Mercury Mariner Models 135 150 175 200 Service Manual
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- Mercury Mariner Models 135 150 175 200 Service Manual
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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Reference and Info files
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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