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Mercury Mariner Models 135 150 175 200 Service Manual

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Original Mercury Mariner Outboards Service and Repair Manual. It covers everything to fix/repair your Mercury Mariner Outboard. This is a complete manual with detailed instructions, diagrams and more.

Manual is deeply indexed and searchable. It includes very descriptive diagrams, detailed repair and diagnostic procedures with appropriate part numbers and all required references.

Mercury models covered by this manual:
  - 135
  - 150
  - 175
  - 200

With Serial Numbers
United States - 0G960500 and Above

Manual Chapters:

  - Specifications
  - Maintenance
  - General Information
  - Outboard Motor Installation
  - Ignition
  - Charging and Starting System
  - Timing, Synchronizing & Adjusting
  - Wiring Diagrams
  - Fuel Pump
  - Carburetors
  - Fuel Injection
  - Oil Injection
  - Emissions
  - Powerhead
  - Cooling
  - Clamp/Swivel Brackets & Driveshaft Housing
  - Power Trim
  - Right Hand Non-Ratcheting
  - Left Hand Non-Ratcheting
  - COLOR DIAGRAMS

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Reviews   -   Write a Review

Rated: 5 by: Randy Posted: Tuesday, June 20, 2023 at 4:36PM

super high quality OEM manual; no issues downloading
thanks

Rated: 5 by: Justin Posted: Friday, September 15, 2023 at 1:29PM

Nice quality manual with fast service. thanks

Full list of manual chapters:

MERCURY MARINER MODELS 135 * 150 * 175 * 200
    Notice
    Notice to Users of This Manual
    Cleanliness and Care of Outboard Motor
    Page Numbering
    Service Manual Outline
Section 1A - Specifications
    Table of Contents
    Specifications
Section 1B - Maintenance
    Table of Contents
    Specifications
    Special Tools
    Quicksilver Lubricant/Sealant
    Inspection and Maintenance Schedule
        Before Each Use
        After Each Use
        Every 100 Hours of Use or Once Yearly, Whichever Occurs First
    Flushing Engine
        Flushing Cooling System – Using Cowl Flush Plug
        Flushing Cooling System – Using Flushing Attachment 44357A2
    Fuel System
        Fuel Line Inspection
        Fuel Line Filter (Models With Carburetors)
        Water Separating Fuel Filter – EFI Models
    Corrosion Control Anode
    Spark Plug Inspection
    Battery Inspection
    Fuse Replacement
    Lubrication Points
    Checking Power Trim Fluid
    Gear Case Lubrication
    Storage Preparation
Section 1C - General Information
    Table of Contents
    Serial Number Location
    Conditions Affecting Performance
        Weather
        Boat
        Trim
        Engine
        Engine Compression
    Following Complete Submersion
    Model 135/150/200 Powerhead Front View
    Model 135/150/200 Powerhead Starboard View
    Model 135/150/200 Powerhead Port View
    Model 135/150/200 Powerhead Top View
    Model 135/150/200 Powerhead Aft View
    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
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
    Filling the Oil Injection System
    Bleeding Air from Oil Injection Pump and Oil Injection Outlet Hose
    Adjusting the Oil Injection Pump
    Trim In Stop Adjustment
    Trim Tab Adjustment
        Models Without Power Steering
        Models With Power Steering
Section 2A - Ignition
    Table of Contents
    Specifications
    Special Tools
    Flywheel/Starter Motor
    CDM Mounting
    Solenoid Mounting
    Theory of Operation
    V-6 2.0/2.5L CDM Ignition
        Capacitor Charging #1, #2, and #3 CDMs
        Capacitor Charging #4, #5 and #6 CDMs
        #1 CylinderTrigger Circuit
        Ignition Coil Circuit
        Stop Circuit
    Ignition Component Description
        Capacitor Discharge Module (CDM)
        Trigger Coil
        Control Module
        Stator Assembly
        Flywheel
    CDM (P/N 827509) Trouble Shooting Flowchart
        CDM (P/N 827509)
        CDM Stop Diode Trouble Shooting
        CDM Trouble Shooting Flowchart
        Direct Voltage Adaptor (DVA)
        Troubleshooting Tips
    Ignition Test Procedures
        Direct Voltage Adaptor (DVA) Test
        Resistance Tests
    Bias Circuit
    Shift Stabilizer Circuit
    Idle Stabilizer
    Rev-Limit Circuit
    EFI Injector Timing Signal Test
    EFI Detonation Control System
    Ignition Component Removal
        Flywheel Removal
        Flywheel Installation
        Stator Removal
        Stator Installation
        Trigger Removal
        Trigger Installation
        CDM Removal
        CDM Installation
        Control Module Removal
        Control Module Installation
        Detonation Module Removal (200 XRI only)
        Detonation Module Installation
Section 2B - Charging and Starting System
    Table of Contents
    Specifications
    Electrical Plate
    Flywheel/Starter Motor
    Starter Motor
    Battery Cable Size
    Replacement Parts
    Recommended Battery
    Special Tools
    Battery
    Charging a Discharged Battery
    Winter Storage of Batteries
    Flywheel Removal and Installation
        Removal
        Installation
    Battery Charging System Description
        Precautions
    Battery Charging System Troubleshooting
        General Troubleshooting
        40 Ampere Alternator System
        Troubleshooting 40 Amp Alternator System
        Removal of Voltage Regulators
        Installation of Voltage Regulators
        Incorporating a Battery Isolator with a 40 Ampere Charging System
        System Wired for 40 Ampere Output to Isolator
        System Wired for Split Output
    Starter System
        Starter System Components
        Description
        Troubleshooting the Starter Circuit
        Starter Circuit Troubleshooting Flow Chart
        Starter Removal
        Installation
        Disassembly
        Starter Cleaning, Inspection and Testing
        Starter Reassembly
Section 2C - Timing, Synchronizing and Adjusting
    Table of Contents
    Specifications
    Special Tools
    Adjustments
        Carburetor Models
        Electronic Fuel Injection Models
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
    Instrument/Lanyard Stop Switch Wiring Diagram
    Oil Level Gauge Wiring Diagram
    Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
    Panel Mount Remote Control Wiring Installation
    QSI Gauge Wiring Diagrams
        Tachometer Wiring Diagram
        Water Temperature Gauge
        Oil Level Gauge Wiring
        Engine Synchronizer Wiring Diagram
    Maintenance
    Multi-Function Gauge
        Dip Switch Setting/Testing
        Outboard Multi-Function Gauge Setting
    2.5 Litre V-6 Carburetor Wiring Diagram 2000 Models
    2.5 Litre V-6 150/175 EFI Wiring Diagram 2000 Models
    2.5 Litre V-6 200 EFI Wiring Diagram 2000 Models
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
Section 3B - Carburetors
    Table of Contents
    Attenuator And Carb Throttle Levers
    Fuel Lines
    Carburetor
    Fuel System - Troubleshooting
    Reed Valve Leak Test
    Thermal Air Valve Circuit Description
    Enrichener System Description
        Manual Operation of Enrichener Valve
        Enrichener Valve Test
    Carburetor
    Carburetor Fuel Circuits
        Float Bowl Circuit
        Idle Circuit
        Cold Start Circuit
        Off-Idle Circuit
        Main Circuit
        Back Draft Circuit
        Carburetor Specifications
        Carburetor Placement and Jet Location for Each Cylinder
        Carburetor Jet Placement
        High Altitude Recommendations
        Jet Part Number Chart
        High Altitude Jet Chart
    Removing Carburetor(s) from Engine
        Throttle Shaft Screws
        Float Adjustment
        Installing Carburetor(s) to Engine
Section 3C - Fuel Injection
    Table of Contents
    Specifications
    Special Tools
    Ignition Controller and Detonation Module
    ECM Assembly
    Fuel Management System
    Fuel Pump
    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 (k)
        Water Separating Filter (i)
        Vapor Separator (n)
        Bleed System (f,g)
        Final Filter (t)
        Electric Fuel Pump (Inside Vapor Separator) (q)
        Fuel Injectors (a)
        Induction Manifold (r)
        Fuel Pressure Regulator (e)
        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
        Vapor Separator Float Test
        Water Separating Filter Flow Test
        Pulse Fuel Pump Delivery Test
        Final Filter Check and De-Pressurizing EFI System Procedures
        Pressure Regulator Test
        Electric Fuel Pump Voltage Test
        Injector Electrical Harness Test
        ECM Injector Driver Test
        Injector Fuel Delivery Test
        Injector Operation Test (Manifold Cover Removed)
        Induction Manifold Leak Check (Manifold Cover Removed)
        Air Temperature Sensor Test
        Engine Head Temperature Sensor Test
        Detonation Control System Test (200 Models Only)
        Detonation Sensor Check
        Detonation Control Module Check
        Throttle Position Sensor Test
        Map Sensor Test
        Problem Diagnosis
    Engine Head Temperature Sensor Removal
    EFI Induction Manifold Removal
        Water Separating Filter Assembly Removal
        Water Separating Filter Assembly Installation
        Throttle Position Sensor and Temperature Sensor Fuel Injector Harness Disconnections
        Oil Reservoir Removal
        Fuel Pressure Regulator Removal
        Fuel Pressure Regulator Disassembly
        Fuel Pressure Regulator Reassembly
        Vapor Separator Removal
        Vapor Separator Disassembly
        Installing Vapor Separator Assembly to Induction Manifold
        Manifold Removal
    EFI Induction Manifold Disassembly
        Air Temperature Sensor Removal
        Throttle Position Sensor Removal
        Fuel Rail Removal
        Fuel Rail Disassembly
        Fuel Injector Removal and Disassembly
        Injector Harness Removal
        Throttle Linkage Removed
    EFI System Cleaning and Inspection
    Induction Manifold Assembly
        Injector Harness Installation
        Fuel Injector Assembly and Installation
        Fuel Rail Assembly
        Fuel Rail Installation
        Throttle Position Sensor Installation
        Air Temperature Sensor Installation
    EFI Induction Manifold Installation
        Oil Reservoir Installation
        Vapor Separator Installation
        Throttle Position Sensor, Air Temperature Sensor and Fuel Injector Harness Connections
        ECM Installation
        Engine Head Temperature Sensor Installation
Section 3D - Oil Injection
    Table of Contents
    Operation of the Oil Injection System
        Final Checks Before Operation of Engine
        Checking Operation of the Oil Injection System (Engine Running)
    Oil Injection Components
    Oil Injection Flow System
    Pump Drive Assembly
    Pump Drive System
        Set Up Instructions for Oil Injection System
        Bleeding Air from Oil Injection Pump and Oil Injection Outlet Hose
        Adjusting Oil Injection Pump
    Oil Injection Pump
    Worm Bushing
        Worm Bushing Removal
        Worm Bushing Installation
        Oil Injection Pump Installation
        Installing Drive Gear (for Oil Injection Pump) onto Crankshaft
        Oil Injection System Trouble Shooting Chart
    Oil Pump Volume (Flow) Test
        Engine Mounted Oil Reservoir
Section 3E – 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
        Removal
        Date Code Identification
        Installation
        Decal Location:
Section 4A - Powerhead
    Table of Contents
    Powerhead Specifications (2 Liter Model 135)
    Powerhead Specifications (2.5 Liter Model 150/175/200)
    Special Tools
        Powerhead Repair Stand
    Cylinder Block Assembly
    Exhaust Manifold and Exhaust Plate
    Crankshaft, Pistons and Connecting Rods
    Reed Block and Cylinder Head
    Bleed System Routing (Carburetor Models)
    Bleed System Routing (EFI Models)
    Torque Sequence
    General Information
    Powerhead Removal from Driveshaft Housing
        Removing Engine Components
    Powerhead Disassembly
    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
        Assembly of Reed Blocks to Intake Manifold
        Assembly of Exhaust Manifold to Block
    Cleaning and Inspection
        Cylinder Block and Crankcase Cover
        Reinstalling Engine Components
    Throttle Lever and Shift Shaft
    Powerhead Installation On Driveshaft Housing
    Gasoline/Oil Break-in Mixture
    Break-ln Procedure
Section 4B - Cooling
    Table of Contents
    Specifications
    Special Tools
        Temperature Sensor
    Water Flow
    2.5 Litre V-6 Water Flow Diagram 2000 Models
    Troubleshooting
        Thermostat Test
        Water Pressure Check
        Water Pump Cleaning and Inspection
        Problem Diagnosis
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
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
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
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
Section 7
    Table of Contents
    Ride Guide Steering Cable/Attaching Kit Installation (92876A1)
        Single Cable
        Maintenance Instructions
    Ride Guide Steering Cable/Attaching Kit Installation (92876A3)
        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 (92876A6)
        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
    Table of Contents
    2.5 Liter V-6 Carburetor Color Wiring Diagram 2000 Models
        2.5 Litre V-6 Carburetor 2000 Models
    2.5 Liter V-6 150/175 EFI Color Wiring Diagram 2000 Models
        2.5 Litre V-6 150/175 EFI 2000 Models
    2.5 Liter V-6 200 EFI Color Wiring Diagram 2000 Models
        2.5 Litre V-6 200 EFI 2000 Models
    2.5 Liter V-6 Color Water Flow Diagram 2000 Models
        2.5 Litre V-6 Water Flow Diagram 2000 Models

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