2003+ Mercury Mariner 225 HP EFI 4-Stroke Service Manual
- Home
- Outboard motors
- Mercury
- 2003 Mercury Mariner 225HP EFI 4 Stroke Service Manual
Complete Service manual for the Mercury: 4 Stroke 225HP EFI Models
This manual is your source for repair and service information.
Manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure.
Manual chapters:
- Specifications
- Maintenance
- General Information
- Outboard Motor Installation
- Ignition
- Charging & Starting System
- Timing, Synchronizing, & Adjusting
- Theory of Operation
- Troubleshooting and Diagnostics
- Service Procedures
- Emissions
- Cylinder Head
- Cylinder Block/Crankcase
- Lubrication
- Clamp/Swivel Brackets & Drive Shaft Housing
- Power Trim
- Lower Unit
- Throttle/Shift Linkage
- Color Diagrams
Manual is printable, has clickable chapters and is searchable for easy access to information.
To find information in PDF file please use "Ctrl+F" or "Command+F" for Mac and enter keywords you need to find in a manual.
File will be available for download in minutes!
This Manual PDF file is:
- + Printable: Yes
- + Viewable on: MS Windows, Mac, Android, iOS, Linux
- + Requires: Adobe Acrobat/Preview
Once manual is downloaded any number of pages could be printed or it could be printed in whole.
Manual could be opened in Adobe Acrobat on any mobile device (like iPad, iPhone or Android device etc.) any computer capable of viewing a PDF files including IBM compatible computers running Windows, Linux (or any other flavor of UNIX). Apple Computers have native support for PDF files.
Reference and Info files
Write a Review
Full list of manual chapters:
Cover
Section 1A - Specifications
Table of Contents
Specifications
Propeller Information Charts
Right Hand Rotation Propellers
Left Hand Rotation Propellers
Mercury/Quicksilver Lubricants and Sealants
Torque Specifications
Section 1B - Maintenance
Table of Contents
Special Tools
Inspection And Maintenance Schedule
Before Each Use
After Each Use
After First 20 Hours (Break-in)
Every 100 Hours or 6 Months
Every 300 Hours or 3 Years
Every 400 Hours or 2 Years
Every 1000 Hours or 5 Years
Flushing the Cooling System
Corrosion Control Anode
Battery Inspection
Spark Plug Inspection
Timing Belt Inspection
Fuse Replacement
Lubrication Points
Power Trim/Tilt Unit
Fuel System
Checking the Fuel Joint and Fuel Hoses
Fuel Filter
Checking/Changing Engine Oil
Checking the Engine Oil
Changing the Engine Oil
Changing Oil Filter
Lower Unit
Storage Preparation
Fuel System
Protecting External Outboard Components
Protecting Internal Engine Components
Gear Case
Positioning Outboard for Storage
Battery Storage
Section 1C - General Information
Table of Contents
Special Tools
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Model 225 (4-Stroke) Powerhead Front View
Model 225 (4-Stroke) Powerhead Starboard View
Model 225 (4-Stroke) Powerhead Port View
Model 225 (4-Stroke) Powerhead Top View
Model 225 (4-Stroke) Powerhead Aft View
Propeller Selection
Propeller Removal/Installation
Power Trim System
General Information
Power Trim Operation
Trim "In" Angle Adjustment
Trim Tab Adjustment
Compression Check
Cylinder Leakage Testing
Analysis
Water Pressure Measurement
Painting Procedures
Decal Application
Section 1D - Outboard Motor Installation
Table of Contents
Electric Fuel Pump
Boat Horsepower Capacity
Start in Gear Protection
Warning Horn Requirement
Selecting Accessories For The Outboard
Dual Engine Center Line Dimension
Lifting Outboard
Steering Cable
Steering Cable Seal
Steering Link Rod
Installing Outboard
Front Cable Clamp Assembly
Remote Wiring Harness
Battery Cable Connections to the Engine
Battery Cable Connections to the Battery
Fuel Hose Connection
Shift Cable Installation
Throttle Cable Installation
Propeller Installation
Trim Tab Adjustment
Section 2A - Ignition
Table of Contents
Specifications
Special Tools
Flywheel
Electrical Components
Ignition Components
Sensors
Theory of Operation
Ignition Component Description
Protection Controls
Over-revolution Control
Overheating Control
Shift Cut Out Switch
Neutral Switch
Low Oil Pressure Protection
Throttle Position Sensor (TPS)
Engine Water Temperature Thermoswitch
Engine Temperature Sender
Flywheel Assembly
Stator Assembly
Crank Position Sensors (CPS)
Ignition Coils
Ignition Test Procedures
Ignition Troubleshooting
Ignition Diagnostic Procedures
Recommended Test
Testing Ignition Components
ECM Peak Voltage (Coil Primary)
Crank Position Sensor (CPS) - Peak Voltage
Throttle Position Sensor
Ignition Coil (Primary)
Ignition Coil (Secondary)
Ignition Spark Gap
Engine Temperature Sensor
Temperature Switch
Air Temperature Sensor
Shift Switch
Neutral Switch
Oil Pressure Switch
Flywheel
Removal
Installation
Stator
Removal
Installation
Timing Belt
Removal
Installation
Crank Position Sensor (CPS)
Voltage Regulator/Rectifier
Removal
Installation
ECM
Ignition Coil
Removal
Installation
Port Thermoswitch
Starboard Thermoswitch
Removal
Installation
Engine Temperature Sensor
Section 2B - Charging and Starting System
Table of Contents
Specifications
Special Tools
Starter Motor
Battery
Battery Charging System
Alternator System Test
Stator Coil Continuity Test
Stator Coil Resistance Test
Stator Coil Peak Voltage Test
Rectifier/Voltage Regulator Test
Starting System Components
Description
Starting System Wiring Diagram
Troubleshooting the Starting Circuit
Starter Solenoid Test
Starter Relay
Starter Motor
Removal
Disassembly
Cleaning and Inspection
Testing
Reassembly
Installation
Section 2C - Timing, Synchronizing, and Adjusting
Table of Contents
Specifications
Special Tools
Timing
Checking Ignition Timing
Throttle Shutter Synchronization
Engine Idle Speed
Engine Idle Speed Check
Engine Idle Speed Adjustment
Throttle Cable Adjustment
Section 3A - Theory of Operation
Table of Contents
Electronic Control System
EFI System
Ignition System
Sensors
Intake Air Temperature Sensor
Crank Position Sensors
Oil Pressure Switch
Manifold Absolute Pressure (MAP) Sensor
Throttle Position Sensor (TPS)
Engine Water Temperature Sensor
Shift Cutoff Control
Neutral Switch
Thermoswitch
Idle Air Control (IAC)
Step-Motor-Type Actuator
Starting and Idling
Warming Up
Rapid Deceleration
Air Induction System
Fuel System
Low Pressure Fuel Pump
Fuel Cooler
Pressure Regulator
Vapor Separator
Secondary Vapor Separator (SVS)
Section 3B - Troubleshooting and Diagnostics
Table of Contents
Specifications
Special Tools
Control and Function
EFI System Diagnostic Procedures
Pressure Regulator Test
Checking the Fuel Pump and High Pressure Fuel Pump
Checking the High Pressure Fuel Pump Relay Continuity
Injector Operation Test
Fail Safe Function Table
Self-Diagnosis
Diagnosis Code Information
Diagnosis of the Electronic Control System
Diagnostic Code Chart
Diagnosis/Correction Complete
Section 3C - Service Procedures
Table of Contents
Specifications
Special Tools
Intake Silencer
Vapor Separator Hose Routing
Vapor Separator
Throttle Body Starboard
Throttle Body Port
Throttle Body Hose Routing
Throttle Linkage
Fuel Filter
Fuel Injection Hose Routing
Idle Air Control (IAC) Motor
MAP Sensor
Intake Silencer Assembly
High Pressure Fuel Line
Releasing Fuel Pressure
Releasing Fuel Pressure in the VST
Starboard Intake Assembly
Removal
Installation
Starboard Rail Fuel Hoses
Starboard Fuel Rail
Removal
Installation
Disassembly
Assembly
Starboard Fuel Injector
Starboard Throttle Body
Removal
Installation
High Pressure Fuel Line
Releasing Fuel Pressure
Releasing Fuel Pressure in the VST
Port Intake
Removal
Installation
Fuel Pressure Regulator
Removal
Installation
MAP Sensor Hoses
Port Rail Fuel Hose
Port Fuel Rail
Removal
Installation
Disassembly
Assembly
Port Fuel Injectors
Port Throttle Body
Removal
Installation
Fuel Cooler
Removal
Installation
Vapor Separator
Removal
Installation
Disassembly
Assembly
Secondary Vapor Separator (SVS)
Removal
Installation
Fuel Filter
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
Emissions Information
Manufacturer's Responsibility
Dealer Responsibility
Owner Responsibility
EPA Emission Regulations
Manufacturer's Certification Label
Service Replacement Certification Label
Removal
Date Code Identification
Installation
Decal Location
Section 4A - Cylinder Head
Table of Contents
Specifications
Special Tools
Cylinder Head
Timing Belt and Head Covers
Torque Sequence
Cylinder Head Screws
Camshaft Caps Screws
Exhaust Cover Screws
Removing the Oil Filter
Timing Belt and Sprocket
Valve Clearance Measurement and Adjustments
Preparation for Valve Clearance Measurement
Valve Clearance Measurement Steps
Changing Shim Thickness
Powerhead Removal
Preparing Cylinder Head for Removal
Cylinder Head Removal
Cylinder Head Disassembly
Cleaning/Inspection/Repair
Camshaft
Timing Chain Tensioner
Timing Chain
Thermostat
Valves
Valve Springs
Cylinder Head
Valve Guides
Valve Seats
Refacing the valve seat
Cylinder Head Reassembly
Cylinder Head Installation
Following Cylinder Head Installation
Section 4B - Cylinder Block/Crankcase
Table of Contents
Specifications
Special Tools
Cylinder Block And Crankcase
Crankshaft, Pistons And Connecting Rods
Torque Sequence
Crankcase Screws
Crankcase Cover Screws
Powerhead Removal
Removing Powerhead Components
Ignition Components
Charging and Starting System Components
Fuel Components
Harness and Battery Cable Removal
Cylinder Head Removal
Powerhead Disassembly
Crankcase and Crankshaft Removal
Piston Ring Removal
Cleaning/Inspection/Repair
Cylinder
Piston
Piston Rings
Crankshaft
Crankcase and Bearings
Connecting Rod Oil Clearance
Powerhead Assembly
Crankcase and Crankshaft Installation
Piston/Connecting Rod Assembly
Piston Ring/Piston Installation
Baffle Plate Installation
Exhaust Cover Installation
Oil Filter Installation
Installing Powerhead Components
Cylinder Head Installation
Harness and Battery Cable Removal
Fuel Components
Charging and Starting System Components
Ignition Components
Powerhead Installation
Following Powerhead Installation
Section 4C - Lubrication
Table of Contents
Specifications
Oil Pump
Low Oil Pressure Protection
Oil Flow Chart
Oil Pressure Measurement
Oil Pump Reference Drawing
Oil Pump
Oil Strainer
Section 5A - Clamp/Swivel Brackets and Drive Shaft Housing
Table of Contents
Specifications
Shift Linkage
Bottom Cowl
Drive Shaft Housing, Steering Arm and Swivel Bracket
Drive Shaft Housing, Oil Pan and Muffler
Steering Arm, Swivel Bracket and Clamp Bracket
Drive Shaft Housing Removal and Disassembly
Oil Pan Removal
Oil Pan Installation
Upper and Lower Mount Installation
Steering Arm Removal
Steering Arm Installation
Drive Shaft Housing Installation
Clamp Bracket Removal and Installation
Power Trim and Tilt Unit Removal
Clamp Bracket Removal
Clamp Bracket Installation
Power Trim Unit Installation
Section 5B - Power Trim
Table of Contents
Specifications
Special Tools
Power Trim and Tilt Components
Power Trim and Tilt Cylinders
Power Trim Pump
Theory Of Operation
Adjustments
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Power Trim System Hydraulic Schematic
Power Trim Flow Diagrams - Trim Up Circuit
Power Trim Flow Diagrams - Trim Down Circuit
Power Trim Flow Diagrams - Trim Ram Retraction Circuit
Stationary Condition
Power Trim Flow Diagrams - Shock System
Troubleshooting
Preliminary Checks
Hydraulic System Troubleshooting Flow Chart
Electrical System Diagram
Power Trim System
Removal
Installation
Adjusting the Trim Sensor
Motor and Electrical Tests
Motor Disassembly
Motor Tests
Motor Assembly
Electrical System Tests
Pump and Hydraulic System Tests
Power Trim and Tilt Unit Disassembly
Pump Disassembly
Trim and Tilt Cylinder Disassembly
Power Trim and Tilt Unit Inspection
Gear Pump/Valve Inspection
Power Trim and Tilt Unit Assembly
Gear Pump Assembly
Cylinder Assembly
Power Trim Motor Installation
Power Trim Reservoir Installation
Tilt Ram Installation
Bleeding the Power Trim and Tilt System
Section 6A - Lower Unit
Table of Contents
Specifications
Special Tools
Gear Housing (Driveshaft)
Gear Housing (Prop shaft)
General Service Recommendations
Draining and Inspecting Gear Lubricant
Removing the Gear Housing Assembly
Installation
Removing the Water Pump and Shift Rod
Checking the Water Pump and Shift Rod
Installation
Bearing Carrier Assembly
Removal
Installation
Disassembly
Inspection
Assembly
Propeller Shaft
Disassembly
Inspection
Assembly
Drive Shaft
Removal
Inspection
Installation
Driveshaft Bearing Carrier
Forward Gear
Pinion and Forward Gear
Bearings
Gear Case
Inspection
Disassembly
Assembly
Shimming
Selecting the Pinion Shims
Selecting the Forward Gear Shims
Selecting the Reverse Gear Shims
Measuring Backlash
Forward Gear
Reverse Gear
Section 6B - Lower Unit
Table of Contents
Specifications
Special Tools
Gear Housing (Driveshaft)(Counter Rotation)
Gear housing (Prop Shaft)(Counter Rotation)
General Service Recommendations
Draining and Inspecting Gear Lubricant
Gear Housing Assembly
Removal
Installation
Water Pump and Shift Rod
Removal
Inspection
Installation
Bearing Carrier Assembly
Removal
Disassembly
Inspection
Propeller Shaft Inspection
Bearing Carrier
Assembly
Installation
Drive Shaft
Removal
Inspection
Installation
Drive Shaft Bearing Carrier
Reverse Gear
Disassembly
Pinion and Reverse Gear Inspection
Checking the Bearings
Reverse Gear Assembly
Gear Housing
Disassembly
Inspection
Assembly
Shimming
Selecting the Pinion Shims
Selecting the Reverse Gear Shims
Selecting the Forward Gear Shims
Selecting Propeller Shaft Shims
Backlash
Section 7 - Throttle/Shift Linkage
Table of Contents
Throttle Linkage
Shift Linkage, Detent Bracket
Throttle Linkage
Removal
Installation
Disassembly
Assembly
Accelerator Arm Assembly
Removal
Installation
Shift Bracket
Removal
Installation
Disassembly
Assembly
Detent Bracket
Color Diagrams
225 4-Stroke EFI Color Wiring Diagram