2002+ Mercury 40/50/60 BigFoot 40 Jet EFI 4-Stroke Outboard motor Service Manual
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- 2002 Mercury Mariner 40 50 60 4 stroke EFI Outboard Service Manual
Original Mercury Service Manual for 40/50/60 BigFoot 40 Jet EFI FourStroke 4 Cylinder models.
Manual includes high resolution diagrams, images, detailed instruction and technical recommendations and more.
Manual is deeply indexed and searchable.
Part Number: 90-899975 JANUARY 2008
Serial Number 1C050252 and Above 2002+ year
Manual Chapters:
- Section 1A - Specifications
- Maintenance
- General Information
- Outboard Motor Installation
- Ignition
- Charging and Starting System
- Timing, Synchronizing, and Adjusting
- Theory of Operation
- Diagnostics and Troubleshooting
- Service Procedures
- Emissions
- Cylinder Head
- Cylinder Block/Crankcase
- Lubrication
- Clamp/Swivel Brackets and Driveshaft Housing
- Power Trim
- Gas Assist Manual Trim/Tilt
- Gear Housing - EZ Shift (1.83:1 Gear Ratio)
- Gear Housing - BigFoot EZ Shift (2.33:1 Gear Ratio)
- Throttle/Shift Linkage
- Tiller Handle
- Jet Drive Outboard
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Full list of manual chapters:
Cover
Manual Outline
Notice to Users of This Manual
Precautions
Replacement Parts
Cleanliness and Care of Product
Manual Outline
Section 1A - Specifications
Table of Contents
40/50/60 FourStroke EFI Master Specifications
General Specifications
Fuel System Specifications
Ignition Specifications
Charging and Starting Specifications
Cylinder Head Specification
Cylinder Block/Crankshaft Specifications
Piston Specifications
Lubrication Specifications
Mid-Section Specifications
Gear Housing Specifications (1.83:1)
Gear Housing Specifications - BigFoot (2.33:1) (S/N 0T625304 and Above)
Power Trim Specifications
Propeller Information Charts
50 EFI FourStroke Non-BigFoot
60 EFI FourStroke Non-BigFoot
40 EFI FourStroke BigFoot
50 EFI FourStroke BigFoot
60 EFI FourStroke BigFoot
Section 1B - Maintenance
Table of Contents
Inspection and Maintenance Schedule
Before Each Use
After Each Use
Jet Models Every 30 Hours of Use
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
Every 300 Hours of Use or Three Years
Every 400 Hours
Before Periods of Storage
Flushing the Cooling System
Outboard Models
Jet Drive Models
Steering Link Rod Fasteners
Corrosion Control Anode
Spark Plug Inspection and Replacement
Battery Inspection
Lubrication Points
Checking Power Trim Fluid
Fuse Replacement
Timing Belt Inspection
Fuel System
Fuel Line Inspection
Engine Fuel Filter
Removal
Installation
Changing Engine Oil
Engine Oil Capacity
Oil Changing Procedure
Changing Oil Filter
Oil Filling
Changing Gearcase Lubricant
Gearcase Lubrication - For 87.3 mm(3-7/16 in.) Diameter Gearcase
Draining Gearcase
Gearcase Lubricant Capacity
Checking Gearcase Lubricant Level And Refilling Gearcase
Gearcase Lubrication - For 108 mm(4-1/4 in.) Diameter Gearcase
Draining Gearcase
Gearcase Lubricant Capacity
Checking Lubricant Level and Filling Gearcase
Jet Maintenance
Steering Pull Adjustment
Flushing the Cooling System
Impeller Clearance Adjustment
Impeller Removal and Installation
Installation
Lubrication Points
Worn/Dull Impeller
Storage
Storage Preparation
Fuel System
Protecting External Outboard Components
Protecting Internal Engine Components
Gearcase
Positioning Outboard for Storage
Battery Storage
Section 1C - General Information
Table of Contents
Recording Serial Number
Conditions Affecting Performance
Weather
Weight Distribution (Passengers and Gear) Inside the Boat
Bottom of Boat
Water Absorption
Cavitation
Detonation
Following Complete Engine Submersion
Engine Submerged While Running (Special Instructions)
Saltwater Submersion (Special Instructions)
Freshwater Submersion (Special Instructions)
Powerhead Views
Model 40/50/60 EFI FourStroke Powerhead Front View
Model 40/50/60 EFI FourStroke Powerhead Starboard View
Model 40/50/60 EFI FourStroke Powerhead Port View
Model 40/50/60 EFI FourStroke Powerhead Top View
Model 40/50/60 EFI FourStroke Powerhead Aft View
Propeller Selection
Propeller Replacement - 87.3 mm (3-7/16 in.) Diameter Gearcase
Propeller Replacement - 108 mm (4-1/4 in.) Diameter Gearcase
Power Trim System
General Information
Power Trim Operation
Trim Tab Adjustment
Compression Check
Cylinder Leakage Testing
Analysis
Painting Procedures
Propellers
Gear Housing
Water Pressure Measurement
Decal Removal
Decal Application
Section 1D - Outboard Motor Installation
Table of Contents
Boat Horsepower Capacity
Start in Gear Protection
Selecting Accessories for Your Outboard
Electric Fuel Pump
Installation Specifications
Lifting Outboard
Steering Cable - Starboard Side Routed Cable
Steering Cable Seal
Steering Link Rod Fasteners
Installing Outboard - Non Thumb Screw Models
Remote Wiring Harness
Battery Cable Connections
Single Outboard
Dual Outboards
Shift and Throttle Cable Installation
Shift Cable Installation
Throttle Cable Installation
Trim Tab Adjustment
Trim-In Stop Adjustment - Power Trim Models
Jet Drive Installation
Boat Horsepower Capacity
Start in Gear Protection
Selecting Accessories for Your Outboard
Electric Fuel Pump
Lifting Outboard
Determining the Mounting Height of the Outboard
Boats with a "V" Bottom Hull
Boats with a Flat Bottom Hull
Checking Boat Transom Construction
Fastening the Outboard
Steering Cable - Starboard Side Routed Cable
Steering Link Rod Fasteners
Remote Wiring Harness
Battery Cable Connections
Single Outboard
Dual Outboards
Throttle Cable Installation
Shift Cable Installation
Trim-In Stop Adjustment - Power Trim Models
Water Testing
Checking for Cavitation
Section 2A - Ignition
Table of Contents
Ignition Specifications
Ignition Coil Mounting Components
Ignition Description
Ignition Troubleshooting
Ignition Diagnostic Procedures
Ignition Coils
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Resistance Test
Spark Plug Lead Resistance Test
Section 2B - Charging and Starting System
Table of Contents
Charging and Starting Specifications
Flywheel Components
Electrical Components
Wire Color Code Abbreviations
Battery
Battery Cable Test
Original Battery Cable Length and Gauge Shipped with Engine
Battery Cable Size for Outboard Models
Replacement Parts
Recommended Battery
Battery Precautions
Charging a Discharged Battery
Winter Storage of Batteries
Battery Charging System
Description
Wiring Diagram
Flywheel
Stator
Battery
Voltage Regulator/Recifier
Troubleshooting the Battery Charging System
Alternator System Test
Stator Resistance Test
Test
Voltage Regulator/Rectifier Test
Test
Flywheel Removal and Installation
Removal
Installation
Stator Removal and Installation
Removal
Installation
Voltage Regulator/Rectifier Removal and Installation
Removal
Installation
Starting System
Description
Starting System Wiring Diagram
Troubleshooting the Starting System
Suppression Diode
Suppression Diode Replacement
Suppression Diode Test
Starter Solenoid
Starter Solenoid Removal
Starter Solenoid Installation
Starter Solenoid Test
Starting Circuit Fuse
Ignition Key Switch Test
Neutral Start Switch Test (Tiller Handle Model)
Continuity Test - Neutral (Switch Depressed)
Continuity Test - In Gear (Switch Not Depressed)
Starter Motor Removal and Installation
Removal
Installation
Section 2C - Timing, Synchronizing, and Adjusting
Table of Contents
Ignition Specifications
Throttle Link Setting - Tiller Handle Models and 40 HP Jet Models
Idle
Full Throttle Setting
Throttle Link Setting - Remote Control Models
Timing
Idle Speed
Throttle Position Sensor (TPS)
Idle Air Control (IAC)
Setup Procedure
Section 3A - Theory of Operation
Table of Contents
Electronic Fuel Injection System
Air Induction System
Fuel System
Fuel System Components
Fuel Pump
Vapor Separator and Fuel Regulator
Vapor Separator
Fuel Regulator
Fuel Cooler
Sensors
Function of Sensors
Crank Position Sensor (CPS)
Engine Coolant Temperature (ECT) Sensor
Manifold Absolute Pressure (MAP) Sensor
Manifold Air Temperature (MAT) Sensor
Throttle Position Sensor (TPS)
Oil Pressure Switch
Actuators
Function of Actuators
Idle Air Control (IAC)
Fuel Injector
Main Power Relay (MPR)
Fuses
Suppression Diode
Engine Control Module
ECM Systems Control Matrix
Outline of the Engine Control System
Ignition Timing Control
Fuel System
IAC Control
Control and Function
Section 3B - Diagnostics and Troubleshooting
Table of Contents
Fuel System Specifications
Wire Color Code Abbreviations
Troubleshooting Without a Computer Diagnostic System (CDS)
Troubleshooting with the Computer Diagnostic System (CDS)
Accessing ECM Information
System Information
Default Sensor Values
Fault Conditions
Fault Information
40/50/60 EFI FourStroke ECM Pin Identification
CDS Text - Guardian Due To
Mechanical Fuel Pump
Pressure Regulator Test
Anti-Siphon Valves
Mechanical Fuel Pump Test (Vacuum)
Mechanical Fuel Pump Test (Pressure)
Fuel Pump Pressure Troubleshooting
Guardian Protection System
Overheat Temperature Parameters
40/50/60 EFI FourStroke
EFI System Troubleshooting Guide
Component Resistance Tests
Engine Coolant Temperature (ECT) Sensor and Manifold Air Temperature (MAT) Sensor
Fuel Injector
Main Power Relay
Manifold Absolute Pressure (MAP) Sensor
Crank Position Sensor (CPS)
Section 3C - Service Procedures
Table of Contents
Fuel System Specifications
Intake Manifold Components
VST Components
Fuel Pump Components
Fuel Line Components
Intake Manifold
Releasing Fuel Pressure in the High-Pressure Fuel Line
Intake Manifold Removal
Intake Manifold Installation
Throttle Body
Removal
Installation
Idle Air Control (IAC)
Removal
Installation
Fuel Injectors
Removal
Installation
Manifold Absolute Pressure (MAP) Sensor
Removal
Installation
Fuel Distribution Manifold
Removal
Installation
Manifold Air Temperature (MAT) Sensor
Removal
Installation
Throttle Position Sensor (TPS)
Removal
Installation
Engine Control Module (ECM)
Removal
Installation
Crank Position Sensor (CPS)
Removal
Installation
Engine Coolant Temperature (ECT) Sensor
Removal
Installation
Low-Pressure Fuel Pump
Low-Pressure Fuel Pump Removal and Disassembly
Removal
Disassembly
Cleaning/Inspection/Repair
Check Valve Inspection/Replacement
Removal
Installation
Low-Pressure Fuel Pump Assembly and Installation
Assembly
Installation
Fuel Filter Replacement
Vapor Separator Tank (VST)
Removal
Installation
Vapor Separator Tank (VST) S/N 1B036614 and Above
Disassembly
Assembly
High-Pressure Fuel Line
Removal
Installation
Section 3D - Emissions
Table of Contents
Exhaust Emission 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 Reduction
Emissions Information
Manufacturer's Responsibility
Dealer Responsibility
Owner Responsibility
Exceptions
EPA Emission Regulations
Manufacturer's Certificate Label
Service Replacement Certification Label
Removal
Date Code Identification
Installation
Section 4A - Cylinder Head
Table of Contents
Cylinder Head Specification
Cylinder Head Components
Camshaft Components
Intake/Exhaust Valve Components
Valve Cover
Removal
Installation
Valve Clearance Adjustment
No. 1 and No. 2 Intake Valves and No. 1 and No. 3 Exhaust Valves
No. 3 and No. 4 Intake Valves and No. 2 and No. 4 Exhaust Valves
Timing Belt
Removal
Installation
Cylinder Head Removal
Cylinder Head Disassembly
Rocker Arm Assembly Removal
Oil Pump Removal
Camshaft Removal
Valve Removal
Valve Components
Removal
Cleaning/Inspection/Repair
Rocker Shaft and Rocker Arm Inspection
Camshaft Inspection
Cylinder Head Inspection
Valve Guides
Valve Guide Replacement
Valves
Valve Springs
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Installation
Valve Components
Installation
Camshaft Oil Seal Installation
Camshaft Installation
Oil Pump Installation
Rocker Arm Shaft Assembly
Rocker Arm Shaft Installation
Cylinder Head Installation
Section 4B - Cylinder Block/Crankcase
Table of Contents
Cylinder Block/Crankshaft Specifications
Piston Specifications
Crankshaft Components
Cylinder Block and Crankcase Components
Powerhead Removal
Removing Powerhead Components
Cylinder Block Disassembly
Cleaning/Inspection/Repair
Cylinder Bore
Piston
Piston Pin
Piston Rings
Piston Ring Side Clearance
Piston Ring End Gap Clearance
Crankshaft
Crankshaft Runout
Crankcase Main Bearings
Crankshaft Main Bearing Clearance Measurement
Connecting Rod Oil Clearance
Connecting Rod Oil Clearance Measurement
Thermostat
Thermostat Measurement Test
Oil Pressure Switch Test
Cylinder Block Assembly
Selecting New Main Bearings
Main Bearing Installation
Selecting New Connecting Rod Bearings
Connecting Rod Bearing Installation
Piston Assembly
Piston Ring Installation
Piston Installation
Crankshaft Installation
Crankcase Cover Installation
Exhaust Cover Installation
Drive Gear Installation
Installing Powerhead Components
Cylinder Head
Engine Wiring Harness, Ignition, and Electrical Components
Ignition Components
Charging and Starting Components
Fuel Components
Powerhead Installation
Section 4C - Lubrication
Table of Contents
Lubrication Specifications
Oil Pump Removal
Oil Pump Disassembly
Oil Pump Inspection
Oil Pump Assembly
Oil Pump Installation
Oil Pressure Measurement
Section 5A - Clamp/Swivel Brackets and Driveshaft Housing
Table of Contents
Mid-Section Specifications
Swivel Bracket Components
Steering Arm Components
Transom Bracket Components
Adapter Plate Components
Driveshaft Housing Components
Bottom Cowl Components
Bottom Cowl Removal/Installation
Lower Mount/Steering Tube
Removal
Installation
Adapter Plate and Driveshaft Housing Removal
Water Tube
Removal
Installation
Exhaust Tube Removal/Installation
Exhaust Tube Removal
Exhaust Tube Installation
Adapter Plate Inspection/Cleaning/Assembly
Adapter Plate Installation
Driveshaft Housing Installation
Section 5B - Power Trim
Table of Contents
Power Trim Specifications
Power Trim Components
Wire Color Code Abbreviations
Power Trim General Information
General Information
Power Trim Operation
Trailering Boat/Outboard
Manual Tilting
Power Trim Flow Diagrams
Trim Up Circuit
Tilt Circuit
Maximum Tilt
Trim Down
Shock Function Up
Shock Function Return
Manual Tilt
Trim Limit
Reverse Operation
Troubleshooting
Hydraulic System Troubleshooting
Condition/Problem
Problem/Solution
Troubleshooting the Power Trim Electrical System
Troubleshooting the Up circuit
Troubleshooting the Down circuit
Troubleshooting the Up and Down circuits (All Circuits Inoperative)
Testing Power Trim System with Test Gauge Kit
Up Pressure Check
Down Pressure Check
Power Trim System Removal
Power Trim Disassembly
Draining Power Trim
Trim Motor Removal
Power Trim Pump and Components Removal
Manifold Removal
Shock Rod Removal
Shock Rod Disassembly
Memory Piston Removal
Power Trim Cleaning, Inspection, and Repair
Trim Motor Electrical Tests
Power Trim Assembly
O-Ring and Seal Placement
O-Ring Size
Shock Rod Assembly
Shock Rod Installation
Trim Limit Installation
Manual Release Valve Installation
Manifold Installation
Power Trim Pump and Components Installation
Pump Installation
Pressure Operated Plugs
Trim Motor Installation
Bleeding Power Trim Unit
Power Trim System Installation
Section 5C - Gas Assist Manual Trim/Tilt
Table of Contents
Gas Assist Manual Trim/Tilt Components
Gas Assist Manual Trim/Tilt - Up Circuit
Gas Assist Manual Trim/Tilt - Down Circuit
Gas Assist Manual Trim/Tilt - Slow Tilt Down Under Pressure
Gas Assist Manual Trim/Tilt - Underwater Strike (Valves Open)
Gas Assist Manual Trim/Tilt - Underwater Strike (Valves Closed)
Gas Assist Manual Trim/Tilt - Shock Return Function
Gas Assist Manual Trim/Tilt System Troubleshooting
Manual Release Cam Adjustment
External Leaks
Accumulator
Gas Assist Manual Trim/Tilt System Removal
Gas Assist System Disassembly
Shock Rod Disassembly
Valve Block Removal
Memory Piston Removal
Valve Block Disassembly
Gas Assist System Cleaning and Inspection
O-Ring and Seal Placement
Actual O-Ring Size
O-Ring Description and Size
Gas Assist System Assembly
Camshaft Lever Assembly
Valve Block Assembly
Accumulator Check Valve Assembly
Valve Block Installation
Shock Rod Assembly
Shock Rod Installation and Fluid Filling Procedure
Filling Procedure Option One
Filling Procedure Option Two
Manual Tilt System Installation
Manual Release Valve Adjustment
Section 6A - Gear Housing - EZ Shift (1.83:1 Gear Ratio)
Table of Contents
Gear Housing Specifications (1.83:1)
Gear Housing Driveshaft Components (1.83:1)
Gear Housing Propeller Shaft Components (1.83:1)
General Service Recommendations
Bearings
Shims
Seals
Draining and Inspecting Gear Housing Lubricant
Gear Housing Removal
Gear Housing Disassembly
Water Pump Disassembly
Shift Shaft Removal
Bearing Carrier and Propeller Shaft Disassembly
Propeller Shaft Disassembly
Pinion Gear, Driveshaft, and Forward Gear
Driveshaft Bearing Removal
Upper Bearing
Lower Bearing
Forward Gear Bearing Race Removal
Gear Housing Assembly
Clutch Actuator Rod Assembly and Installation
Propeller Shaft Assembly
Forward Gear Bearing Race Installation
Bearing Carrier Assembly
Bearings and Seals
Reverse Gear
Forward Gear
Lower Driveshaft Bearing Installation
Upper Driveshaft Bearing Installation
Forward Gear, Pinion Gear, Upper Driveshaft Race, Retainer, and Driveshaft Installation
Pinion Gear Depth
Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Shift Shaft Assembly and Installation
Water Pump Assembly and Installation
Gear Housing Pressure Test
Filling Gear Housing with Lubricant
Gearcase Installation
Trim Tab Adjustment and Replacement
Replacement
Adjustment
Section 6B - Gear Housing - BigFoot EZ Shift (2.33:1 Gear Ratio)
Table of Contents
Gear Housing Specifications - BigFoot (2.33:1) (S/N 0T625304 and Above)
Gear Housing Driveshaft EZ Shift Components - BigFoot S/N 1C033811 and Above
Gear Housing Propeller Shaft EZ Shift Components - BigFoot S/N 1C033811 and Above
General Service Recommendations
Bearings
Shims
Seals
Draining and Inspecting Gear Housing Lubricant
Gear Housing Removal
Gear Housing Disassembly
Water Pump Disassembly
Shift Shaft Disassembly
Bearing Carrier and Propeller Shaft Removal
Propeller Shaft Disassembly
Propeller Shaft Inspection
Pinion Gear, Driveshaft, and Forward Gear Removal
Upper Driveshaft Bearing Removal
Oil Sleeve Removal
Lower Driveshaft Bearing Race Removal
Forward Gear Bearing Race Removal
Gear Housing Assembly
Forward Gear Bearing Race Assembly
Bearing Carrier Assembly
Forward Gear Assembly
Clutch Actuator Rod Assembly and Installation
Propeller Shaft Assembly
Driveshaft Wear Sleeve Installation
Lower Driveshaft Bearing Race Installation
Oil Sleeve Installation
Driveshaft Upper Bearing Installation
Forward Gear, Driveshaft Lower Bearing, Pinion Gear, and Driveshaft Installation
Pinion Gear Depth
Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Shift Shaft Assembly
Water Pump Assembly and Installation
Gear Housing Pressure Test
Filling Gear Housing with Lubricant
Gearcase Installation
Trim Tab Adjustment and Replacement
Replacement
Adjustment
Section 7A - Throttle/Shift Linkage
Table of Contents
Tiller Handle Throttle Linkage Components
Remote Control Throttle Linkage Components
Tiller Handle Shift Linkage Components
Remote Control Shift Linkage Components
Throttle Link Setting - Tiller Handle Models and 40 HP Jet Models
Idle
Full Throttle Setting
Throttle Link Setting - Remote Control Models
Tiller Handle Shift Linkage Assembly
Section 7B - Tiller Handle
Table of Contents
Tiller Handle Components
Disassembly/Assembly
Tiller Handle Removal
Tiller Handle Disassembly
Throttle Cable Case
Disassembly/Inspection
Assembly
Tiller Handle Assembly
Tiller Handle Installation
Throttle Cable Installation and Adjustment
Wire Color Code Abbreviations
40/50/60 EFI Electric Start Tiller Handle Wiring Diagram - 14 Pin Connector
Section 8A - Jet Drive Outboard
Table of Contents
Jet Unit Components
Jet Water Pump Components
Jet Throttle Linkage Components
How the Jet Drive Operates
Water Testing
Checking for Cavitation
Steering Pull Adjustment
Impeller Removal and Installation
Installation
Worn/Dull Impeller
Jet Drive Disassembly
Jet Drive Removal
Water Pump Disassembly
Bearing Carrier Removal
Liner Removal
Jet Drive Assembly
Bearing Carrier Installation
Water Pump Assembly and Installation
Liner Installation
Jet Drive Installation
Shift Cable (Remote Control Models)
Shift Cable Connection to the Shift Cam and Adjustment (Tiller Models)
Installation
Adjustment
Throttle Cable Installation and Adjustment
