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Mercury 3.0 MPI ECT Operation & Maintenance Manual Download Page 1

www.mercurymarine.com.au

41-71 Bessemer Drive

Dandenong South, Victoria 3175 Australia

www.mercurymarine.com

P.O. Box 1939

Fond du Lac, WI 54936-1939 USA

www.brunswick-marine.com

Parc Industriel de Petit-Rechain

B-4800 Verviers, Belgium

© Mercury Marine. All rights reserved.

Printed in U.S.A.

90-8M0113856   NOVEMBER 2015         

3.0 MPI ECT

and 3.0 TKS

Sterndrive Models

OPERATION &

MAINTENANCE

MANUAL

Summary of Contents for 3.0 MPI ECT

Page 1: ...ercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S A 90 8M0...

Page 2: ......

Page 3: ...th these special instructions while performing the service plus common sense operation are major accident prevention measures WARNING Indicates a hazardous situation which if not avoided could result...

Page 4: ...erCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MotorGuide OptiMax Quicksilver SeaCore Skyhook SmartCraft Sport Jet Verado VesselView...

Page 5: ...Stopping the Engine 21 Starting the Engine After Stopped While in Gear 21 Starting and Stopping the Engine 3 0 TKS 21 Starting and Stopping the Engine 21 Starting the Engine 21 Stopping the Engine 22...

Page 6: ...ount Models 49 Power Steering Pump Drive Belt if equipped 49 Alternator Belt 49 Changing the Water Separating Fuel Filter 49 Engine Oil 3 0 MPI ECT 50 Checking and Filling 50 Changing the Oil and Filt...

Page 7: ...90 Poor Performance 90 Troubleshooting Charts for 3 0 MPI ECT and 3 0 TKS 90 Excessive Engine Temperature 90 Insufficient Engine Temperature 91 Low Engine Oil Pressure 91 Battery Will Not Recharge 91...

Page 8: ...Page iv 90 8M0113856 eng DECEMBER 2015...

Page 9: ...SmartCraft Digital Instruments 5 System Link Digital Instruments 6 Remote Controls 6 Panel Mount Features 7 Console Mount Features 7 Power Trim 8 Single Engine Trim Trailer 9 Dual Engine Trim Trailer...

Page 10: ...rCruiser power package When contacting MerCruiser about service always specify model and serial numbers Engine Serial Number Decal The serial number decal is located on the aft portion of the starboar...

Page 11: ...cated on the port side of the sterndrive 54406 Alpha sterndrive Alpha Transom Serial Number The Alpha transom serial number is stamped in the transom assembly decal Transom Serial No 53651 The serial...

Page 12: ...should the operator choose to move around in an area close to the operator s normal position The operator can shorten the lanyard by wrapping the lanyard around his wrist or by tying a knot in the lan...

Page 13: ...nstrumentation VesselView There are several VesselView products available VesselView will display all engine information fault codes vessel information basic navigation data and system information Whe...

Page 14: ...ackages include system link gauges that augment the information provided by VesselView or a SmartCraft system tachometer and speedometer The owner and operator should be familiar with all the instrume...

Page 15: ...for information on the use of this switch Control handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a qu...

Page 16: ...the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions Also the trailering feature allows the operator to raise and lower the...

Page 17: ...ternal tie bar raise and lower all drives together as a unit Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for...

Page 18: ...ion plate Fuse locations a O2 sensor fuses b Main power fuel pump ignition and accessory fuses a Fuel pump relay IAC ignition coil 20 amp b Fuel injectors distributor 20 amp c Spare 15 amp d Main powe...

Page 19: ...lectrical system Check for an open fuse or open circuit breaker if you turn the ignition key to the start position and nothing happens mc70525 1 Ignition switch fuse typical The power trim system is p...

Page 20: ...MerCathode b Red purple wire c 5 amp fuse Electrical System Overload Protection 3 0 TKS An electrical overload will either open a fuse or open a circuit breaker You must find and repair the source of...

Page 21: ...gine wiring harness and instrumentation circuit breaker A 90 amp fuse located on the large post of the starter solenoid protects the engine wiring harness if an electrical overload occurs mc74907 1 En...

Page 22: ...trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump The trim pump may also have an in line circuit protection device in the power trim positive lead...

Page 23: ...t cranking the engine 2 The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning correctly Audio Warning System IMPORTANT The audio warni...

Page 24: ...full water flow is restored Engine Guardian restores engine power to normal Audio Warning System 3 0 TKS Your Mercury MerCruiser power package may be equipped with an Audio Warning System The audio wa...

Page 25: ...ttle Only Operation 22 Trailering the Boat 22 Freezing Temperature Operation 22 Drain Plug and Bilge Pump 22 Protecting People in the Water 23 While You Are Cruising 23 While Boat Is Stationary 23 Hig...

Page 26: ...passengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal law requires that there be a U S...

Page 27: ...urther assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal comb...

Page 28: ...gon effect Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat Operation Chart Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Install...

Page 29: ...itch to return to ON position 6 Inspect the power package for fuel oil water and exhaust leaks 7 Move control handle with a firm quick motion forward to shift to forward gear or backward to shift to r...

Page 30: ...handle until handle returns to the neutral idle position This may take several tries if the power package was operating above idle RPM when the engine stopped 2 After the handle returns to the neutral...

Page 31: ...boat For additional information refer to Hi Performance Boat Operation booklet 90 849250R03 from your dealer distributor or Mercury Marine Passenger Safety in Pontoon Boats and Deck Boats Whenever the...

Page 32: ...s down far enough while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occup...

Page 33: ...r or where underwater objects are known to be present No impact protection is provided in reverse use extreme care to prevent striking submerged objects while operating in reverse IMPORTANT Impact pro...

Page 34: ...wear and damage After initial propeller selection the following common problems may require that the propeller be changed to a lower pitch Warmer weather and greater humidity cause a loss of RPM Opera...

Page 35: ...m Avoid full throttle acceleration from idle speed Do not operate at full throttle until the engine reaches normal operating temperature Frequently check engine oil level Add oil as needed It is norma...

Page 36: ...Section 2 On the Water Notes Page 28 90 8M0113856 eng DECEMBER 2015...

Page 37: ...ygenated Gasoline USA Only 30 Gasoline Containing Alcohol 31 Bu16 Butanol Fuel Blends 31 Methanol and Ethanol Fuel Blends 31 Engine Oil 31 Fluid Specifications 32 Sterndrives 32 Engine 32 Specificatio...

Page 38: ...R6EFS Spark plug gap 0 9 mm 0 045 in Emission control system Electronic control EC heated oxygen sensor HO2S catalyst Fuel Requirements NOTICE Running out of fuel can damage catalyst components Do not...

Page 39: ...ercury Marine engine on gasoline containing methanol or ethanol do not store the gasoline in the fuel tank for long periods Cars normally consume these blended fuels before they can absorb enough mois...

Page 40: ...Engine oil with filter 3 8 L 4 US qt Mercury Quicksilver 25W 40 Synthetic Blend Engine Oil NMMA FC W Catalyst Compatible rated Seawater cooling system 9 L 8 5 US qt Propylene glycol and purified wate...

Page 41: ...nes are acceptable for use in your Mercury MerCruiser engine Gasolines Containing Alcohol If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aw...

Page 42: ...Engine Oil is unavailable use the following lubricants listed in order of recommendation 1 Mercury Quicksilver 25W 40 Mineral NMMA FC W Catalyst Compatible IMPORTANT If you are servicing a catalyst en...

Page 43: ...qt Mercury Quicksilver 25W 40 Synthetic Blend Engine Oil NMMA FC W Catalyst Compatible rated Seawater cooling system 9 L 8 5 US qt Propylene glycol and purified water Closed cooling system 9 L 8 5 US...

Page 44: ...Section 3 Specifications Notes Page 36 90 8M0113856 eng DECEMBER 2015...

Page 45: ...Models 48 Power Steering Pump Drive Belt if equipped 48 Alternator Belt 48 Replacing Side Mount Models 49 Power Steering Pump Drive Belt if equipped 49 Alternator Belt 49 Changing the Water Separatin...

Page 46: ...e explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components WARNING...

Page 47: ...opeller If badly nicked bent or cracked contact your authorized Mercury MerCruiser dealer Repair nicks and corrosion damage on power package exterior finish Contact your authorized Mercury MerCruiser...

Page 48: ...ater separating fuel filter Check the steering system and the remote control for loose missing or damaged parts Lubricate the cables and the linkages Check the continuity circuit for loose or damaged...

Page 49: ...stor a Flame arrestor b Clamp IMPORTANT Do not use an acid based cleaner as it can deteriorate portions of the flame arrestor 3 Clean the flame arrestor with warm soapy water 4 Inspect the flame arres...

Page 50: ...methyl ethyl ketone on the IAC or on electrical connections 4 Clean the muffler with warm water and mild detergent Replace if necessary 5 Allow the IAC muffler to dry completely before use 6 Install...

Page 51: ...ts on Front Mount Models a Power steering belt b Alternator belt c Alternator d Spacer block e Crankshaft position sensor Power Steering Pump Drive Belt 1 Loosen the power steering pump attaching bolt...

Page 52: ...steering brace to its original position and adjust the tension of both drive belts Description Deflection 6 mm 0 25 in Maintenance Schedules 3 0 TKS Routine Maintenance NOTE Only perform maintenance...

Page 53: ...d Change the engine oil and filter Every 100 hours or annually whichever occurs first Touch up the paint on the power package Change the engine oil and filter Change the sterndrive gear lube If the co...

Page 54: ...the clamps Lubricate the U joint splines and cross bearing if equipped with a grease fitting Inspect the gimbal bearing for roughness Replace if necessary See your certified Mercury MerCruiser dealer...

Page 55: ...ve PCV Changing NOTE We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations NOTE On V6 models the PCV valve is non serviceable and is an internal c...

Page 56: ...length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 6 mm 1 4 in deflection with moderate thumb pressure on the belt at the location that has the longest distan...

Page 57: ...wer steering belt b Alternator belt c Alternator Description Deflection 6 mm 1 4 inches Alternator Belt 1 Remove power steering pump drive belt if equipped 2 Loosen the alternator Remove and replace t...

Page 58: ...t or other engine drive fluids into the environment is restricted by law Use caution not to spill oil coolant or other fluids into the environment when using or servicing your boat Be aware of the loc...

Page 59: ...91 Aids in the removal of engine oil without draining the crankcase 4 Insert the hose end of the crankcase oil pump onto an appropriate container and use the handle to pump until the crankcase is empt...

Page 60: ...ation marks facing the rear of the engine flywheel end a Dipstick tube 3 Remove the dipstick and observe the oil level 4 If the level is below the add mark remove the oil fill cap and add the specifie...

Page 61: ...will increase the level from the add mark to the top of the OK range Engine Model Capacity Fluid Type 3 0 MPI 3 8 L 4 US qt Mercury Quicksilver 25W 40 Synthetic Blend Engine Oil NMMA FC W Catalyst Com...

Page 62: ...level a Proper fluid level with engine at normal operating temperature should be within the warm range b Proper fluid level with engine cold should be within the cold range a Power steering pump fill...

Page 63: ...the filler neck If the coolant level is low contact your authorized Mercury MerCruiser dealer 3 Check the antifreeze concentration for adequate freeze protection and correct if necessary Refer to the...

Page 64: ...an trap air in the system and make purge procedures more difficult Operate at idle when filling the system or purging air 2 Fill to the full mark with the specified coolant Tube Ref No Description Whe...

Page 65: ...the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine is higher than the rear of the engine NOTE Add coolant only wh...

Page 66: ...he gear lube monitor if water appears at the fill and drain plug hole or if the gear lube appears discolored these conditions can indicate a water leak in the sterndrive Contact your authorized Mercur...

Page 67: ...y a Oil vent screw b Sealing washer IMPORTANT If any water drained from the oil fill drain hole or if the oil appears milky the sterndrive unit is leaking and should be checked immediately by your aut...

Page 68: ...l fluctuates during operation Check when the engine is cold Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive un...

Page 69: ...ring cable before applying lubricant NOTE If the steering cable does not have a grease fitting the inner wire of the cable cannot be greased 1 If the steering cable has grease fittings Turn the steeri...

Page 70: ...r pivot points Tube Ref No Description Where Used Part No 139 Mercury 25W 40 Synthetic Blend 4 Stroke Engine Oil Tie bar pivot points 92 8M0078629 5 After starting the engine turn the steering wheel s...

Page 71: ...erCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 Shift Plate Control Cable Lubrication Lubricate the points shown in the following illustration with oil a...

Page 72: ...8 10 pumps of grease from a typical hand operated grease gun NOTE If the boat is operated at idle for prolonged periods of time the coupler should be lubricated every 50 hours a Grease fitting Tube Re...

Page 73: ...boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place...

Page 74: ...e and locking tab washer 6 Install and tighten the propeller nut to the specified torque Description Nm lb in lb ft Propeller nut minimum 136 100 7 Bend three tabs on the tab washer down into the groo...

Page 75: ...death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the eng...

Page 76: ...flames WARNING An operating or charging battery produces gas that can ignite and explode spraying out sulfuric acid which can cause severe burns Ventilate the area around the battery and wear protecti...

Page 77: ...d some models have a MerCathode System as standard equipment 1 Gearcase anodic plate 2 Ventilation plate anode 3 Gimbal mounted anodic block 4 MerCathode System 5 Anode kit 6 Trim cylinder anodes 7 Be...

Page 78: ...of the gearcase a Anode Drive Mounted Anodic Block if equipped Mounted to underside of gimbal housing 5640 MerCathode System Electrode assembly replaces Anodic block System should be tested to ensure...

Page 79: ...wash a MerCathode controller b MerCathode assembly Anode Kit if equipped Mounted to the boat transom 5642 Trim Cylinder Anodes Mounted on each trim cylinder a Trim cylinder anodes Bearing Carrier Anod...

Page 80: ...oat transom but you must observe the following IMPORTANT Do NOT paint anodes or MerCathode System reference electrode and anode as this will render them ineffective as galvanic corrosion inhibitors IM...

Page 81: ...eparing Power Package for Storage Carburetor Models 76 Engine and Fuel System Preparation 76 Draining the Seawater System 77 Draining the 3 0 MPI ECT Seawater System 77 Single Point Drain System 77 Dr...

Page 82: ...e presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required IMPORTANT When operating a Mercury Marine engine on gasoline containing alcohol storage of gasol...

Page 83: ...an irritant cause difficulty breathing or may ignite resulting in a fire or explosion Always ventilate the engine compartment before servicing the power package NOTICE Running out of fuel can damage c...

Page 84: ...l in the tank determine the type of fuel that is in the fuel tanks and proceed with the following a Vessels using fuel without alcohol fill the vessel fuel tanks with fresh gasoline that does not cont...

Page 85: ...to ensure complete draining of the cooling system IMPORTANT The engine must not be operating at any point during the draining procedure Draining the 3 0 MPI ECT Seawater System Single Point Drain Sys...

Page 86: ...ng system immediately after operation or before any length of storage in freezing temperatures If the boat is in the water keep the seacock closed until restarting the engine to prevent water from flo...

Page 87: ...to the heat exchanger a Power steering cooler b Water inlet to heat exchanger hose 5 Ensure that the speedometer pitot hole gear housing water vent and drain holes and trim tab cavity vent and drain h...

Page 88: ...es can cause serious burns due to hot water Check all hose connections before operating the engine and never disconnect the hoses until the engine has had suffient time to cool NOTICE If the boat is a...

Page 89: ...nspect that the blue drain hoses are connected and not leaking Draining the Seawater Section of Models With Closed Cooling NOTICE Water trapped in the seawater section of the cooling system can cause...

Page 90: ...ff piece of wire until the entire system is drained NOTE It may be necessary to lift or bend hoses to allow water to drain completely 4 Remove and lower the hose from the water inlet to the power stee...

Page 91: ...at exchanger plug 92 34227Q02 8 Prior to launching the boat or starting the engine install the drain plugs reconnect the hoses and tighten all hose clamps securely 9 If the boat was drained in the wat...

Page 92: ...he water source if connected to a flush device 8 Attach the female end of the water hose adapter fitting to a water supply 7252 Hose Adapter Fitting 22 863840 9 Attach the clogged blue drain hose to t...

Page 93: ...l mixed to the manufacturer s recommendation to protect the engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage Battery Storage Whenever the b...

Page 94: ...Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly 6 Carefully inspect the engine for fuel oil fluid water and exhaust leaks 7 Inspect the steer...

Page 95: ...ically for 3 0 TKS 89 Starter Motor Will Not Crank Engine or Cranks Slow 89 Engine Will Not Start or Is Hard to Start 89 Engine Runs Rough Misses or Backfires 90 Poor Performance 90 Troubleshooting Ch...

Page 96: ...attery switch turned off Turn the switch on Remote control not in neutral position Position the control lever in neutral Open circuit breaker or fuse Check and reset the main power circuit breaker or...

Page 97: ...res Engine overheating See Excessive Engine Temperature EFI system fault Have EFI system checked by an authorized Mercury MerCruiser dealer Troubleshooting Charts Specifically for 3 0 TKS Starter Moto...

Page 98: ...and check for cause of entry Boat overloaded or load improperly distributed Reduce load or redistribute load more evenly Flame arrestor dirty Clean the flame arrestor Boat bottom fouled or damaged Cl...

Page 99: ...e Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fasteners Lubricate Obstruction in shift or throt...

Page 100: ...g Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not Operate Motor Operates but Sterndrive...

Page 101: ...rvice Away From Home 94 Stolen Power Package 94 Attention Required After Submersion 94 Replacement Service Parts 94 Parts and Accessories Inquiries 94 Resolving a Problem 94 Contact Information for Me...

Page 102: ...in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standa...

Page 103: ...de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S...

Page 104: ...ditional literature for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Ma...

Page 105: ...Section 8 Checklists 90 8M0113856 eng DECEMBER 2015 Page 97 Section 8 Checklists Table of Contents Predelivery Inspection PDI 98 Customer Delivery Inspection CDI 99 8...

Page 106: ...ers tight Battery of proper rating fully charged secured with protective covers in place All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct propeller...

Page 107: ...Resident of California CARB hang tag in boat CARB decal properly affixed to boat hull Customer Delivery Inspection CDI IMPORTANT This checklist is for packages that are not equipped with Axius For eng...

Page 108: ...SmartCraft accessories if applicable Off season storage and maintenance schedule Engine starting stopping shifting using throttle Boat lights battery switch location fuses breakers Trailer if applica...

Page 109: ...Section 9 Maintenance Log 90 8M0113856 eng DECEMBER 2015 Page 101 Section 9 Maintenance Log Table of Contents Scheduled Maintenance Log 102 Vessel Maintenance Notes 103 9...

Page 110: ...me Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name Signa...

Page 111: ...90 8M0113856 eng DECEMBER 2015 Page 103 Vessel Maintenance Notes Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Co...

Page 112: ......

Page 113: ...ercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S A 90 8M0...

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