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2003+ Mercury Mariner 225 HP EFI 4-Stroke Service Manual

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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

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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

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