Mercury MerCruiser 3.0 MPI User Manual

SECTION - 6 DRIVE SYSTEM AND ENGINE INSTALLATION
90-899883183 DECEMBER 2007 Page 1 / 54
SECTION 6 - DRIVE SYSTEM AND ENGINE
INSTALLATION
Table of Contents
Transom Cutout....................................................................................................................................................... 3
Finding The Crankshaft Centerline....................................................................................................................3
Single Engine ............................................................................................................................................. 3
Dual Engine ............................................................................................................................................... 4
Finding Crankshaft Horizontal Center Line (X‑dimension)................................................................................4
90 Degree Tool Method ............................................................................................................................. 5
Tape Measure Method ............................................................................................................................... 5
Cutting Out The Transom..................................................................................................................................6
Checking The Transom Thickness....................................................................................................................8
Transom Connections............................................................................................................................................. 8
Installing Gimbal Housing..................................................................................................................................8
Installing the Alpha Inner Transom Plate..........................................................................................................8
Connecting Speedometer Pickup......................................................................................................................9
Alpha Gear Lube Monitor Connection At Gimbal Housing..............................................................................10
Alternative Mounting of Gear Lube Monitor on Transom................................................................................11
Power Trim Pump............................................................................................................................................11
Power Trim Pump Connections and Filling.....................................................................................................12
Trim Limit Switch Connection..........................................................................................................................13
Transom Harness............................................................................................................................................13
Installing Steering System for the Alpha Drive...................................................................................................... 14
Hydraulic (Helm) Steering .............................................................................................................................. 14
Manual Steering Installation ........................................................................................................................... 14
Power Steering Instalation ............................................................................................................................. 16
Engine Installation................................................................................................................................................. 21
Transom Preparation for the Alpha Drive........................................................................................................21
3.0 MPI Engine Preparation............................................................................................................................22
Fuel Inlet Fitting...............................................................................................................................................23
3.0 MPI Installation..........................................................................................................................................24
Initial Engine Alignment...................................................................................................................................28
Exhaust Connections......................................................................................................................................30
Engine Harness Connections..........................................................................................................................30
Continuity Wire Connection ..................................................................................................................... 31
Electrical Connections.....................................................................................................................................31
Instrumentation Connections ................................................................................................................... 31
Audio Warning System Connections, If Equipped ................................................................................... 32
Power Trim Electrical Connection...................................................................................................................33
Power Trim Pump Connections.......................................................................................................................33
Fluid Connections............................................................................................................................................34
Gear Lube Monitor Connection ................................................................................................................ 34
Power Steering Hoses ............................................................................................................................. 34
Seawater Pickup ...................................................................................................................................... 35
Coolant Recovery System ....................................................................................................................... 35
Cable Installation................................................................................................................................................... 36
Shift Cable Installation.....................................................................................................................................36
Alpha Models...................................................................................................................................................36
Shift Cable Travel .................................................................................................................................... 36
Separate Shift and Throttle Controls ....................................................................................................... 37
Installation ................................................................................................................................................ 38
Throttle Cable Installation and Adjustment......................................................................................................41
Alpha Sterndrive Installation.................................................................................................................................. 42
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Mercury MerCruiser 3.0 MPI Specifications

General

Brand	Mercury
Model	MerCruiser 3.0 MPI
Category	Engine
Language	English