Mercury 3.0 Liter Service Manual Page 132
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90-898303
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Table of Contents
Table of Contents .............................................................................................2
Model Year Changes........................................................................................4
ECM/PCM ....................................................................................................4
Throttle Roller ..............................................................................................4
Cylinder Head Location Pins - 3.0 Litre Models...........................................5
Piston Pin Material Change - 3.0 Litre Models.............................................5
New Model - 200 HP 3.0 Litre...................................................................... 6
2004 MY.......................................................................................................6
Returnable Engine Carton ...........................................................................7
Trim Tab Removed - 2.5L EFI ....................................................................9
250 Long 20 Inch .........................................................................................9
Shift Link 3.0 EFI........................................................................................ 10
Thermostat Hose Clamp - 3.0 EFI .............................................................10
Starter Motor – 2.5 and 3.0L ......................................................................11
2005/2006 Model Year Changes14 Pin Adapter and Control Harnesses..12
Adapter Harnesses (Key/Choke) ............................................................... 12
Adapter Harness ........................................................................................13
Adapter Harness ........................................................................................13
Analog Instrument Harness .......................................................................14
New Test Key Switch 14 pin15000A12..................................................... 14
8 pin Service Key Switch 15000A7 ............................................................ 14
New Decal Design .....................................................................................15
Power Trim Rams ......................................................................................15
Dielectric Grease .......................................................................................16
Drive Shaft Seal Carrier .............................................................................16
Upper Engine Mounts ................................................................................17
Thermostat Discharge Fitting.....................................................................17
Gear Case Mounting Nuts .........................................................................18
Traditional 2-Stroke.................................................................................... 18
Hi-Performance Gear Lub.......................................................................... 18
- Outboard V6 EFI 1
- Speed/Density System 5
- Ignition 10
- 2.4/2.5L Fuel Flow Component 15
- Fuel Pressure Regulator 17
- Fuel Injectors 17
- 1987–1999 2.4L & 2.5L 18
- 2000–2001 2.5L 18
- EFI Electrical Components 19
- 12 VOLT BATTERY 20
- FUEL INJECTORS 20
- 2.4L & 2.5L (1987–1999) 21
- 2-18 23
- VOLTAGE TEST CHART 24
- 2-20 25
- Ignition Systems 26
- 2-22 27
- 2-24 29
- Idle Stabilizer Shift System 31
- 2-28 33
- Theory of Operation 34
- #1 Cylinder Trigger Circuit 35
- Ignition Coil Circuit 35
- Stop Circuit 35
- Control Module 36
- Bias Circuit 36
- Shift Stabilizer Circuit 36
- Idle Stabilizer Circuit 36
- 2-32 37
- 2.0/2.5 LITRE 6 CYL.: 37
- 2-34 39
- Miscellaneous Checks 41
- Low Battery Voltage 42
- Ignition Spark Check 43
- 2-40 44
- Adjustment 45
- 2-42 46
- 2-46 49
- ECM Injector Driver Test 50
- Marine Diagnostics 51
- 824003 Fuel ECM 52
- Injector Test 53
- Multi Pulse Test 55
- 824003 ECM 56
- 2-56 58
- Programmable - ECM History 59
- 1995-2001 3.0L Fuel Flow 63
- ELECTRIC FUEL PUMP 65
- 3.0L Fuel Pump Test 67
- 3.0L ECM Wiring Diagram 68
- FLYWHEEL 73
- CRANK POSITION SENSOR 73
- THROTTLE POSITION SENSOR 73
- ENGINE TEMPERATURE SENSOR 73
- SHIFT INTERUPT SWITCH 74
- 3.0L LITRE 6 CYLINDER 74
- Operation of Warning Panel 75
- ENGINE OVER-SPEED 76
- 3 Function Gauge Wiring 77
- Injector Test (Cont.) 79
- Single Pulse Test 81
- 3.0L EFI Scan Data Worksheet 82
- Ignition ECM 83
- 3.0L PROM ID Chart 84
- 3.0L PROM ID Chart (Cont.) 85
- Oil Injection Components 94
- Priming The Oil Pump 95
- Priming Procedure – Method 1 96
- Ignition Coil 100
- Electronic Control Module 101
- Flywheel 102
- Crank Position Sensor 102
- 90-898303 103
- VISUAL INSPECTION 105
- SENSOR HEAT TEST 105
- SENSOR PRESSURE TEST 106
- DDT TEST 107
- Air Temperature Sensor 108
- VOLTAGE TEST 110
- Spark Plugs and Wires 113
- Main Power Relay 114
- Stop Switch Circuit 114
- Shift Interrupt Switch 114
- Water Sensing System 115
- 2002 Warning System Signals 118
- Guardian Protection System 119
- Guardian System Activation 120
- Smartcraft Data Worksheet 121
- Description 124
- Overview 127
- SmartCraft System Products 127
- SmartCraft System Rules 128
- System Monitor 130
- Section 5 - Product Changes 131
- Table of Contents 132
- Model Year Changes 133
- 2004 MY 134
- 2004 RUNNING CHANGE 134
- New Model - 200 HP 3.0 Litre 135
- Returnable Engine Carton 136
- Shift Link 3.0 EFI 139
- Starter Motor – 2.5 and 3.0L 140
- Control Harnesses 141
- New Decal Design 144
- Power Trim Rams 144
- Dielectric Grease 145
- Drive Shaft Seal Carrier 145
- Upper Engine Mounts 146
- Thermostat Discharge Fitting 146
- Special Tools 150
- Spark Board - P/N 91-850439T 153
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