2002+ Mercury Mariner 150/175/200 EFI 2-stroke Factory Service Manual
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- 2002 plus Mercury Mariner 150 175 200 EFI 2 stroke Service Manual
Original 2002+ Mercury Mariner 150/175/200 EFI 2-stroke Factory Service Manual.
Mercury Mariner 150/175/200 Electronic Fuel Injection
Starting Model Year: 2002
Starting Serial Number: 0T409000
Detailed substeps expand on repair procedure information.
Notes, cautions and warnings throughout each chapter pinpoint critical information.
Numbered instructions guide you through every repair procedure step by step.
Bold figure number help you quickly match illustrations with instructions.
Detailed illustrations, drawings and photos guide you through every procedure.
Enlarged inset helps you identify and examine parts in detail.
Numbered table of contents easy to use so that you can find the information you need fast.
This manual also makes it easy to diagnose and repair problems with your machines electrical system.
Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
- Tools & Techniques
- Troubleshooting
- Lubrication & Maintenance
- Tuning & Adjustments
- Fuel, Ignition & Electrical
- Power Head
- Gearcase
- Tilt and Trim
- Wiring
- Oil Injection
- Rewind Starters
- Engine Synchronisation & Linkage
- and more
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Full list of manual chapters:
COVER
150/175/200 EFI
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
SPECIFICATIONS
Section 1A - Specifications
Table of Contents
Specifications
Mercury/Quicksilver Lubricants and Sealants
MAINTENANCE
Section 1B - Maintenance
Table of Contents
Specifications
Special Tools
Mercury/Quicksilver Lubricants and Sealants
Inspection and Maintenance Schedule
Flushing Engine
Fuel System
Corrosion Control Anode
Spark Plug Inspection and Replacement
Battery Inspection
Fuse Replacement
Lubrication Points
Checking Power Trim Fluid
Gear Case Lubrication
Storage Preparation
GENERAL INFORMATION
Section 1C - General Information
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Trim
Engine
Engine Compression
Following Complete Submersion
Model 150 XRI/175 XRI/200 XRI Powerhead Front View
Model 150 XRI/175 XRI/200 XRI Powerhead Starboard View
Model 150 XRI/175 XRI/200 XRI Powerhead Port View
Model 150 XRI/175 XRI/200 XRI Powerhead Top View
Model 150 XRI/175 XRI/200 XRI Powerhead Aft View
Painting Procedures
Decal Application
OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation
Table of Contents
Installation Specifications
Lifting Outboard
Installing Outboard to Boat Transom
Installing Outboard
Drilling Outboard Mounting Holes
Securing Outboard To Boat Transom
Steering Cable
Steering Link Rod
Electrical, Hoses and Control Cables
Installation Note
Remote Wiring Harness
Battery Cables
Fuel Hose Connection
Oil Hose Connections
Speedometer Tubing Connection
Water Pressure Tubing Connection
Shift Cable
Installation
Throttle Cable
Front Clamp Reassembly
Oil Injection Set-Up
Installing Remote Oil Tank
Installing Oil Hoses To Engine
Filling
Priming the Oil Pump
Priming Procedure – Method 1
Purging Air From the Engine Oil Reservoir
Trim In Stop Adjustment
Trim Tab Adjustment
IGNITION
Section 2A - Ignition
Table of Contents
Specifications
Ignition Coil Ohms Test
Manifold Absolute Pressure (MAP) Sensor Ohms Test
Port and Starboard Temperature Sensors; Air Temperature Sensor
Special Tools
Coil Plate Assembly
Electrical Plate Assembly
Theory of Operation
Ignition Component Description
Fuses
Charging System Alternator
Ignition Coil
Electronic Control Module
Flywheel
Crank Position Sensor
Throttle Position Sensor (TPS)
Throttle Position Sensor (TPS) Troubleshooting
Cylinder Head Temperature Sensor
Air Temperature Sensor
Port and Starboard Temperature Sensors; Air Temperature Sensor
Manifold Absolute Pressure (MAP) Sensor
Ignition Troubleshooting and Fault Chart
Ignition Coil Ohms Test
Manifold Absolute Pressure (MAP) Sensor Ohms Test
Idle Speed Control
RPM-Limit Circuit
EFI Detonation Control System (200 Model only)
Detonation Circuit Test
Troubleshooting
Troubleshooting Without Digital Diagnostic Terminal
Troubleshooting with the Digital Diagnostic Terminal
DDT Functions – EFI Models Software Version 1.2 (P/ N 880118A2)
Ignition Component Removal and Installation
Flywheel Removal
Flywheel Installation
Ignition Coil Removal
Ignition Coil Installation
Electronic Control Module Removal
Electronic Control Module Installation
Temperature Sensor Removal
Engine Head Temperature Sensor Installation
Air Temperature Sensor Removal
Air Temperature Sensor Installation
Manifold Absolute Pressure (MAP) Sensor Removal
Manifold Absolute Pressure (MAP) Sensor Installation
Crank Position Sensor Removal
Crank Position Sensor Installation
CHARGING and STARTING SYSTEM
Section 2B – Charging and Starting System
Table of Contents
Specifications
Special Tools
Battery Cable Size
Replacement Parts
Recommended Battery
Battery
Charging a Discharged Battery
Winter Storage of Batteries
Flywheel Removal and Installation
Removal
Installation
Flywheel/Alternator
System Components
Alternator Description
Diagnosis of Alternator System on Engine
Alternator System Circuitry Test
Output Circuit
Sensing Circuit
Voltage Output
Current Output
Current Output Troubleshooting
Repair
Installation
Alternator Belt Tension Adjustment
Starter System
Starter Motor (Centrifugal Bendix)
Troubleshooting the Starter Circuit (Centrifugal Bendix)
Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix)
Starter Removal (Centrifugal Bendix)
Starter Installation (Centrifugal Bendix)
Starter Disassembly (Centrifugal Bendix)
Starter Cleaning, Inspection and Testing
Starter Reassembly
Starter Motor (Solenoid Driven Bendix)
Troubleshooting the Solenoid Driven Bendix Starter Circuit
Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)
Starter Removal (Solenoid Driven Bendix)
Starter Installation (Solenoid Driven Bendix)
Disassembly (Solenoid Driven Bendix Starter)
Cleaning and Inspection
Reassembly (Solenoid Driven Bendix Starter)
Commander 2000 Key Switch Test
TIMING, SYNCHRONIZING and ADJUSTING
Section 2C - Timing, Synchronizing and Adjusting
Table of Contents
Specifications
Special Tools
Adjustments
Throttle Cam Adjustment
Timing
Maximum Throttle Adjustment
Throttle Position Sensor
Idle Speed
Throttle Cable Installation
Throttle Plate Screw
WIRING DIAGRAMS
Section 2D – Wiring Diagrams
Table of Contents
Power Trim Wiring Diagram
Instrument Wiring Connections
Commander 3000 Classic Panel Remote Control
Commander 3000 Panel Remote Control
4000 Series Mechanical Panel Control
Instrument/Lanyard Stop Switch Wiring Diagram
Oil Level Gauge Wiring Diagram
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
QSI Gauge Wiring Diagrams
Tachometer Wiring Diagram
Water Temperature Gauge
Oil Level Gauge Wiring
Engine Synchronizer Wiring Diagram
Maintenance
Warning System Signals
Guardian Protection System
Analog Gauge Panel Mount Remote Control Wiring Installation
System Monitor V2.0
Basic Operation
Initial Power Up (Or After Master Reset)
Standard Information Display Screens
Display of Range and Depth Information
Warning System
Warning Display Screens
CAL1 Calibration
CAL2 Calibration
Master Reset Command
System Tach and Speed
Basic Operation and Features
Speedometer Display Screens
Tachometer Display Screens
Troll Control
Warning System
Alarm Messages
Auto-Detection Engine Function
Master Reset Command
Tachometer Calibration
Speedometer Calibration
SmartCraft Gauge Operation
Basic Operation and Features
Speedometer Display Screen
Tachometer Display Screens
Troll Control
Warning System
Alarm Messages
Tachometer Calibration
Speedometer Calibration
SmartCraft Gauge Test Specifications
150/175/200 EFI Wiring Diagram
FUEL PUMP
Section 3A - Fuel Pump
Table of Contents
Specifications
Special Tools
Fuel Pump Assembly
Fuel Pump Description/Operation
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
Checking Fuel Pump Lift (Vacuum)
Vacuum Test Troubleshooting
Testing Fuel Pump
Fuel Pump Removal/Disassembly
Cleaning/Inspection
Reassembly/lnstallation
FUEL INJECTION
Section 3B - Fuel Injection
Table of Contents
Specifications
Special Tools
Fuel Management System
Vapor Separator Components
Electronic Fuel Injection (EFl) System
Introduction
Using the Test Procedures
EFI System Tests
Safety Precautions
Fuel Injection System Function
Preliminary Checks
Ignition Spark Check
Electronic Fuel Injection Set Up
Fresh Quality Fuel
Low Battery Voltage
Fuel Flow Diagram
Fuel Flow Component Description
Pulse Fuel Pump (d)
Water Separating Filter (e)
Vapor Separator (h)
Final Filter (n)
Electric Fuel Pump (Inside Vapor Separator) (j)
Fuel Injectors (c)
Fuel Pressure Regulator (p)
EFI Electrical Components
EFI Fuel Management (Low Pressure Fuel Route)
EFI Fuel Management (High Pressure Fuel Route)
Fuel Rail Electrical/Fuel Determination
EFI System Test Procedures
Fuel Gauge Connection/Pressure Test
Vapor Separator Fuel Delivery Test
Pulse Fuel Pump Delivery Test
Water Separating Filter Inspection
Vapor Separator Float Test
Electric Fuel Pump Inlet Filter Check and De-Pressurizing EFI System Procedures
Pressure Regulator Test
Electric Fuel Pump Voltage/Pressure Test
Injector Electrical Harness Test
Injector Load Test
Fuel Rail Assembly Leakage Test
Air Temperature Sensor and Head Temperature Sensor Test
Detonation Control System Test (200 Models Only)
Throttle Position Sensor Test
MAP Sensor Test
Problem Diagnosis
Engine Head Temperature Sensor Removal
Engine Head Temperature Sensor Installation
Fuel Management Assembly Removal
Fuel Rail Removal
Fuel Rail Installation
Reed Block Assembly Removal
Reed Block Assembly Installation
Air Temperature Sensor Removal
Air Temperature Sensor Installation
Manifold Absolute Pressure (MAP) Sensor Removal
Manifold Absolute Pressure (MAP) Sensor Installation
Throttle Plate Assembly Removal
Throttle Plate Assembly Installation
Vapor Separator Disassembly
Vapor Separator Reassembly
Air Plenum Installation
Vapor Separator (VST) Installation
Water Separating Filter Assembly Removal
Water Separating Filter Assembly Installation
Throttle Position Sensor Removal
Throttle Position Sensor Installation
Oil Reservoir Removal
Oil Reservoir Installation
Fuel Pressure Regulator Removal
Fuel Pressure Regulator Disassembly
Fuel Pressure Regulator Reassembly
EFI System Cleaning and Inspection
OIL INJECTION
Section 3C - Oil Injection
Table of Contents
Specifications
Operation of the Oil Injection System
Oil Injection Components
Oil Lines
Oil Injection Components
Oil Injection Flow System
Oil Pump Removal and Installation
Engine Oil Reservoir Removal and Installation
Priming the Oil Pump
Priming Procedure – Method 1
Remote Oil Hose Connections
Filling the Oil Tanks
Purging Air From the Engine Oil Reservoir and Remote Oil Hose
Oil Warning Systems
Oil System Troubleshooting
EMISSION
Section 3D – Emissions
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons – HC
Carbon Monoxide – CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Outboard Hydrocarbon Emissions Reductions
Stratified vs Homogenized Charge
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer's Responsibility:
Dealer Responsibility:
Owner Responsibility:
EPA Emission Regulations:
Manufacturer's Certification Label:
Service Replacement Certification Label
POWERHEAD
Section 4A - Powerhead
Table of Contents
Specifications
Special Tools
Cylinder Block Assembly
Exhaust Manifold and Exhaust Plate
Crankshaft, Pistons and Connecting Rods
Cylinder Head
Bleed System Routing
Torque Sequence
General Information
Powerhead Removal from Driveshaft Housing
Removing Engine Components
Removing Engine Components Individually
Removing Engine Components as an Assembly
Ignition Coil Plate and Harness Removal
Starter Motor
Electrical Plate Removal
Oil Pump
Air Plenum
Powerhead Disassembly
Water Pressure Relief Valve Components
Torque Specifications
Cleaning and Inspection
Cylinder Block and Crankcase Cover
Special Service Information
Cylinder Bores
Pistons and Piston Rings
Cylinder Heads and Exhaust Divider Plate
Crankshaft
Crankshaft (and End Cap) Bearings
Reed Block Assembly
Reed Block Housing
Connecting Rods
Powerhead Reassembly and Installation
General
Crankshaft Installation
Piston and Connecting Rod Reassembly
Piston and Piston Ring Combinations
Piston Installation
Crankcase Cover Installation
Reed Block Assembly
Assembly of Reed Blocks to Intake Manifold
Assembly of Exhaust Divider Plate to Block
Cleaning and Inspection
Cylinder Block and Crankcase Cover
Reinstalling Engine Components
Throttle Lever and Shift Shaft
Powerhead Installation On Driveshaft Housing
Engine Break-in Procedure
COOLING
Section 4B - Cooling
Table of Contents
Specifications
Thermostat
Water Pressure
Digital Port and Starboard Temperature Sensors
Analog Temperature Sensor
Special Tools
Water Flow
2.5 Litre V-6 Water Flow Diagram 2002 Models
Troubleshooting
Thermostat Test
Water Pressure Check
Water Pump Cleaning and Inspection
Problem Diagnosis
CLAMP/SWIVEL BRACKETS and DRIVESHAFT HOUSING
Section 5A – Clamp/Swivel Brackets and Driveshaft Housing
Table of Contents
Swivel Bracket and Steering Arm
Transom Brackets
Drive Shaft Housing and Exhaust Tube
Drive Shaft Housing and Dyna-Float Suspension
Removal and Disassembly
Reassembly and Installation
POWER TRIM
Section 5B – Power Trim
Table of Contents
Power Trim Specifications
Special Tools
Power Trim Components
Power Trim Motor
Power Trim - General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Manually
Trim "In" Angle Adjustment
Striker Plate Replacement
Anode Plate
Trim Indicator Gauge
Check, Fill and Purge - Power Trim System
Troubleshooting
Power Trim System with Relays and 2 Wire Trim Motor
Electrical System Troubleshooting
Troubleshooting the "Down Circuit"
Troubleshooting the "Up" Circuit
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim Assembly Removal and Installation
Removal
Installation
Testing Power Trim System With Test Gauge Kit (91-52915A6)
"UP" Pressure Check
"DOWN" Pressure Check
Hydraulic Repair
Trim Rod End Cap Seal
Tilt Ram
Disassembly
Scraper Seal Replacement
Motor and Electrical Tests/Repair
Trim Pump Motor Test
Motor Disassembly
Armature Tests
Motor Repair
Reassembly
Reassembly - Motor and Pump
Priming Power Trim System
Trim Sender Test
Trim Indicator Gauge Needle Adjustment
Trim Indicator Wiring Diagrams
RIGHT HAND NON-RATCHETING
Section 6A – Right Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications (Standard Rotation)
Special Tools
Gear Housing (Drive Shaft)(Standard Rotation)
Gear Housing (Prop Shaft)(Standard Rotation)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection – Standard Rotation
Removal
Draining and Inspecting Gear Housing Lubricant
Water Pump
Bearing Carrier and Propeller Shaft Removal
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Pinion Gear and Driveshaft
Forward Gear
Gear Housing
Reassembly and Installation Standard Rotation
Driveshaft Needle Bearing
Bearing Carrier
Forward Gear
Forward Gear Bearing Race
Driveshaft and Pinion Gear
Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash
Clutch Actuator Rod
Shift Shaft Bushing
Propeller Shaft
Water Pump
Gear Lubricant Filling Instructions
Installing Gear Housing to Driveshaft Housing
Right Hand Rotation Outboard
Propeller Installation
Speedometer Tube Installation
LEFT HAND NON-RATCHETING
Section 6B – Left Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications (Counter Rotation)
Special Tools
Gear Housing (Drive Shaft)(Counter Rotation)
Gear Housing (Prop Shaft)(Counter Rotation)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing
Water Pump
Bearing Carrier and Propeller Shaft
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Forward Gear and Bearing Adapter
Pinion Gear and Driveshaft
Reverse Gear
Gear Housing
Reassembly and Installation of Counter Rotation Gear Housing
Driveshaft Needle Bearing
Bearing Carrier, Forward Gear and Bearing Adaptor
Reverse Gear Bearing Adaptor Assembly
Driveshaft and Pinion Gear
Pinion Gear Depth
Reverse Gear
Forward Gear
Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
Water Pump
Gear Lubricant Filling Instructions
Installing Gear Housing to Driveshaft Housing
Propeller Installation
Speedometer Tube Installation
ATTACHEMENT / CONTROL LINKAGE
Section 7
Table of Contents
Ride Guide Steering Cable/Attaching Kit Installation (92876A10)
Single Cable
Maintenance Instructions
Ride Guide Steering Cable/Attaching Kit Installation (92876A8)
Dual Cable - Single Outboard
Super Ride-Guide Steering Kit Installation
Steering Cable Mounting Tube Installation
Installing Steering Cables
Coupler Installation
Installing Link Rod
Maintenance Instructions
Ride Guide Steering Cable/Attaching Kit Installation (92876A9)
Dual Cable - Dual Outboard
Installation Requirements
Parallel Routed Steering Cables and Attaching Kit Installation
Opposite Side Routed Steering Cables and Attaching Kit Installation
Trim Tab Adjustment
Ride Guide Steering Attachment Extension Couplers
Maintenance Instructions
Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
Attaching Kit Installation
Maintenance Instructions
Clevis Attaching Kit Installation (A-70599A5)
Installation Instructions
Maintenance Instructions
COLOR DIAGRAMS
Color Diagrams
Table of Contents
150/175/200 EFI Wiring Diagram 2002 Model Year
Typical SmartCraft System Tachometer and System Speedometer Installation with System Link Gauges 2002 Model Year
Typical SmartCraft System Monitor/Tachometer Installation with System Link Gauges 2002 Model Year
Typical SmartCraft Dual Outboard Installation 2002 Model Year
150/175/200 EFI Oil and Fuel Flow Diagram 2002 Model Year
150/175/200 EFI Water Flow Diagram 2002 Model Year
