accessory Power Supply96
Boat Wiring96
Dual Station96
Boat Harness Installation Guidelines-MPI Sterndrive97
Boat Harness Deutsch Connector to Engine97
Key Switch Connector97
Trim Switch98
Neutral Switch99
Lanyard Stop Switch99
Optional E Stop100
Warning Horn100
Accessory Relay Connection100
Additional Relay Kit100
Gauge Connection100
CAN P (CAN 1) Connections102
CAN V (CAN 3) Connection102
General Repower Information102
Transom Harness-MPI105
Wiring Diagrams105
Boat Harness106
Drawing106
Diagram107
Analog Gauge Harness108
Drawing108
Diagram108
Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly)109
Power Trim System (Non-DTS)111
14-Pin Engine Harness Connector112
Analog Gauge Interface (AGI)112
Analog Gauge Interface (AGI) Installation112
Configuring Analog/Digital Tachometer Signal through PCM113
Steering Helm and Cable116
Steering Cable Specifications117
Sterndrive Shift Cable Information118
Propeller Rotation118
Checking Alpha Shift Cable Installation and Adjustment118
Troubleshooting Shift Problems121
Predelivery Preparation126
Engine Oil126
Checking127
Filling127
Power Steering Fluid128
Power Trim Pump128
Filling Coolant Recovery Bottle130
Trim Limit Switch Adjustment130
Analog Guages130
Trim Position Sender Adjustment131
Analog Gauges131
Drive Unit Gear Lube Monitor132
Propeller Installation (Alpha)133
Alpha Models133
Engine Connections134
Trim Pump Connections134
Boat in the Water Tests135
Engine Idle Speed135
Wide Open Throttle Test135
Trim Tab Adjustment135
Checking Shift Operation135
Priming the Fuel System136
Flushing the Power Package136
Flushing Attachments136
Sterndrive Water Pickups137
Alpha Seawater Pump Output Test138
Cold Weather or Extended Storage139
Preparing Power Package for Storage139
Engine and Fuel System Preparation140
Draining the Seawater System141
Single-Point Drain System141
Draining the Seawater Section of Models with Closed Cooling142
Clearing Clogged Blue Drain Hoses144
Draining the Sterndrive146
Power Package Recommissioning146
Predelivery Inspection147

Mercury MerCruiser 3.0 MPI - Page 16

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