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MerCruiser 3.0 MPI
Mercury MerCruiser 3.0 MPI User Manual
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SECTION - 5
COOLING SYSTEM
90-899883183 DECEMBER 2007
Page 3 / 4
3.0 MPI Water Flow Diagrams
Models with Seawater Cooling
32741
1
2
3
4
5
6
7
8
9
1 -
From Transom
2 -
Seawater intake
3 -
Power steering cooler (if equipped)
4 -
Poppet valve assembly
5 -
Thermostat housing
6 -
Engine circulating pump
7 -
Engine block and cylinder head
assembly
8 -
Intake and exhaust manifold
9 -
Exhaust elbow
36
38
Table of Contents
Table of Contents
5
Torque Specifications for 3.0 MPI
6
Quicksilver Products
6
Accessories
6
Serial Number Decal Placement
6
Corrosion Protection
7
Anti-Fouling Paint
7
Emission Control Information Label
8
Owner Responsibility
9
Emission Certification Star Label
9
Hang Tag
11
Important Information
18
Carbon Monoxide Poisoning
18
Good Ventilation
18
Poor Ventilation
19
Measuring Exhaust Elbow Height
19
General Information
19
Boat Requirements
20
Loading Requirements
20
Loading the Boat with a Capacity Plate
21
Example
22
Loading the Boat-Without a Capacity Plate
23
Example
24
Clear Hose Measurement Method
26
Clear Hose Measurement Method from Seacock or Muffler Drain
27
General Information
30
California Regulations for 2007-Low-Permeation Fuel Hose
30
Special Information about Electric Fuel Pumps
30
Fuel Delivery and Specifications
30
Fuel Delivery System
31
Special Information about Electric Fuel Pumps
32
Fuel Lines and Fittings
32
Specifications
36
Seawater Pickup
36
3.0 MPI Water Flow Diagrams
37
Models with Seawater Cooling
37
Models with Closed Cooling
38
Transom Cutout
41
Finding the Crankshaft Centerline
41
Single Engine
41
Dual Engine
42
Finding Crankshaft Horizontal Center Line (X-Dimension)
42
90 Degree Tool Method
43
Tape Measure Method
43
Cutting out the Transom
44
Checking the Transom Thickness
46
Transom Connections
46
Installing Gimbal Housing
46
Installing the Alpha Inner Transom Plate
46
Connecting Speedometer Pickup
47
Alpha Gear Lube Monitor Connection at Gimbal Housing
48
Alternative Mounting of Gear Lube Monitor on Transom
49
Power Trim Pump
49
Power Trim Pump Connections and Filling
50
Trim Limit Switch Connection
51
Transom Harness
51
Installing Steering System for the Alpha Drive
52
Hydraulic (Helm) Steering
52
Manual Steering Installation
52
Power Steering Instalation
54
Engine Installation
59
Transom Preparation for the Alpha Drive
59
3.0 MPI Engine Preparation
60
Fuel Inlet Fitting
61
3.0 MPI Installation
62
Initial Engine Alignment
66
Exhaust Connections
68
Engine Harness Connections
68
Continuity Wire Connection
69
Electrical Connections
69
Instrumentation Connections
69
Audio Warning System Connections, if Equipped
70
Power Trim Electrical Connection
71
Power Trim Pump Connections
71
Fluid Connections
72
Gear Lube Monitor Connection
72
Power Steering Hoses
72
Seawater Pickup
73
Coolant Recovery System
73
Cable Installation
74
Shift Cable Installation
74
Alpha Models
74
Shift Cable Travel
74
Separate Shift and Throttle Controls
75
Installation
76
Throttle Cable Installation and Adjustment
79
Alpha Sterndrive Installation
80
Trim Cylinder Installation
85
Speedometer Connection
85
Alpha Notice: Increased Trim-In Range Capability
86
Alpha Trim Cylinder Spacer Removal
86
Alpha Trim Cylinder Disassembly
88
Alpha Trim Cylinder Reassembly
89
Alpha Trim Cylinder Installation
90
Information and Check List - Installation Using 14 Pin Connection
94
Battery
94
Battery Cables
94
Power Harness
95
Electrical System Precautions
95
Boat Harness and Installation Connections
96
Engine Harness and Accessory Power Supply
96
Boat Wiring
96
Dual Station
96
Boat Harness Installation Guidelines-MPI Sterndrive
97
Boat Harness Deutsch Connector to Engine
97
Key Switch Connector
97
Trim Switch
98
Neutral Switch
99
Lanyard Stop Switch
99
Optional E Stop
100
Warning Horn
100
Accessory Relay Connection
100
Additional Relay Kit
100
Gauge Connection
100
CAN P (CAN 1) Connections
102
CAN V (CAN 3) Connection
102
General Repower Information
102
Transom Harness-MPI
105
Wiring Diagrams
105
Boat Harness
106
Drawing
106
Diagram
107
Analog Gauge Harness
108
Drawing
108
Diagram
108
Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly)
109
Power Trim System (Non-DTS)
111
14-Pin Engine Harness Connector
112
Analog Gauge Interface (AGI)
112
Analog Gauge Interface (AGI) Installation
112
Configuring Analog/Digital Tachometer Signal through PCM
113
Steering Helm and Cable
116
Steering Cable Specifications
117
Sterndrive Shift Cable Information
118
Propeller Rotation
118
Checking Alpha Shift Cable Installation and Adjustment
118
Troubleshooting Shift Problems
121
Predelivery Preparation
126
Engine Oil
126
Checking
127
Filling
127
Power Steering Fluid
128
Power Trim Pump
128
Filling Coolant Recovery Bottle
130
Trim Limit Switch Adjustment
130
Analog Guages
130
Trim Position Sender Adjustment
131
Analog Gauges
131
Drive Unit Gear Lube Monitor
132
Propeller Installation (Alpha)
133
Alpha Models
133
Engine Connections
134
Trim Pump Connections
134
Boat in the Water Tests
135
Engine Idle Speed
135
Wide Open Throttle Test
135
Trim Tab Adjustment
135
Checking Shift Operation
135
Priming the Fuel System
136
Flushing the Power Package
136
Flushing Attachments
136
Sterndrive Water Pickups
137
Alpha Seawater Pump Output Test
138
Cold Weather or Extended Storage
139
Preparing Power Package for Storage
139
Engine and Fuel System Preparation
140
Draining the Seawater System
141
Single-Point Drain System
141
Draining the Seawater Section of Models with Closed Cooling
142
Clearing Clogged Blue Drain Hoses
144
Draining the Sterndrive
146
Power Package Recommissioning
146
Predelivery Inspection
147
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Mercury MerCruiser 3.0 MPI Specifications
General
Brand
Mercury
Model
MerCruiser 3.0 MPI
Category
Engine
Language
English
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