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Mercury 15 EFI FourStroke, Service Manual

The Mercury 15 EFI FourStroke is a reliable and efficient outboard motor perfect for small boats. Make sure to keep your engine running smoothly by downloading the free Service Manual from manualshive.com. This manual will provide you with all the information you need to properly maintain and repair your motor.

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Important Information

Section 1C - General Information

Table of Contents

Recording Serial Number ................................................. 1C-2

Model Year Production Code.............................................1C-2

Engine Component Identification ‑ Manual Start Model.... 1C-3

15/20 FourStroke EFI Manual Start Front View..........1C-3

15/20 FourStroke EFI Manual Start Starboard View

................................................................................ 1C-4

15/20 FourStroke EFI Manual Start Port View........... 1C-5

15/20 FourStroke EFI Manual Start Aft View..............1C-6

Engine Component Identification ‑ Electric Start Model.... 1C-7

15/20 FourStroke EFI Electric Start Front View..........1C-7

15/20 FourStroke EFI Electric Start Starboard View

................................................................................ 1C-8

15/20 FourStroke EFI Electric Start Port View........... 1C-9

15/20 FourStroke EFI Electric Start Aft View............1C-10

Following Complete Submersion..................................... 1C-11

Engine Submerged while Running (Special

Instructions).......................................................... 1C-11

Freshwater Submersion (Special Instructions).........1C-11

Saltwater Submersion (Special Instructions)............1C-11

Fuel Requirements.......................................................... 1C-11

Low Permeation Fuel Hose Requirement ................1C-12

EPA Pressurized Portable Fuel Tank Requirements

.............................................................................. 1C-12

Fuel Demand Valve (FDV) Requirement..................1C-12

Painting Procedures........................................................ 1C-12

Propeller Painting Procedure....................................1C-12

Gearcase and Lower Housing Refinishing............... 1C-13

Cowl Refinishing.......................................................1C-13

Emissions........................................................................ 1C-14

Exhaust Emission Standards....................................1C-14

Emissions Information.............................................. 1C-15

Manufacturer's Certification Label............................ 1C-16

Service Replacement Certification Label..................1C-16

Shipping of Hazardous Material (HazMat) and Engine/

Components Containing Hazardous Material.............. 1C-17

Outboard Service Bulletin 2008‑07...........................1C-17

Overview of Regulations...........................................1C-17

Overview of Training Requirements......................... 1C-17

Shipping of Complete Engines and Major Assemblies

.............................................................................. 1C-17

More Information on Hazardous Material................. 1C-17

 General Information

90-8M0125265 eng NOVEMBER 2017

© 2018 Mercury Marine

Page 1C-1

1

C

Summary of Contents for 15 EFI FourStroke

Page 1: ...SERVICE MANUAL 15 20 EFI FourStroke...

Page 2: ...st completely satisfy himself that neither his nor the product s safety will be endangered All information illustrations and specifications contained in this manual are based on the latest product inf...

Page 3: ...the repair procedure This is considered standard shop practice even if not specifically stated Whenever components are removed for service they should be retained in order At the time of installation...

Page 4: ...bleshooting and Diagnostics C Service Procedures 4 Powerhead A Cylinder Block Crankcase B Cylinder Head C Oil Pump D Cooling System 5 Midsection A Clamp Swivel Bracket and Driveshaft Housing B Power T...

Page 5: ...90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page iv...

Page 6: ...ifications 1A 3 Fuel System Specifications 1A 3 Cylinder Block Crankcase Specifications 1A 3 Piston Specifications 1A 4 Cylinder Head Specifications 1A 4 Oil System Specifications 1A 5 Cooling System...

Page 7: ...r Tilt 4 75 Transom height Short 41 3 cm 16 3 in Long L 56 2 cm 22 1 in Extra long XL 68 9 cm 27 1 in Ignition Specifications at 20 C 68 F Parameter Specification Ignition type Computer controlled cap...

Page 8: ...high pressure Fuel pump pressure mechanical 30 kPa 20 kPa 4 3 psi 2 9 psi Fuel pump pressure electric 256 kPa 25 kPa 37 1 psi 3 6 kPa Cylinder Block Crankcase Specifications Parameter Specification N...

Page 9: ...0 09 mm 0 0035 in Oil ring side clearance 0 03 0 13 mm 0 0012 0 0051 in Oil ring side clearance service limit 0 15 mm 0 0059 in Top ring end gap 0 15 0 30 mm 0 0059 0 0118 in Top ring end gap service...

Page 10: ...cker arm inside diameter 13 01 mm 0 512 in Rocker arm inside diameter service limit 13 05 mm 0 514 in Rocker arm shaft clearance 0 006 0 035 mm 0 00023 0 0014 in Cylinder head upper camshaft bearing i...

Page 11: ...m fluid Power Trim and Steering Fluid or Automatic Transmission Fluid ATF Type Dexron III Electric motor Maximum current draw 35 A Gearcase Specifications Parameter Specification Gear ratio 2 15 1 Gea...

Page 12: ...ement 1B 5 Fuse Replacement Electric Start Models 1B 7 Spark Plug Inspection and Replacement 1B 8 Timing Belt Inspection 1B 8 Engine Oil 1B 9 Changing the Oil Filter 1B 9 Draining the Engine Oil 1B 10...

Page 13: ...re Cleaning and Waxing Procedure 1 Before washing rinse the cowls with clean water to remove dirt and dust that may scratch the surface 2 Wash the cowls with clean water and a mild nonabrasive soap Us...

Page 14: ...icate more frequently when used in saltwater Refer to Lubrication Points Replace the spark plugs Refer to Spark Plug Inspection and Replacement Check the remote control cable adjustment if applicable...

Page 15: ...for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system c...

Page 16: ...g to assist emptying the contents into an approved container a Mounting bracket b Drain valve c Empty contents into an approved container Fuel Filter Replacement Filter Removal 1 Pull the filter assem...

Page 17: ...l the fuel filter O ring seal into the fuel filter Verify the O ring does not have any folds or kinks 63114 2 Lubricate the O ring with clean engine oil 3 Push the fuel filter element onto the filter...

Page 18: ...ircuit are protected from overload by 20 amp and 15 amp fuses respectively If a fuse opens try to locate and correct the cause of the overload If the cause is not found the fuse may open again a Volta...

Page 19: ...lator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark plug gap 0 9 mm 0 035 in 4 Before installing the spark plugs clean off any dirt...

Page 20: ...lter 1 Position the engine for a full starboard turn NOTE For models with kicker straps temporarily disconnect one end of the port kicker strap This will allow the engine to be rotated when the engine...

Page 21: ...he gasket contacts the base tighten the filter an additional 3 4 to 1 turn 8 If any components were moved or removed to gain access to the oil filter restore them to their original positions or instal...

Page 22: ...f the oil level range Reinstall the oil fill cap a Oil fill cap b Dipstick c Oil level operating range 3 With cooling water properly supplied idle the engine for five minutes and check for leaks Stop...

Page 23: ...of the transom brackets On power tilt models the anodes are on the inside faces of the brackets On manual tilt models the anodes are secured to the rear face of the brackets The anodes on both models...

Page 24: ...R 63077 Tiller handle models N 63103 Remote control models 3 Straighten the cotter pin and pull it out using a pair of pliers 4 Place a block of wood between the gearcase and the propeller to prevent...

Page 25: ...ith the propeller shaft hole after tightening tighten the nut further to align with the hole 5 Align the propeller nut with the propeller shaft hole Insert a new cotter pin in the hole and bend the en...

Page 26: ...gear lubricant This is not an indication of water intrusion If during subsequent draining of the gearcase lubricant appears cream colored or milky water may be present The gearcase should be disassemb...

Page 27: ...les steering cable grease fitting 92 802859A 1 Swivel bracket lubrication fitting 63095 Tilt tube lubrication fittings Transom clamp screws lubrication fittings a Tilt tube lubrication fittings b Tran...

Page 28: ...e water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation IMPORTANT Gasoline containing alcohol ethanol or methanol ca...

Page 29: ...ay of storage seal inside of each cylinder Rotate the flywheel manually several times to distribute the oil in the cylinders Install spark plugs Change the engine oil Gearcase Drain and refill the gea...

Page 30: ...in the laying down position Storing the engine on the port side will prevent oil from draining out of the crankcase into the cylinders or crankcase ventilation system There are bumpers on the aft side...

Page 31: ...Maintenance Notes Page 1B 20 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 32: ...11 Freshwater Submersion Special Instructions 1C 11 Saltwater Submersion Special Instructions 1C 11 Fuel Requirements 1C 11 Low Permeation Fuel Hose Requirement 1C 12 EPA Pressurized Portable Fuel Ta...

Page 33: ...ha code This code can be deciphered into a corresponding number utilizing the following table XXXXXXXXX XXXXXXXX XXXX AG 62972 Serial number decal alpha code Model Year Manufactured Code Alpha Product...

Page 34: ...box e Recoil interlock cable f Engine harness 14 pin connector g Fuel line connector h Shift lever i Throttle control j Stop engine off button k Lanyard l Throttle friction knob m Copilot handle n Ti...

Page 35: ...e body h Throttle position sensor TPS connector NOTE The TPS is behind on the port side of the throttle body i Temperature and manifold absolute pressure TMAP sensor j Idle air control IAC valve k Thr...

Page 36: ...ctor c Crankshaft position sensor CPS d Stator output wires e Oil filter f Thermostat housing g Electrical bracket h Spark plug 2 i Cowl latch j Spark plug wire 2 k Fuel filter l Ignition coil m Oil p...

Page 37: ...Engine coolant temperature ECT sensor f Engine lifting eye g Air intake h Oil level dipstick i Vent tank vent hose j Vapor separator tank VST hoses 2 k Oil fill cap l Fuel hose from low pressure fuel...

Page 38: ...le b Battery cable c Rubber plug start push button on electric start tiller models d Warning light e Starter motor f Recoil handle for manual start g Recoil interlock cable h Air box i Engine harness...

Page 39: ...rottle body h Throttle position sensor TPS connector NOTE The TPS is behind on the port side of the throttle body i Temperature and manifold absolute pressure TMAP sensor j Idle air control IAC k Thro...

Page 40: ...ay power tilt models only h Tilt down relay power tilt models only i Thermostat housing j 20 amp fuse housing k Voltage regulator rectifier l Spark plug 2 m Fuel filter n Spark plug wire 2 o Ignition...

Page 41: ...ent tank e Engine coolant temperature ECT sensor behind voltage regulator rectifier wires f Engine lifting eye g Air intake h Oil level dipstick i Vent tank vent hose j Vapor separation tank VST hoses...

Page 42: ...ast one hour to eliminate any water in the engine If the engine fails to start determine if the cause is fuel related electrical or mechanical Repair as required IMPORTANT The engine should be run wit...

Page 43: ...anufactured for sale sold or offered for sale in the United States The Environmental Protection Agency EPA requires that any outboard manufactured after January 1 2009 must use low permeation fuel hos...

Page 44: ...at areas of bare aluminum with Alumiprep 33 PPG DX 533 or Metalprep 79 Rinse the area with clean water and blow dry with clean compressed air 5 When they are dry treat the bare aluminum areas with Alo...

Page 45: ...ixing and use guidelines Use two full wet coats of a high quality clear coat for long term durability 10 If a top quality finish is required or if errors in the clear coat need to be corrected cut and...

Page 46: ...as possible Emissions Information Manufacturer s Responsibility Beginning with 1998 model year engines manufacturers of all marine propulsion engines must determine the exhaust emission levels for eac...

Page 47: ...install new label over the old label Use a suitable solvent to remove any traces of the old label adhesive from the display location Date Code Identification Cut and remove a V notch through the mont...

Page 48: ...e Hazardous Materials Regulations Any employee who works in a shipping receiving or material handling area or who may be involved in preparing or transporting hazardous materials is required to have t...

Page 49: ...General Information Notes Page 1C 18 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 50: ...llation 1D 4 Steering Link Rod Fasteners 1D 4 Remote Wiring Harness and Control Cable Installation 1D 5 Remote Wiring Harness Connection 1D 5 Shift Cable Installation 1D 5 Throttle Cable Installation...

Page 51: ...r Lifting the Outboard Use the lifting eye on the engine 62883 Installing Outboard Boat Transom Height Requirement Measure the transom height of your boat The boat bottom should be aligned or be withi...

Page 52: ...the outboard to the transom with the supplied mounting hardware Use a 7 9 mm 5 16 in drill bit to bore the holes into the transom Use the transom bracket mounting holes for the alignment guide Secure...

Page 53: ...link rod fastening hardware supplied with the engine Never replace the locknuts with common nonlocking nuts they will work loose and vibrate off allowing the link rod to disengage from the steering c...

Page 54: ...ll the cables into the remote control following the instructions provided with the remote control NOTE The shift cable is the first cable to move when moving the control box out of neutral 1 Locate th...

Page 55: ...loser to the cable guide Repeat steps a through c Throttle Cable Installation Install the cables into the remote control following the instructions provided with the remote control 1 Verify the thrott...

Page 56: ...ption Nm lb in lb ft Screw 6 53 Battery Installation NOTE Outboards with battery charging capabilities must not be operated with the battery cables disconnected from the battery Damage to the charging...

Page 57: ...n connect the black battery cable to the negative battery terminal Disconnecting Outboard Battery Cables First disconnect the black battery cable from the negative terminal and then disconnect the red...

Page 58: ...1E 5 Engine Overheat 1E 6 Low Oil Pressure 1E 6 Engine Overspeed Limiter 1E 6 Wire Color Code Abbreviations 1E 7 Warning System Wiring Diagram 1E 7 Troubleshooting without a Computer Diagnostic System...

Page 59: ...m and allows bow to drop thus greatly increasing wetted surface and reducing boat speed Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during stora...

Page 60: ...RTANT The engines covered in this manual are equipped with an RPM rev limiter that is set to an upper RPM limit This limit which is slightly above the normal operating range of the engine helps preven...

Page 61: ...ceeding with an engine tune up 8 Cylinder scoring If powerhead shows any indication of overheating such as discolored or scorched paint visually inspect cylinders for scoring or other damage as outlin...

Page 62: ...cowl It will turn on or flash to alert the operator to the warning system situations listed in Warning System Operation 62873 Warning System Operation Overview The warning system is designed to alert...

Page 63: ...es to overheat service is required Operating an overheated engine will cause engine damage NOTE Should overheating occur and you are stranded stop the engine and allow it to cool down This will usuall...

Page 64: ...res or pins pushed back into the connector Verify the connectors are properly seated Inspect the harness for damage pinched or cut wires and chafing Secure the grounds and all connections involving ri...

Page 65: ...or location approximate 5 Connect the red and black clips on the diagnostic adapter harness to the positive and negative battery terminals respectively Diagnostic adapter harness a To serial adapter c...

Page 66: ...n for 10 15 20 EFI FourStroke a Units of measure are configurable U S units shown b Default temperature reading is 25 C 77 F ENGINE SENSOR NAME VALUE DESCRIPTION STARBOARD Fuel Flow Engine Speed Throt...

Page 67: ...ts To perform one of the listed diagnostics click the appropriate button and follow the on screen instructions 64646 Injector Pulse Ignition Spark LED Output Horn Output Idle Air Control Fuel Pump Out...

Page 68: ...or 2 20 Green red IAC valve 21 Gray Tachometer 22 N A Not used 23 Blue white TPS 24 Green yellow ECT sensor power 25 Green white MAT sensor 26 N A Not used 27 Black blue Sensor ground 28 Yellow Diagno...

Page 69: ...al Fault Code Table 10 15 20 Refer to the following table for an explanation of faults and possible solutions when using the CDS G3 diagnostic interface tool Fault Code Type Code Code Description Type...

Page 70: ...Wiring issue bad component Fuel injector 2 output Caution None 202 1 Wiring issue bad component Fuel pump output Caution None 3061 2 Contamination in the electric fuel pump or failure of the pump IAC...

Page 71: ...General Troubleshooting Notes Page 1E 14 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 72: ...emoval 2A 4 Installation 2A 4 Wire Color Code Abbreviations 2A 5 Sensors 2A 5 Crankshaft Position Sensor 2A 5 Engine Coolant Temperature ECT Sensor 2A 7 Oil Pressure Switch 2A 9 Temperature and Manifo...

Page 73: ...mV V Hz TEMP mA A IG IP OFF Hz TEMP 4516 Measures RPM on spark ignition SI engines ohms amperes AC and DC voltages records maximums and minimums simultaneously and accurately reads in high RFI environ...

Page 74: ...bsolute pressure MAP sensor and manifold air temperature MAT sensor to formulate the correct ignition timing The output from an oil pressure switch indirectly affects ignition timing as the ECM will l...

Page 75: ...s with electric start disconnect the battery and remove the positive battery cable from the starter solenoid 2 For models with power tilt remove the positive and negative wires from the tilt up relay...

Page 76: ...g key indentation in the flywheel casting below the ring gear and when the key passes the CPS the CPS generates an electric pulse This pulse is sent to the engine control module ECM The timing and fre...

Page 77: ...Starter 2 Disconnect the CPS from the engine harness at the 2 pin connector 3 Remove the two screws that secure the CPS and remove the CPS a CPS 2 pin connector b Screw 2 c CPS d Flywheel CPS Installa...

Page 78: ...g Diagram a ECM connector b ECT connector ECT Sensor Removal 1 Remove the air box and recoil starter It is easiest to remove and install these two items together Refer to Section 3C Air Box Removal an...

Page 79: ...ECT sensor into the engine a ECT sensor b Flywheel c Engine lifting eye 2 Tighten the sensor to the specified torque Description Nm lb in lb ft ECT sensor 4 0 35 4 3 Connect the ECT sensor 2 pin conn...

Page 80: ...nector b Oil pressure switch Removal 1 Remove the port side driveshaft housing cover Refer to Section 5A Driveshaft Housing Covers 2 Slide the rubber boot off the oil pressure switch 3 Remove the scre...

Page 81: ...the electrical connection with dielectric grease to prevent corrosion Tube Ref No Description Where Used Part No 6 Dielectric Grease Oil pressure switch electrical connection 92 823506 1 5 Slide the...

Page 82: ...or 3 Remove the TMAP sensor and discard the O ring seal TMAP Installation 1 Install a new O ring onto the TMAP sensor 2 Apply one drop of clean engine oil to the O ring 3 Install the TMAP sensor into...

Page 83: ...screws positioned in the center of the two slots a Torx screw 2 b Slot 2 4 Connect the TPS to the engine harness and connect and launch CDS G3 5 Navigate to the Live Data screen to view the Throttle...

Page 84: ...position information to regulate ignition and fuel injector timing The flywheel also has magnets on the inside circumference to generate voltage within the stator Refer to Stator for additional infor...

Page 85: ...the spark plug leads to the spark plugs 8 Install the air box and recoil starter assembly It is easiest to install the recoil starter and air box together Refer to Section 8A Recoil Starter and Secti...

Page 86: ...Meter Test Leads Meter Scale Reading Red Black Ignition winding Blue Black red 1 04 1 56 Battery charge winding Yellow White 0 17 0 25 Stator Removal 1 Remove the air box and recoil starter It is easi...

Page 87: ...ecified torque Description Nm lb in lb ft Flywheel nut 78 0 57 5 6 Install the air box and recoil starter assembly It is easiest to install the recoil starter and air box together Refer to Section 8A...

Page 88: ...rter assembly It is easiest to install the recoil starter and air box together Refer to Section 8A Recoil Starter and Section 3C Air Box Installation Ignition Coil The primary side of the ignition coi...

Page 89: ...he two high tension leads spark plug boots 65049 Meter Test Leads Meter Scale Reading Red Black High tension lead High tension lead 16 8 20 2 k 3 If the reading is other than specified replace the ign...

Page 90: ...ecified torque Description Nm lb in lb ft Ignition coil mounting screws 6 0 53 1 2 Attach the spark plug wires to the spark plugs Be sure to connect the correct plug to the correct wire Ensure that th...

Page 91: ...Ignition Notes Page 2A 20 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 92: ...ator Rectifier Diode Test 2B 9 Voltage Regulator Rectifier Removal and Installation 2B 10 Starting System 2B 11 Starting System Description 2B 11 Starting System Components 2B 11 Starter Solenoid Test...

Page 93: ...put at 900 RPM 4 6 A Alternator output at 5000 RPM 11 5 A Starter Type Bendix Output 0 6 kW at 12 V Brush length 14 0 mm 0 551 in Brush length service limit 11 0 mm 0 433 in Commutator undercut 0 95 1...

Page 94: ...Charging and Starting Systems Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 2B 3...

Page 95: ...Starter Motor Components 33809 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Charging and Starting Systems Page 2B 4 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 96: ...y 2 1 Pinion assembly 3 1 Washer 4 1 Brush card 5 2 Screw M4 x 8 1 5 13 3 6 1 Bushing 7 2 Screw 6 0 53 1 8 2 Lockwasher 9 2 Washer 10 1 O ring 11 1 Bushing 12 1 Washer 13 2 Lockwasher M6 14 2 Nut 4 0...

Page 97: ...Starter Motor and Solenoid Electrical Components 64407 1 1 2 3 4 5 6 7 8 9 10 11 10 12 13 15 14 16 Charging and Starting Systems Page 2B 6 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 98: ...0 53 1 6 1 Red terminal boot 7 1 Red terminal boot 8 1 Battery cable assembly 9 1 Protective sleeve 10 2 Screw 6 0 53 1 11 1 Starter motor bracket 12 1 Rubber mount 13 1 Red terminal boot 14 1 Protec...

Page 99: ...the rectifier An open circuit such as a broken wire or loose connection A fault in the battery charging system usually will cause the battery to become discharged Check the battery electrolyte level...

Page 100: ...eter if the correct measurement cannot be obtained place the meter selector to a lower resistance range DMT 2004 Digital Multimeter 91 892647A01 Meter Test Leads Meter Scale Reading Red Black White Ye...

Page 101: ...r Removal and Installation Removal 1 Release the reusable cable tie that secures the voltage regulator rectifier wires 2 Disconnect the bullet connectors for the white yellow and red wires from the vo...

Page 102: ...or key switch Starter Solenoid Test 1 Disconnect all wires from the solenoid 2 Connect an ohmmeter R 1 scale between terminals 1 and 2 3 Connect a 12 volt power supply between terminals 3 and 4 The s...

Page 103: ...nnect at TP2 for tests 2 through 6 c Battery d 15 amp fuse e Chassis ground f Engine harness 14 pin connector g Remote control harness 14 pin connector h Key switch i Neutral start switch J5 15A 1 2 G...

Page 104: ...enoid is defective No voltage Proceed to Test 4 Test 4 Test the neutral start switch 1 Connect a voltmeter between engine ground and TP4 2 Turn the ignition key to START or push in the start button Ba...

Page 105: ...t secure the starter motor isolation bracket to the engine 6 Remove the two starter motor mounting screws 7 Lift the starter motor and isolation bracket out and away from the engine Some items shown r...

Page 106: ...cap Remove the brush card a Nut securing power stud to insulator b End cap insulator c Screw securing brush card d Brushes Starter Motor Reassembly 1 Install the power stud insulator onto the power st...

Page 107: ...iption Nm lb in lb ft Brush card screw 2 1 5 13 3 7 Install the top thrust washer and shims onto the armature IMPORTANT The thrust washer must be installed first onto the armature The shims must be be...

Page 108: ...es to the commutator 13 Install the field frame to the end cap Ensure the locating key of the field frame and the end cap are aligned 10537 14 Lubricate the armature shaft with SAE Engine Oil 30W and...

Page 109: ...t over the isolator and move the starter motor and isolator bracket into place 2 Attach the starter motor to the engine with two mounting screws Tighten the screws to the specified torque Description...

Page 110: ...this view c Negative cable connection point d Starter motor mounting screws 2 e Starter motor isolator bracket positioned around rubber isolator 8 Install the air box and recoil starter assembly It is...

Page 111: ...Charging and Starting Systems Notes Page 2B 20 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 112: ...ECM and Fuel Injection 3A 3 Troubleshooting 3A 4 Additional Information 3A 4 Sensors 3A 4 Crankshaft Position Sensor CPS 3A 4 Engine Coolant Temperature ECT Sensor 3A 4 Temperature and Manifold Absolu...

Page 113: ...fuel is then delivered to the high pressure fuel pump inside the VST The high pressure fuel pump then supplies fuel to the injectors in the fuel rail Fuel rail pressure is regulated both via pulse wi...

Page 114: ...from the stator to supply power to the various electrical components used on the engine excluding the optional electric starting charging and power tilt components The ECM is itself powered by voltag...

Page 115: ...e housing The two sensors are the manifold air temperature MAT sensor and the manifold absolute pressure MAP sensor The MAT sensor is a thermistor that monitors the temperature of the intake air as it...

Page 116: ...cally charged by the ECM through the stator assembly when the flywheel starts to rotate The ECM controls the injection by completing the ground circuit lifting the solenoid which allows high pressure...

Page 117: ...Fuel System Operation Notes Page 3A 6 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 118: ...ral Troubleshooting 3B 2 Testing Fuel System Inlet Vacuum 3B 2 Fuel Pressure Test 3B 2 Wire Color Code Abbreviations 3B 3 Fuel System Wiring Diagram 3B 3 Sensor Wiring Diagram 3B 4 Troubleshooting and...

Page 119: ...at fuel line 3 Install a clear fuel line on the opposite side of the T fitting 4 Connect the clear fuel line to the engine fuel line 5 Install a fuel vacuum gauge obtain locally on the T fitting 6 Cla...

Page 120: ...L Yellow LT Light DK Dark Fuel System Wiring Diagram 15 20 EFI fuel system wiring diagram a Engine control module b Fuel injector 1 c Fuel injector 2 d Idle air control valve e High pressure fuel pump...

Page 121: ...T BLK BLU WHT GRN YEL GRN WHT BLK BLU GRN WHT RED WHT BLK BLU GRN ORN RED WHT BLU WHT BLK BLU BLK BLU GRN YEL RED WHT BLK 1 2 1 2 3 4 1 2 3 1 18 17 34 17 1 10 3 2 4 5 6 7 13 15 12 11 14 16 9 8 34 18 2...

Page 122: ...y 3C 14 Fuel Cooler 3C 15 VST Installation 3C 16 Camshaft Gear Cover Vent Tank 3C 17 Removal 3C 17 Installation 3C 18 Throttle Body 3C 18 Throttle Body Removal 3C 18 Throttle Body Installation 3C 19 F...

Page 123: ...Measures RPM on spark ignition SI engines ohms amperes AC and DC voltages records maximums and minimums simultaneously and accurately reads in high RFI environments Fuel System Specifications Paramet...

Page 124: ...Service Procedures Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 3C 3...

Page 125: ...2 1 3 4 5 6 8 9 7 10 11 11 10 9 12 13 14 15 16 17 18 19 20 21 20 21 22 23 24 25 26 27 28 29 28 30 31 30 32 32 33 34 35 36 36 37 38 39 40 41 42 43 44 42 Service Procedures Page 3C 4 2018 Mercury Marin...

Page 126: ...embly not a service item 19 1 Fuel rail 20 2 Fuel injector assembly 21 2 Seal ring 22 1 Holding plate 23 1 Screw 6 0 53 1 24 2 O ring 25 1 Fuel inlet tube 26 2 Screw 6 0 53 1 27 1 Insulator 28 2 Clamp...

Page 127: ...Vapor Separator Tank Components 64412 1 2 4 4 6 7 8 9 10 11 13 14 15 16 17 18 20 21 22 23 23 3 12 5 19 Service Procedures Page 3C 6 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 128: ...sket 7 1 O ring 8 1 Fuel regulator 9 1 Holder 10 1 Screw 2 0 17 7 11 1 Float valve assembly 12 1 Float arm pin 13 1 Float 14 1 O ring 15 1 Fuel pump 16 1 Filter holder 17 1 Filter 18 1 Grommet 19 1 VS...

Page 129: ...Air Intake Components 64529 1 2 3 4 1 2 5 6 7 8 9 10 11 12 13 14 15 14 15 16 17 18 19 Service Procedures Page 3C 8 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 130: ...Throttle body assembly 7 1 Idle air control valve 8 2 Screw 3 0 26 6 9 2 Screw 3 0 26 6 10 1 TMAP sensor 11 1 Gasket 12 1 Restrictor 10 15 hp models only 13 1 Gasket 14 2 Rubber mount 15 2 Collar 16 1...

Page 131: ...e the driveshaft housing covers Refer to Section 5A Driveshaft Housing Covers 2 Remove the two screws securing the fuel pump to the cylinder head cover 3 Pull the fuel pump assembly from the cylinder...

Page 132: ...ngine and wipe up any spilled fuel immediately CAUTION Failure to release pressure from the fuel system will result in fuel spraying out which can cause a fire or explosion Allow the engine to cool co...

Page 133: ...cooler water supply hose fitting 9 Remove the Oetiker clamp securing the high pressure fuel hose to the VST and remove the fuel hose from the VST 10 Remove the two vent hoses from the top of the VST a...

Page 134: ...ll come free a High pressure fuel pump b Float pin c Float 4 Disconnect the red yellow and white wires from the fuel pump 5 Loosen the screw and remove the screw and clamp that secure the check valve...

Page 135: ...ump electrical connector a Spade connector for white wire b Spade connector for yellow wire c Spade connector for red wire d O ring 2 Secure the connector with the clip 3 Place a new seal in the botto...

Page 136: ...ce the float in position and secure it with the float pin 8 Ensure that the O ring is in position on the fuel pump and press it into position in the VST cover a High pressure fuel pump b Float pin c F...

Page 137: ...ective holes in the midplate 2 Attach the two vent hoses to the top of the VST assembly 3 Connect the high pressure fuel hose to the VST with a new Oetiker clamp Clamp Tool 91 803146T a VST vent hoses...

Page 138: ...fitting a Hose clamp securing the low pressure fuel supply hose b High pressure fuel pump electrical connector c Screws 2 d VST drain screw e VST drain hose 9 Install the starboard driveshaft housing...

Page 139: ...ses from the vapor separator tank The hose with the white mark attaches to the upper fitting 4 Attach the vent hose Throttle Body Throttle Body Removal 1 Remove the air box and recoil starter It is ea...

Page 140: ...s Tighten the nuts to the specified torque Description Nm lb in lb ft Nuts securing the throttle body 6 0 53 1 3 Install the grommet onto the throttle body 4 Install the idle air control IAC valve ont...

Page 141: ...rt the engine and wipe up any spilled fuel immediately CAUTION Failure to release pressure from the fuel system will result in fuel spraying out which can cause a fire or explosion Allow the engine to...

Page 142: ...ube 2 Remove the fuel injectors from the fuel rail a Screw securing the fuel inlet tube b Fuel injectors 2 Fuel Rail Reassembly 1 Wash the fuel rail with a solvent Use compressed air to clean and dry...

Page 143: ...nstall the fuel injectors into the fuel rail Fuel Rail Installation 1 Install the fuel hose onto the fuel rail inlet tube Ensure that an Oetiker clamp is in position on the fuel hose 2 Lubricate the f...

Page 144: ...ase ventilation hose from the valve cover and maneuver the hose to create enough slack to allow it to reach the air box Attach the hose to the air box 2 Ensure that the bypass hose is connected to the...

Page 145: ...d remove the IAC 3 Disconnect the IAC from the engine harness 4 Remove the bypass hose from the IAC a IAC mounting screws 2 b Bypass hose c Engine harness connector IAC Test 1 Apply 69 kPa 10 psi vacu...

Page 146: ...hrottle assembly and attach with two screws Tighten the screws to the specified torque Description Nm lb in lb ft IAC mounting screws 2 3 0 26 6 3 Attach the bypass hose to the IAC 4 Connect the IAC t...

Page 147: ...Service Procedures Notes Page 3C 26 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 148: ...ction and Repair 4A 16 Flywheel 4A 16 Crankshaft Timing Gear 4A 17 Timing Belt 4A 17 Anode 4A 17 Measuring Cylinder Bore 4A 17 Piston Measurements 4A 17 Connecting Rod Measurements 4A 19 Crankshaft 4A...

Page 149: ...bore service limit 61 06 mm 2 4039 in Cylinder bore maximum taper service limit 0 08 mm 0 0032 in Cylinder bore maximum out of round service limit 0 06 mm 0 0023 in Crankshaft main bearing journal 33...

Page 150: ...00 mm 0 6298 0 6299 in Wrist pin diameter service limit 15 993 mm 0 6296 in Top ring side clearance 0 03 0 08 mm 0 0012 0 0031 in Top ring side clearance service limit 0 1 mm 0 004 in Second ring side...

Page 151: ...Cylinder Block and Crankcase Components 64413 Cylinder Block Crankcase Page 4A 4 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 152: ...3 0 115 11 1 Thermostat 12 1 Thermostat cover 13 1 Thermostat gasket 14 1 Bracket 15 2 Screw 9 0 79 7 16 2 Washer 17 1 Exhaust cover 18 1 Exhaust cover gasket 19 5 Screw First 6 0 53 1 Final 9 0 79 7...

Page 153: ...Crankshaft Components 64577 Cylinder Block Crankcase Page 4A 6 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 154: ...ssembly 4 1 Plain shaft bearing blue set of 2 1 Plain shaft bearing red set of 2 5 1 Upper oil seal 6 1 Lower oil seal 7 2 Piston assembly 8 1 Piston 9 1 Piston pin 10 2 Piston pin clip 11 2 Piston ri...

Page 155: ...ion 5A Driveshaft Housing Covers 3 Remove the front cowl Refer to Section 5A Front Cowl 4 Remove the remote control harness and cables when applicable 5 Remove the following components from the top of...

Page 156: ...ng throttle and shift linkage Refer to Section 7A Throttle and Shift Linkage 10 Remove the fuel system components from the engine a Cut the cable tie securing the fuel inlet hose to the engine harness...

Page 157: ...e on each side starboard shown 12 Lift the powerhead off of the driveshaft housing 13 Install the powerhead onto an appropriate powerhead stand obtain locally Cylinder Block Disassembly Electrical Com...

Page 158: ...nd harness e Ground terminal f Black fuse housing 8 Disconnect the ECM from the harness 9 Power tilt models Disconnect the pink light blue and green bullet connectors 10 Release the reusable cable tie...

Page 159: ...cket from the engine a Bracket screws 2 b Voltage regulator rectifier Throttle Body Removal 1 Remove two nuts to remove the throttle body 2 Remove one screw to remove the dipstick extension tube a Dip...

Page 160: ...or 4 Remove and inspect the anode Discard and replace if it is corroded 50 or more 5 Remove the five exhaust cover screws Remove the exhaust cover 6 Remove the oil pressure switch a Oil filter b Therm...

Page 161: ...b Screw M6 x 30 6 2 Remove the connecting rod cap screws 3 Identify the connecting rod and cap position with indelible ink or paint Do not use a scribe or punch for identification IMPORTANT Each conne...

Page 162: ...hem as used 7 Install the connecting rod caps onto their respective connecting rods Tighten the connecting rod cap screws finger tight a Piston and connecting rod b Connecting rod cap c Cap screws 8 P...

Page 163: ...e the connecting rod from the piston 2 Use a piston ring expander to remove the top ring and the second ring 3 Use a piston ring expander to remove the oil ring top scraper bottom scraper and the oil...

Page 164: ...wn the cylinder bore to determine taper Turn the gauge to different points around the cylinder wall to determine the out of round condition The measurement for cylinder taper should be taken at three...

Page 165: ...earance Piston to Cylinder Wall Clearance Minimum clearance 0 020 0 055 mm 0 0008 0 0022 in Maximum clearance service limit 0 150 mm 0 0059 in Piston Ring Side Clearance Measure the piston ring side c...

Page 166: ...e piston wrist pin if out of specification 22026 Piston Wrist Pin Diameter 15 996 16 000 mm 0 6298 0 6299 in Diameter service limit 15 993 mm 0 6296 in Connecting Rod Measurements 1 Ensure the connect...

Page 167: ...a Crankshaft pin journals b Main bearing journals Crankshaft Bearing Journal Crankshaft pin journal 28 972 28 985 mm 1 1406 1 1411 in Crankshaft pin journal service limit 28 970 mm 1 1405 in Main bea...

Page 168: ...ll the bearing halves into the crankcase cover NOTE Align each bearing projection with the notch in the crankcase cover 7 Install the crankcase cover onto the cylinder block 8 Lightly lubricate the ma...

Page 169: ...r block is stamped with a code letter on the upper end of the cylinder block NOTE The identification code for the upper main bearing is A B The identification code for the lower main bearing is X Y B...

Page 170: ...of the crankshaft 3 Place a piece of gauging plastic on the crankpin journals NOTE Do not put the gauging plastic over the oil hole in the bearing surface of the crankshaft a Gauging plastic b Cranks...

Page 171: ...in and secure it with new piston pin clips a Connecting rod b Piston c Piston pin clip 2 d Piston pin Tube Ref No Description Where Used Part No 110 4 Stroke 10W 30 Outboard Oil Piston pin 92 8M007862...

Page 172: ...oning as necessary After honing clean the cylinder bores with water and mild detergent After cleaning swab out the cylinder bores with engine oil and a clean cloth Wipe the cylinder bore with a clean...

Page 173: ...e cylinder block and crankcase cover 2 Lubricate the following areas generously with 10W 30 4 Stroke Marine Engine Oil Crankshaft seal and main bearing area Crankshaft main and connecting rod journals...

Page 174: ...ue in two steps a Up arrow and text b Connecting rod cap bolt c Connecting rod cap Description Nm lb in lb ft Connecting rod cap bolt First 6 0 53 1 Final 10 0 88 5 10 Clean the cylinder block to cran...

Page 175: ...t tang inserted into the keyway on the timing gear 5 Install the timing gear nut 6 Install the flywheel key Tighten the timing gear nut to the specified torque Description Nm lb in lb ft Timing gear n...

Page 176: ...ews M6 x 50 2 9 0 79 7 6 Install a new anode onto the anode plug Tighten the anode screw to the specified torque Install a new O ring onto the anode plug a Anode plug b O ring c Anode d Anode screw 7...

Page 177: ...Oil filter 18 0 159 3 Oil Strainer Installation 1 Secure the hose and oil strainer to the cylinder block fitting 2 Secure components with two cable ties a Hose b Cable tie c Oil strainer Throttle Bod...

Page 178: ...ed on its mounting bracket If any additional disassembly was performed refer to the appropriate service procedure for reassembly 1 Electric start models Install the voltage regulator rectifier and bra...

Page 179: ...ECM connector b Reusable cable ties c Start solenoid green bullet connector d Power tilt pink and light blue bullet connectors e Oil pressure switch 7 Insert the black fuse housing into the pocket on...

Page 180: ...ector IMPORTANT Additional connections will be made after the powerhead is installed onto the driveshaft housing Secure all loose items as necessary for the powerhead installation Powerhead Installati...

Page 181: ...p Secure the connections with hose clamps c Secure the fuel outlet hose to the engine harness with the reusable cable tie a Fuel pump b Fuel pump inlet hose from fuel filter c Fuel pump outlet hose to...

Page 182: ...nd washer 4 each b J clip to secure stator leads c Crankshaft position sensor b Attach the relay solenoid bracket to the side of the stator starter bracket with one screw and washer Tighten all five s...

Page 183: ...electrical bracket and around the harness wires Cinch the cable tie to secure the wires b Flywheel Refer to Section 2A Flywheel c Engine lifting eye Tighten the screw to the specified torque Descripti...

Page 184: ...Part No 110 10W 30 4 Stroke Marine Engine Oil Engine crankcase 92 8M0078625 11 For electric start models connect the battery cables to the battery Cylinder Block Crankcase 90 8M0125265 eng NOVEMBER 2...

Page 185: ...Cylinder Block Crankcase Notes Page 4A 38 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 186: ...10 Cylinder Head Removal 4B 11 Cylinder Head Disassembly 4B 13 Cleaning and Inspection 4B 15 Camshaft 4B 15 Valves 4B 15 Valve Springs 4B 16 Cylinder Head Resurfacing 4B 16 Valve Guides 4B 17 Rocker A...

Page 187: ...er Pulley side 17 98 mm 0 708 in Pulley side service limit 17 95 mm 0 707 in Oil pump side 15 97 mm 0 629 in Oil pump side service limit 15 95 mm 0 628 in Cam lobe height Intake 23 63 mm 0 9303 in Exh...

Page 188: ...vice limit 0 07 mm 0 0028 in Exhaust 0 025 0 057 mm 0 001 0 0022 in Exhaust service limit 0 1 mm 0 004 in Rocker arm shaft outside diameter 12 99 mm 0 511 in Rocker arm shaft outside diameter service...

Page 189: ...Cylinder Head Components 64414 1 2 2 3 4 5 5 5 13 13 12 11 10 9 7 8 7 6 6 14 15 15 16 17 18 18 19 20 21 Cylinder Head Page 4B 4 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 190: ...Final 10 0 88 5 7 3 Washer 8 1 Screw M6 x 40 First 6 0 53 1 Final 10 0 88 5 9 1 Screw 2 0 17 7 10 1 Anode 11 1 O ring 12 1 Anode plug 18 0 159 3 13 2 Spark plug 18 0 159 3 14 1 Cylinder head cover gas...

Page 191: ...e Exhaust Valve Components 1 2 3 4 5 6 7 8 9 10 10 1 2 3 4 5 6 7 8 9 3 4 5 6 7 8 9 11 12 13 14 3 4 5 6 7 8 9 11 12 13 14 15 64539 Cylinder Head Page 4B 6 2018 Mercury Marine 90 8M0125265 eng NOVEMBER...

Page 192: ...seal 3 4 Valve spring seat 4 4 Valve spring 5 4 Retainer 6 8 Keeper 7 4 Adjusting screw 8 4 Rocker arm 9 4 Locknut 7 0 62 10 2 Collar 11 2 Exhaust valve 12 2 Exhaust valve stem seal 13 2 Rocker shaft...

Page 193: ...Camshaft and Oil Pump Components 64415 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cylinder Head Page 4B 8 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 194: ...lt guide 4 1 Lockwasher 5 1 Nut 64 0 47 2 6 1 Timing belt 7 1 Screw M6 x 20 11 5 101 8 8 1 Washer 9 1 Driven gear 10 1 Key 11 1 Oil seal 12 1 Camshaft assembly 13 1 Oil pump gasket 14 1 Oil pump assem...

Page 195: ...k plugs 2 Rotate the crankshaft until the timing marks on the crankshaft and camshaft are in proper alignment a Crankshaft drive gear timing mark b Timing mark on the cylinder block for the crankshaft...

Page 196: ...install these two items together Refer to Section 8A Recoil Starter and Section 3C Air Box Installation Spark plugs Cylinder Head Removal 1 Remove the powerhead from the driveshaft housing Refer to Se...

Page 197: ...b Cylinder head cover 9 Remove the camshaft key 10 Remove the three cylinder head perimeter screws 11 Remove the six cylinder head retaining screws a Camshaft key b Cylinder head retaining screw M8 x...

Page 198: ...shaft 3 Remove the springs rocker arms spacers and washers a Rocker shaft b Washer 2 c Spring 2 d Rocker arm 4 e Spacer 2 Lock Ring Pliers Snap On SRP 4 4 Remove the camshaft Be careful to not damage...

Page 199: ...essor 91 809494A1 7 Remove keepers upper seats springs seals lower seats and intake exhaust valves NOTE Valve seals are not reusable a Exhaust valve b Intake valve c Valve seat d Valve seal e Valve sp...

Page 200: ...outside diameter b Upper bearing outside diameter Cam Bearing Journal Lower bearing outside diameter 15 95 15 97 mm 0 628 0 629 in Upper bearing outside diameter 17 95 17 98 mm 0 707 0 708 in Valves 1...

Page 201: ...pecification NOTE Check each spring on a flat surface using a square Rotate the spring and check the space between the top coil and the square 20974 Valve Spring Tilt limit 1 1 mm 0 043 in maximum Cyl...

Page 202: ...2 94 12 99 mm 0 5094 0 5114 in Clearance 0 006 0 035 mm 0 0003 0 0014 in Valve Seat Reconditioning 1 Clean the carbon deposits from the combustion chambers and valve seats Check the valve seats for pi...

Page 203: ...e the 30 cutting tool to adjust the contact width of the top edge of the valve seat a Previous contact width 9 Use the 60 cutting tool to adjust the contact width of the bottom edge of the valve seat...

Page 204: ...ea of contact and set its width a Previous contact width Cylinder Head Assembly IMPORTANT Reassemble the valve train components in their original location 1 Lubricate the valve stems with 4 Stroke 10W...

Page 205: ...al with the seal lip facing in 64123 4 Lubricate the camshaft oil seal lip and the camshaft bearings with clean engine oil Install the camshaft 64128 5 Lubricate the rocker shaft components and the ca...

Page 206: ...all a new cylinder head gasket a Drive gear and cylinder timing marks aligned b Pistons at TDC c Cylinder head gasket 3 Rotate the camshaft so the valves are fully closed 4 Lubricate the threads and h...

Page 207: ...1 cylinder should be pointing to the timing mark on the cylinder head 9 Apply Loctite 222 Threadlocker to the threads of the camshaft gear screw Install the screw and washer Tighten the screw to the...

Page 208: ...ck for the camshaft d Timing mark for 1 cylinder e Timing mark for 2 cylinder 12 Install the timing belt 13 Adjust the valve clearance Refer to Valve Adjustments 14 Install the gasket into the groove...

Page 209: ...59 3 17 Install the following components Throttle body refer to Section 4A Throttle Body Installation Electrical components removed from the cylinder head refer to Section 4A Electrical Component Inst...

Page 210: ...il System Specifications 4C 2 Oil Pump Removal 4C 2 Oil Pump Disassembly 4C 2 Oil Pump Inspection 4C 3 Oil Pump Assembly 4C 3 Oil Pump Installation 4C 4 Oil Flow Diagram 4C 6 Oil Pump 90 8M0125265 eng...

Page 211: ...inside diameter clearance service limit 0 18 mm 0 007 in Outer rotor height service limit 14 96 mm 0 589 in Rotor to oil pump cover clearance service limit 0 11 mm 0 004 in Inner rotor to outer rotor...

Page 212: ...tor to pump housing maximum 0 18 mm 0 007 in b Inner rotor to outer rotor maximum 0 13 mm 0 005 in c Outer rotor to oil pump cover maximum 0 11 mm 0 004 in d Oil pump housing inside diameter maximum 2...

Page 213: ...ide and outside diameter I D and O D of the mounting hub with 4 Stroke 10W 30 Outboard Oil 2 Pour approximately 15 drops of 4 Stroke 10W 30 Outboard Oil into the inlet and outlet of the oil pump 3 Lub...

Page 214: ...linder head oil pump bore camshaft 92 8M0078625 6 Fasten the oil pump to the cylinder head with three M6 x 35 screws Tighten the screws to the specified torque a Cylinder head b Screw M6 x 35 Descript...

Page 215: ...ery i Oil pressure switch j Camshaft faces k Rocker arm shaft and valve l Crankshaft main bearing m Crankshaft rod journal n Cylinder wall o Piston p Piston pin a b c d f e e g h i j o o k l l m m n n...

Page 216: ...ng System Description 4D 2 General Troubleshooting 4D 2 Thermostat 4D 2 Thermostat Electrical Bracket Removal 4D 2 Testing the Thermostat 4D 2 Thermostat Electrical Bracket Installation 4D 3 Water Flo...

Page 217: ...llow the cooling system to drain while the outboard is in a normal operating position General Troubleshooting For general troubleshooting information including connecting and using the CDS G3 diagnost...

Page 218: ...the engine block and the thermostat housing are clean 3 Thread a new cable tie through the two holes in the electrical bracket 4 Attach the gasket thermostat housing and electrical bracket to the eng...

Page 219: ...pump c Water tube d Cylinder block e Thermostat f Cylinder head g Fuel cooler part of the vapor separator tank h Water pump indicator outlet 64794 a b c d e f h g Cooling System Page 4D 4 2018 Mercur...

Page 220: ...r Mount 5A 23 Lower Mount 5A 23 Clamp Brackets Swivel Bracket Power Tilt Models 5A 25 Clamp Brackets Power Tilt 5A 25 Steering Arm Removal 5A 30 Power Tilt Removal 5A 31 Swivel Bracket Removal 5A 32 S...

Page 221: ...ite 222 Threadlocker Shoulder screw 92 809818 66 Loctite 242 Threadlocker Idle exhaust port cover screws 92 809821 95 2 4 C with PTFE Tilt tube washer Swivel bracket bushings Tilt pin and bushings Til...

Page 222: ...Clamp Swivel Bracket and Driveshaft Housing Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 5A 3...

Page 223: ...9 11 12 13 14 15 16 17 18 14 20 21 22 19 23 24 25 6 26 6 6 14 28 27 30 22 31 32 2 10 16 29 15 33 34 35 9 36 12 11 8 7 24 4 3 37 38 38 39 40 41 44 43 42 45 Clamp Swivel Bracket and Driveshaft Housing...

Page 224: ...ing pin 21 1 Washer 22 2 Collar 23 1 Swivel bracket 24 2 Bushing 25 1 Bushing 26 1 Lower pin 27 1 Power tilt assembly 28 1 Ground wire port clamp bracket to power tilt assembly 29 2 Cable tie 30 1 Spr...

Page 225: ...8 4 9 10 8 8 7 6 5 11 12 4 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 22 29 30 31 32 35 34 20 33 17 36 16 37 38 39 40 41 42 43 44 45 46 47 48 48 49 Clamp Swivel Bracket and Driveshaft Housing Pag...

Page 226: ...to lower mount bracket 20 3 Grease fitting 21 2 Pin 22 2 Reverse lock spring 23 1 Reverse lock 24 1 Reverse lock arm 25 1 Reverse lock spring 26 1 Reverse lock link 27 1 Reverse lock rod 28 1 Split p...

Page 227: ...No Qty Description Torque Nm lb in lb ft 47 2 Transom screw M8 x 85 48 4 Washer 49 2 Nut 13 5 120 Clamp Swivel Bracket and Driveshaft Housing Page 5A 8 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2...

Page 228: ...8 4 9 10 8 8 7 6 5 11 12 4 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 22 29 30 31 32 35 34 20 33 17 36 16 37 38 39 40 41 42 43 44 45 46 47 48 48 49 Clamp Swivel Bracket and Driveshaft Housing 90...

Page 229: ...ts 25 26 27 29 30 28 31 32 29 33 34 30 64416 1 2 3 3 4 2 5 6 6 7 8 9 8 10 11 12 13 14 15 16 17 17 18 18 19 20 20 21 22 23 22 24 Clamp Swivel Bracket and Driveshaft Housing Page 5A 10 2018 Mercury Mari...

Page 230: ...mount bracket 14 1 Screw M6 x 10 6 0 53 1 15 1 Ground wire swivel bracket to lower mount bracket 16 1 Grease fitting 17 2 Upper rubber mount 18 4 Screw 13 115 19 2 Screw 20 2 Upper rubber damper 21 1...

Page 231: ...g Components 64417 22 1 2 24 5 29 28 29 27 25 26 26 7 15 16 19 18 20 14 13 4 3 6 6 21 21 17 12 10 11 8 9 22 23 Clamp Swivel Bracket and Driveshaft Housing Page 5A 12 2018 Mercury Marine 90 8M0125265 e...

Page 232: ...rew 6 0 53 1 15 1 Flushing connector cap 16 1 Seal ring 17 1 Idle exhaust port cover 18 1 Idle exhaust cover plate 19 3 Screw 4 0 35 4 20 1 Idle exhaust port gasket 21 6 Screw M6 x 16 6 0 53 1 22 2 Wa...

Page 233: ...Driveshaft Housing Cover Components 64676 Clamp Swivel Bracket and Driveshaft Housing Page 5A 14 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 234: ...8 1 Starboard driveshaft housing cover 19 1 Port driveshaft housing cover manual tilt models 20 1 Port driveshaft housing cover power tilt models 21 10 Screw 6 0 53 1 22 1 Rigging ingress grommet 23 1...

Page 235: ...ver 63039 NOTE To remove the port cover without removing the starboard cover loosen only the three captive screws at the rear of the cover 5 To completely remove the port cover for models with power t...

Page 236: ...secure the wires to the electrical bracket with a cable tie c If the engine has a cowl mounted tilt switch ensure that the tilt switch is correctly installed in the port cover and connect the switch t...

Page 237: ...upper shift shaft boot seats in the notch in the front cowl 3 Ensure that all of the grommets and washers are still in place and secure the front cowl to the shift lever brackets with two screws Tigh...

Page 238: ...ng surfaces on the driveshaft housing and on the idle exhaust port cover 3 Place a new gasket onto the idle exhaust port cover 4 Apply Loctite 242 Threadlocker to the six idle exhaust port cover screw...

Page 239: ...shift cables a Bow tie retainer b Flat washer c Throttle cable d Cable barrel a b c d 63129 a Bow tie retainer b Flat washer c Shift cable d Cable barrel a b c d 63123 2 Remove the screw from the cabl...

Page 240: ...the coupler up a Upper shift shaft b Coupler c Jam nut d Lower shift shaft c Remove the coupler from the upper shift shaft and lift the upper shift shaft out of the steering arm swivel bracket assemb...

Page 241: ...Install the lower mount Refer to Lower Mount 5 Install the upper shift shaft a Insert the upper shift shaft down through the midplate shift shaft boot and steering arm swivel bracket assembly b Conne...

Page 242: ...the rubber spacer and the mount over the shaft of the long upper mount screw Attach the mount assembly to the driveshaft housing with two screws a Ensure that the arrow on the mount is pointing toward...

Page 243: ...ounts in the pockets on the driveshaft housing The third large rubber mount spans the two halves of the lower mount bracket Ensure that the lower continuity wire passes between the large rubber mount...

Page 244: ...y the lifting eye or Lay the outboard on its back side 1 Disconnect the green and blue power tilt wires from the power tilt relays a Blue up tilt relay terminal and wire b Green down tilt relay termin...

Page 245: ...ecified torque 3 Install the anode and ground cable Tighten the anode screw to the specified torque a Ground cable b Screw M6 x 16 c Anode d Lower pivot pin bushing e Tilt lock pin Description Nm lb i...

Page 246: ...clip d Cable ties 2 e Tilt lock pin locknut and washer f Lower pivot pin screw M8 x 20 and washer g Ground cable screw on power tilt unit h Port clamp bracket Tube Ref No Description Where Used Part N...

Page 247: ...ew and washer 2 Remove the screw securing the ground cable 3 Remove the port tilt tube cap 4 Loosen the locknut 5 Push the tilt tube towards the starboard side to allow the starboard nut to be removed...

Page 248: ...cknut 13 115 Ground cable screw M6 x 12 6 0 53 1 4 Install the clamp bracket partially onto the tilt tube 5 Align the lower pivot pin with the port clamp bracket bushing and push the clamp bracket ont...

Page 249: ...he powerhead driveshaft housing gearcase assembly from the clamp bracket swivel bracket steering arm assembly Refer to Powerhead Midsection Assembly Separation 2 For tiller handle models remove the co...

Page 250: ...ivel bracket away from the rest of the assembly a Open the power tilt manual release valve b Raise the swivel bracket to the full tilt position c Close the manual release valve For details refer to Se...

Page 251: ...remove the swivel bracket 1 Remove the starboard side nut securing the tilt tube a Port clamp bracket b Swivel bracket c Tilt tube with cap and nut d Starboard clamp bracket 2 Partially remove the til...

Page 252: ...e bushings and pin 7 Install a washer onto the tilt lock pin 8 Install the spring pin through the tilt lock pin 9 Install the tilt spring onto the swivel bracket Port side shown at left starboard show...

Page 253: ...locknut 24 0 17 7 Ground cable screw M6 x 12 6 0 53 1 Power Tilt Installation 1 Raise the swivel bracket and engage the tilt lock lever 2 Ensure the tilt rod eye bushing and the lower pivot pin bushin...

Page 254: ...cable to the power tilt unit Tighten the screw to the specified torque 12 Lubricate the tilt tube with 2 4 C with PTFE through the grease fittings on the swivel bracket a P clip b Hole through the por...

Page 255: ...t locknut 11 0 97 3 4 Lubricate the steering arm O ring with 2 4 C with PTFE 5 Install the O ring onto the steering arm shaft a Swivel bracket b O ring c Steering arm shaft Tube Ref No Description Whe...

Page 256: ...tube cap b Locknut c Tilt pin d Nut and washer on the clamp bracket spacer e Anode Port Bracket Installation 1 Install the anode Tighten the screw to the specified torque a Channel for tilt lock guid...

Page 257: ...e clamp bracket spacer e Anode Description Nm lb in lb ft Tilt tube locknut 24 0 17 7 Clamp bracket spacer nut 6 0 53 1 Starboard Bracket Removal 1 Remove the tilt tube caps 2 Loosen the locknut on th...

Page 258: ...2 4 C with PTFE Tilt tube washer 92 802859A 1 4 Install the clamp bracket onto the spacer Ensure that the tilt lock is in the channel Then install the washer and nut Tighten the nut to the specified t...

Page 259: ...air box need not be fully removed for this procedure Removing the three screws and moving the air box far enough out of the way to allow the recoil starter to be removed is sufficient This will ease...

Page 260: ...ube cap b Tilt tube port side locknut c Spacer bar nut and washer d Tilt pin 3 Remove the swivel bracket and bushings from the tilt tube a Bushing b Swivel bracket Swivel Bracket Inspection 1 Remove t...

Page 261: ...g the reverse lock lever be certain to apply Loctite 222 Threadlocker to the shoulder screw and tighten the screw to the specified torque a Button b Grip c Lever d Washer e Washer f Spring g Bushing h...

Page 262: ...gs the swivel bracket and the carry handle onto the tilt tube a Starboard clamp bracket b Bushing 2 c Swivel bracket d Carry handle e Tilt tube 4 Install a washer onto the clamp bracket spacer 5 Insta...

Page 263: ...t nut 6 0 53 1 Steering Arm Installation 1 Install a washer onto the steering arm shaft 2 Insert the steering arm into the swivel bracket Ensure that the lower bushing remains in the swivel bracket 3...

Page 264: ...nd continuity wire Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Steering arm O ring 92 802859A 1 6 Attach the outboard to the swivel bracket Refer to Powerhead Midsection Assembly Sep...

Page 265: ...nt cowl Refer to Front Cowl 3 Remove the gear housing Refer to Section 6A Gear Housing Removal 4 Remove the powerhead Refer to Section 4A Powerhead Removal 5 Remove the lower mount Refer to Lower Moun...

Page 266: ...a Water pump indicator tube b Screw Description Nm lb in lb ft Screw 6 0 53 1 2 Install the rubber seal onto the driveshaft housing 3 Install the driveshaft seal 4 Install the powerhead gasket a Power...

Page 267: ...propeller shaft is rotated counterclockwise b Place the shift handle or remote control in neutral Resistance should not be felt when the propeller shaft is rotated in either direction c Place the shi...

Page 268: ...engine is being returned to service without the kicker strap be certain to install the upper engine mount screws and tighten them to the specified torque Description Nm lb in lb ft Upper engine mount...

Page 269: ...Clamp Swivel Bracket and Driveshaft Housing Notes Page 5A 50 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 270: ...er Tilt System 5B 10 Preliminary Troubleshooting Steps 5B 10 Power Tilt Leakage Test Procedure 5B 10 Hydraulic System Troubleshooting 5B 11 Tilt Electrical System General Troubleshooting 5B 11 Power T...

Page 271: ...Fluid or Automatic Transmission Fluid ATF Type Dexron III Electric motor Maximum current draw 35 A General Troubleshooting For general troubleshooting information including connecting and using the CD...

Page 272: ...Power Tilt Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 5B 3...

Page 273: ...Power Tilt Components 33822 1 2 13 3 14 14 15 16 4 5 6 7 8 9 10 11 12 17 18 19 20 21 22 23 24 25 26 27 Power Tilt Page 5B 4 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 274: ...O ring 10 2 O ring 11 1 Pump 12 1 Up relief valve assembly 13 1 O ring 14 2 Bolt M5 x 20 5 2 46 0 15 1 Bolt M5 x 25 5 2 46 0 16 1 Filter 17 1 Coupling 18 1 O ring 19 1 Motor bracket assembly 20 1 Oil...

Page 275: ...pump As the pump s gears rotate fluid is drawn through a check valve and into the pump s inlet The pump s flow passes through a check valve then passes through a pressure operated PO check valve and...

Page 276: ...through a return check valve Fluid below the memory piston is trapped in place therefore stopping the cylinder piston and returning the outboard to its previous tilt position Power Tilt Features and...

Page 277: ...ositioned to run perpendicular to the water when the boat is running at full speed This allows the boat to be driven parallel to the water Arrange passengers and load in the boat so the weight is dist...

Page 278: ...s more than 3 mm 0 125 in air is present in the system Cycle tilt cylinder again and repeat this step Recheck the fluid level Cowl Mounted Tilt Switch On remote control models the cowl mounted tilt sw...

Page 279: ...s not been corrected proceed with the next check 1 Check that the manual release valve is tightened fully clockwise 2 Check the power tilt pump fluid level in the full up position Fill if necessary Re...

Page 280: ...leaking or cut Replace power tilt assembly 4 Manual release valve leaking check condition of O rings valve not fully closed Ensure that valve is fully closed Inspect O rings 5 Debris in system Inspect...

Page 281: ...ontact to ground The opposite is true if the system will not run down When the system is not energized both relays should connect the heavy motor leads to ground To test which relay is faulty if the t...

Page 282: ...NK Pink PPL Purple RED Red TAN Tan WHT White YEL Yellow LT Light DK Dark Tilt System Wiring Diagrams NOTE The numbered callouts in these wiring diagrams correspond to test points identified in the fol...

Page 283: ...Tiller handle tilt switch A B D J K M N P E F H C G L UP DN RED PPL LT BLU WHT GRN WHT J5 J8 J7 A B D J K M N P E F H C G L E H J K L M N A B C D F G P 1 2 15A BLK BLK BLK BLK BLK BLK RED RED RED RED...

Page 284: ...hooting the Down Circuit NOTE Refer to the preceding wiring diagrams for test points when troubleshooting the electrical systems Test points are specified by number A B D J K M N P E F H C G L UP DN R...

Page 285: ...2 and black lead to ground 2 Press the down tilt button Battery voltage measured Go to step 6 No battery voltage measured Relay is defective Step 6 Check up relay Test up relay Refer to Power Tilt Re...

Page 286: ...number Step Test Procedure Test Result Step 1 Check fuse Visually inspect power tilt motor fuse Fuse blown Correct problem that caused to blow and Replace fuse Fuse not blown Go to step 2 Step 2 Check...

Page 287: ...an open circuit between point 5 and red terminal on back of ignition switch Power Tilt Removal 1 Tilt the outboard to the full up position and engage the tilt support lever a Tilt support lever 2 Remo...

Page 288: ...clamp brackets Manual Release Valve Removal and Repair IMPORTANT The power tilt system is pressurized The tilt cylinder rod must be fully extended in the up position prior to removing the reservoir pl...

Page 289: ...Transmission Fluid ATF Type Dexron III prior to installation Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Lubrication of O rings 92 858074K01 9 Install two new O rings...

Page 290: ...pection and Repair 1 Remove the two cross slotted screws securing the motor housing to the bracket assembly a Motor cover b Screws 2 c Motor bracket 2 Remove the armature from the motor housing Test f...

Page 291: ...utator end of the armature must be installed in brushes when performing the following tests DMT 2004 Digital Multimeter 91 892647A01 Meter Test Leads Meter Scale Reading Red Black Green motor wire Blu...

Page 292: ...Install the brush holder and secure with a screw 6 Attach the green wire and brush wire terminal to the motor bracket Secure with a screw 7 Install two springs into the brush and breaker slots under...

Page 293: ...re clean and lint free during reassembly IMPORTANT The power tilt system is pressurized The tilt cylinder rod must be fully extended in the up position prior to removing the reservoir plug or manual r...

Page 294: ...the power tilt assembly a Filter b Pump motor coupling NOTE Relief valve components are held in place by the power tilt pump When removing the pump ensure that these components are not lost 10 Remove...

Page 295: ...Inspect the down orifice screen and up relief valve seat a Up relief valve seat b Down orifice screen Power Tilt Pump Reassembly 1 Install two new lubricated O rings in the power tilt housing 2 Insta...

Page 296: ...114 Power Trim and Steering Fluid Lubrication of power tilt O rings 92 858074K01 5 Assemble the pump with three internal hex screws Tighten the screws to the specified torque a Power tilt pump b Inter...

Page 297: ...tilt system with Power Trim and Steering Fluid Refer to Check Fluid and Purge the Power Tilt System preceding 12 Install the reservoir fill plug a Wire harness retaining screw b Power tilt pump and cy...

Page 298: ...assembly between the clamp brackets 5 Install the tilt cylinder pivot pin through the clamp brackets and the power tilt unit 6 Install the washer and retaining screw into the pivot pin Tighten the sc...

Page 299: ...rew 6 0 53 1 8 Connect the power tilt electrical wires to the power tilt relays a Blue up tilt relay terminal and wire b Green down tilt relay terminal and wire 9 Connect the battery cables to the bat...

Page 300: ...ing screw and washer b Tilt cylinder rod pin Description Nm lb in lb ft Tilt cylinder rod pin retaining screw 6 0 53 1 15 Disengage the tilt support lever and lower the outboard 16 Cycle the outboard...

Page 301: ...Power Tilt Notes Page 5B 32 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 302: ...d Reverse Gear Inspection 6A 22 Driveshaft Pinion Bearing Removal 6A 24 Driveshaft Inspection 6A 25 Upper Driveshaft Bearing Inspection 6A 26 Gear Housing Assembly 6A 26 Pinion Bearing Installation 6A...

Page 303: ...pump drive key Inside diameter of the water pump liner Driveshaft splines Propeller shaft splines 92 802859A 1 Special Tools Bearing Puller Assembly 91 83165T 3610 Removes bearings races and bearing c...

Page 304: ...earing races Spring 8M0011503 37830 Applies upward force to the driveshaft for checking forward gear backlash Clamp 8M0033741 37831 Used as part of an assembly to provide upward force on the driveshaf...

Page 305: ...or Adapter 91 83155 2999 Dial indicator holding fixture Gearcase Specifications Parameter Specification Gear ratio 2 15 1 Gearcase capacity 460 ml 15 6 fl oz Gear lubricant type Premium Gear Lubricant...

Page 306: ...Gear Housing 2 15 1 Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 6A 5...

Page 307: ...iveshaft 35 36 37 38 39 64672 1 2 3 4 5 6 3 4 8 9 11 12 10 5 7 13 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 32 33 34 34 Gear Housing 2 15 1 Page 6A 6 2018 Mercury Marine 90 8M0125265...

Page 308: ...16 1 Cam rod 17 1 Spring pin 18 1 Screw 5 0 44 3 19 1 Stopper 20 1 Lower pump case gasket 21 1 Lower pump case assembly 22 1 Oil seal 23 1 O ring 24 1 Stopper 25 1 Screw 6 0 53 1 26 1 Guide plate gask...

Page 309: ...Propeller Shaft 64673 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 21 22 Gear Housing 2 15 1 Page 6A 8 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 310: ...8 1 Propeller shaft 9 1 Thrust washer 10 1 Reverse gear 11 1 O ring 12 1 Ball bearing 13 1 Bearing carrier 14 1 Needle bearing 15 1 Oil seal 16 2 Screw 9 0 79 6 17 1 Propeller 18 1 Propeller hardware...

Page 311: ...d out while holding the outer race to check for side wear When inspecting tapered bearings determine the condition of the rollers and the inner bearing race by inspecting the bearing cup for pitting s...

Page 312: ...ricant This is not an indication of water intrusion If during subsequent draining of the gearcase lubricant appears cream colored or milky water may be present The gearcase should be disassembled and...

Page 313: ...e 62827 Gearcase screws two per side Gear Housing Disassembly IMPORTANT It is recommended that during complete disassembly of the gear housing all O rings and oil seals be replaced regardless of their...

Page 314: ...ring carrier and propeller shaft assembly from the gearcase a Propeller shaft b Bearing carrier assembly NOTE The cam follower is free to slide out of the propeller shaft a Propeller shaft b Bearing c...

Page 315: ...tch teeth are chipped or worn a Clutch teeth b Gear teeth 6 If the reverse gear must be replaced use a bearing puller assembly to remove the reverse gear from the reverse gear bearing a Bearing carrie...

Page 316: ...Bearing puller assembly Bearing Puller Assembly 91 83165T Torch Lamp 91 63209 8 Use a torch lamp to warm the outer surface of the bearing carrier where the carrier seal is located Use a bearing pulle...

Page 317: ...c Bearing carrier Propeller Shaft Disassembly 1 Inspect the cam follower for wear Replace the follower if it is worn a Propeller shaft b Bearing carrier assembly c Cam follower 2 Remove the clutch pin...

Page 318: ...in c Ring faces forward gear d Clutch spring 5 Replace the clutch if the jaws are rounded or chipped Rounded jaws may be caused by the following Improper shift cable or linkage adjustment Engine idle...

Page 319: ...l pins NOTE The water pump cover liner may remain with the impeller when the cover is removed This is not a problem a Dowel pins 2 b Water pump cover liner impeller is inside the liner 3 Remove the im...

Page 320: ...the impeller sealing bead should be disregarded when inspecting the liner and the faceplate The depth of the groove will not affect the water pump output 7 Inspect the water pump liner and the facepla...

Page 321: ...base seal with a seal puller Do not scar the water pump base seal surface with the seal puller If the surface is damaged replace the water pump base a Notch in shift shaft bracket b Spring pin c Shif...

Page 322: ...moval Tool 91 853996 6 b Use a spring pin removal tool to secure the shift cam to the shift shaft with a new retainer pin The retainer pin must be flush with the shift cam surface a Spring pin removal...

Page 323: ...spect the forward gear and the reverse gear teeth for breakage rust chipping and excessive wear a Forward gear NOTE Do not remove the forward gear and bearing assembly from the gearcase unless replace...

Page 324: ...Inspect the forward and reverse gear clutch jaws for wear Rounded jaws indicate the following a Improper shift cable or linkage adjustment b Engine idle speed too high c Shifting too slowly a Forward...

Page 325: ...he gear housing unless replacement is necessary The removal process will damage the bearing 1 Inspect the pinion bearing surface on the driveshaft Replace the driveshaft if it is pitted grooved scored...

Page 326: ...he tool flange The pinion bearing will drop into the gear housing cavity Discard the pinion bearing The bearing cannot be reused after removal Remove the tool from the driveshaft bore a Head of tool b...

Page 327: ...he old pinion nut onto the driveshaft Place the driveshaft assembly into the press and apply pressure to the old pinion nut to push the driveshaft through the new bearing until the bearing seats again...

Page 328: ...g will then be installed at the correct height in the driveshaft housing bore a Head of pinion bearing tool b Tool flange Forward Gear Bearing Installation 1 Using a mandrel that contacts only the inn...

Page 329: ...ply 2 4 C with PTFE to the bearing carrier seal lips Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Bearing carrier seal lips 92 802859A 1 2 Install the seal with the seal face up 3 Usi...

Page 330: ...NT Do not install the bearing carrier O ring if the torch lamp will be used on the bearing carrier The O ring will be damaged by the heat 6 Use a torch lamp to warm the bearing carrier Use a suitable...

Page 331: ...l press on the face of the water pump seal until the seal is seated in the water pump base 2 Apply 2 4 C with PTFE to the seal lips 3 Apply 2 4 C with PTFE onto a new O ring and install the O ring ont...

Page 332: ...ropeller shaft a Propeller shaft b Clutch c Clutch spring d Cam follower 3 Compress the cam follower against a hard surface while aligning the clutch pin hole with the slots in the propeller shaft 4 I...

Page 333: ...inion nut threads 1 Install the driveshaft assembly with the shims retained on top of the driveshaft bearing through the pinion bearing a Driveshaft b Shims retained c Upper driveshaft bearing 2 Lift...

Page 334: ...p base and the upper driveshaft bearing Adding shims reduces backlash removing shims increases backlash 1 Secure the gearcase in a vise or gearcase holding fixture The driveshaft must be kept vertical...

Page 335: ...two spacers and two screws c Tighten the screws to the specified torque d Thread two nuts onto the end of the backlash preload tool and tighten jam the two nuts against each other e Using the jam nut...

Page 336: ...031 0 059 in 12 If the backlash is not within specification add or remove shims located between the upper driveshaft bearing and the water pump base NOTE Removing a 0 1 mm 0 004 in shim will increase...

Page 337: ...without force to close the gap when all parts are positioned correctly 6 Slide the clamp over the shift shaft and secure it and the water pump base to the gearcase with a screw and washer 7 Ensure tha...

Page 338: ...appearance whenever the gearcase is serviced If the old impeller must be used it must be installed in the direction of the original rotation Installing the impeller with the vanes reversed from their...

Page 339: ...ecure the water pump cover with four screws Tighten the screws to the specified torque a Screws 4 b Water pump cover Description Nm lb in lb ft Water pump cover screws 6 0 53 1 Propeller Shaft and Bea...

Page 340: ...ng or installing the gear housing disconnect and isolate the spark plug leads Disable the ignition system by removing the keys from the ignition if equipped and engaging the lanyard stop switch to pre...

Page 341: ...ading the coupler at least five turns onto the lower shift shaft IMPORTANT Take care to not rotate the lower shift shaft Doing so will damage components within the gearcase 9 Use two wrenches to lock...

Page 342: ...eller shaft so that the larger diameter end is facing the propeller 3 Install the propeller rear thrust washer and propeller nut onto the propeller shaft 4 Place a block of wood between the gearcase a...

Page 343: ...Gear Housing 2 15 1 Notes Page 6A 42 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 344: ...Tiller Handle Models 7A 8 Throttle and Shift Linkage Removal 7A 8 Shift Detent 7A 9 Throttle and Shift Linkage Installation 7A 9 Remote Models 7A 10 Throttle and Shift Linkage Removal 7A 10 Shift Det...

Page 345: ...dhesives Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Shift shaft assembly detents and contact surfaces 92 802859A 1 Throttle and Shift Linkage Page 7A 2 2018 Mercury Marine 90 8M0125...

Page 346: ...Throttle and Shift Linkage Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 7A 3...

Page 347: ...iller Models 64682 1 2 3 3 4 5 6 7 8 9 10 11 12 12 13 13 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 26 25 28 29 30 31 32 29 33 34 35 36 Throttle and Shift Linkage Page 7A 4 2018 Mercury Marine...

Page 348: ...taining clip 14 1 Lower shift arm 15 1 Upper shift arm 16 1 Horizontal shift shaft 17 1 Bushing 18 2 Washer 19 1 Screw 6 0 53 1 20 1 Vertical shift shaft 21 1 Shift shaft coupler 4 0 35 4 22 1 Jam nut...

Page 349: ...l Components 64681 7 1 2 5 3 6 5 4 5 9 27 28 29 8 12 13 15 12 13 15 26 19 25 24 23 11 11 11 10 18 17 18 20 21 16 14 14 22 22 Throttle and Shift Linkage Page 7A 6 2018 Mercury Marine 90 8M0125265 eng N...

Page 350: ...arm 18 1 Collar 19 2 Washer 20 1 Washer 21 1 Screw 6 0 53 1 22 1 Shift lever rod 23 2 Retaining clip 24 1 Throttle arm 25 1 Throttle opener 26 1 Collar 27 1 Screw 6 0 53 1 28 2 Ball joint connector 2...

Page 351: ...e the retaining clip and washer from the shift link 7 Remove one screw two washers and a bushing to remove the shift link from the engine Bracket style may vary a Jam nuts b Interlock cable connection...

Page 352: ...with two brackets and four screws 7 Ensure that the front cowl properly engages the midplate and the vertical shift shaft boot NOTE If the front cowl was removed from the shift lever brackets install...

Page 353: ...nd throttle control cables Refer to Section 7B Shift Cable Installation and Section 7B Throttle Cable Installation 17 Install the starboard driveshaft housing cover Refer to Section 5A Driveshaft Hous...

Page 354: ...b c d 63129 a Bow tie retainer b Flat washer c Shift cable d Cable barrel a b c d 63123 6 Remove the screw from the cable barrel retainer and remove the throttle and shift cables a Cable barrel retain...

Page 355: ...t lever shaft assembly a Shift lever bracket screws 4 b Front cowl c Upper shift shaft Shift Detent Inspect the shift detent hardware Replace any worn or damaged components a Shift detent springs b Sh...

Page 356: ...0 53 1 Shift detent screw 6 0 53 1 7 Install the starter motor Refer to Section 2B Starter Motor Installation 8 Install the shift link using one screw two washers one each side and one bushing Tighte...

Page 357: ...able Installation 14 Install the recoil starter and air box It is easiest to install the recoil starter and air box together Refer to Section 8A Recoil Starter Installation and Section 3C Air Box Inst...

Page 358: ...emoval 7B 9 Tiller Handle Disassembly 7B 9 Throttle Cable Case 7B 11 Disassembly Inspection 7B 11 Assembly 7B 12 Tiller Handle Assembly 7B 13 Tiller Handle Installation 7B 17 Shift Cable Installation...

Page 359: ...iction on the tiller throttle shaft to hold the throttle at a desired speed or decrease friction to allow the throttle to automatically return to idle when the grip is released a Quick reference decal...

Page 360: ...allows the operator to easily stop the engine Align the throttle grip with the idle mark on the tiller handle when starting or shifting into or out of gear Twist the throttle grip to increase the engi...

Page 361: ...13 14 15 63 16 17 17 18 19 20 21 22 24 25 6 26 9 27 28 29 30 30 31 32 28 29 33 34 35 36 36 37 38 39 40 41 42 39 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 62 45 64 23 Tiller Handle Page...

Page 362: ...ver assembly 21 1 Locknut 1 1 9 7 22 1 Hex head screw 20 3 180 23 1 Plug 24 1 Hex head cap screw 25 1 Belleville washer 26 1 Flange spacer 27 1 Shift cable 28 2 Pin 29 2 Tilt locking tab 30 2 Flange b...

Page 363: ...4 1 Washer 55 1 Tiller handle adjusting nut 56 1 Tiller handle bracket 57 1 Pan head screw 2 3 20 3 58 1 Self tapping hex head screw 2 0 17 7 59 1 Pulley cover 60 1 Throttle cable pulley 61 1 Throttle...

Page 364: ...13 14 15 63 16 17 17 18 19 20 21 22 24 25 6 26 9 27 28 29 30 30 31 32 28 29 33 34 35 36 36 37 38 39 40 41 42 39 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 62 45 64 23 Tiller Handle 90 8...

Page 365: ...threads of the pivot screw NOTE It may be necessary to loosen the pivot screw a couple of turns to gain sufficient access to the screw threads Tube Ref No Description Where Used Part No 7 Loctite 271...

Page 366: ...5 Loosen the throttle cable jam nuts 6 Remove the throttle cables from the throttle barrel 7 Disconnect the 14 pin connector Manual tilt model shown power tilt models similar a Shift cable bracket cli...

Page 367: ...ushings fit into the tiller handle bracket If they are loose remove and retain them for reuse 4 Remove the cotter pin from the friction control knob 5 Turn the friction control knob to remove the knob...

Page 368: ...handle partially out b Stop switch electrical connector disconnect and depin c Locknut d Retaining slot 11 Remove two screws that secure the shift detent spring and remove the spring 12 Remove the til...

Page 369: ...stall the cable end barrel into the slot on the pulley a Throttle cable b Cable end barrel in slot c Pulley 2 Apply 2 4 C with PTFE to the throttle cable end barrels the face of the pulley and the out...

Page 370: ...ef No Description Where Used Part No 95 2 4 C with PTFE Shift handle bushings 92 802859A 1 2 Attach the shift handle and cam to the tiller handle housing with a screw Tighten the screw to the specifie...

Page 371: ...art No 95 2 4 C with PTFE Shift cable input rod and eyelet 92 802859A 1 7 Place the shift cable in the retaining slot and attach the shift cable to the shift handle with a locknut 8 Thread new cable t...

Page 372: ...xtured surface facing up NOTE The end of the throttle shaft will only engage with the cable pulley housing when they are both in the correct positions h Slide the throttle handle assembly fully onto t...

Page 373: ...e Used Part No 95 2 4 C with PTFE Tiller handle plastic bushing I D 92 802859A 1 13 Turn and hold the tilt lock lever downward to clear the tiller handle Then attach the tiller handle mount to the til...

Page 374: ...e mounting screws Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Tiller handle mounting screws 92 809819 2 Attach the tiller handle to the outboard with the two screws Tighten t...

Page 375: ...racket and remove the bracket 64461 3 Loosen the shift detent screw a Fuel inlet hose b Horizontal shift shaft c Shift shaft detent springs d Shift detent screw 4 Couple the upper and lower vertical s...

Page 376: ...he lower shift shaft IMPORTANT Take care to not rotate the lower shift shaft Doing so will damage the gearcase f Use two wrenches to lock the jam nut against the coupler a Upper vertical shift shaft b...

Page 377: ...the tiller shift cable a Rotate the horizontal shift shaft to shift the gearcase to neutral b Install the shift cable s ferrule into the shift bracket c Ensure that the shift cable is extended to the...

Page 378: ...ical shift shaft coupler Throttle Cable Installation 1 Ensure that the throttle link is set correctly When the throttle is against the idle set screw the throttle drum idle stop should rest against th...

Page 379: ...um does not contact the WOT stop adjust the lower cable jam nuts until proper contact is made 8 Return the throttle grip to idle a Ensure that the throttle drum rests on the idle stop b Tighten the up...

Page 380: ...at the wide open throttle stop on the throttle drum rests against the throttle stop a Throttle drum idle stop b Throttle stop c Throttle cable jam nut one of four d Throttle drum WOT stop a b c b d 63...

Page 381: ...Tiller Handle Notes Page 7B 24 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 382: ...tarter Components 8A 4 Recoil Starter Removal 8A 6 Recoil Starter Disassembly 8A 6 Recoil Starter Assembly 8A 7 Recoil Starter Installation 8A 11 Neutral Interlock Cable Adjustment 8A 12 Recoil Starte...

Page 383: ...Threadlocker Threads of the friction plate retaining screw Threads of the recoil starter assembly screws 92 809819 95 2 4 C with PTFE Recoil housing Starter pawl bore on the sheave Friction plate 92 8...

Page 384: ...Recoil Starter Notes 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 8A 3...

Page 385: ...Recoil Starter Components 64650 1 2 3 4 5 8 9 6 7 10 9 11 12 15 16 17 18 19 20 21 22 23 24 25 26 13 14 Recoil Starter Page 8A 4 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 386: ...patch M6 x 20 6 0 53 1 9 3 Washer 10 1 Lock spring 11 1 Lock 12 1 Cam gear cover 13 1 Vent tank 14 3 Screw 15 2 Grommet 16 1 Starter rope 17 1 Spring 18 1 Tapping screw 19 1 Bushing 20 1 Sheave 21 1 S...

Page 387: ...the recoil housing 4 Lift the neutral interlock cable up and remove the neutral interlock cable tension spring from the recoil housing a Neutral interlock cable tension spring b Neutral interlock cab...

Page 388: ...push the recoil lock out of the recoil housing a Recoil lock b Interlock lever spring c Recoil lock retainer pinch to remove 10 Remove the E ring securing the starter pawl to the sheave 9725 11 Push...

Page 389: ...o the sheave a Tie a knot on one side of the recoil rope and insert the recoil rope through the sheave b Thread the recoil rope through the sheave as shown c Pull the recoil rope tight in the sheave a...

Page 390: ...rly a Recoil spring b Sheave catch 6 With a slight downward pressure rotate the sheave counterclockwise to engage the spring into the catch on the sheave If the spring is properly positioned on the sh...

Page 391: ...Part No 7 Loctite 271 Threadlocker Threads of the friction plate retaining screw 92 809819 8 Complete the rope installation a Insert the recoil rope into the guide and through the recoil housing b Ins...

Page 392: ...ock cable end 3 Pull on the neutral interlock cable and insert the cable end into the neutral interlock cable retainer on the recoil housing a Recoil housing catch b Neutral interlock cable retainer 4...

Page 393: ...Installation 2 Ensure the outboard is in neutral 3 Loosen the interlock cable jam nuts Electric start model shown manual start model similar a Neutral interlock cable b Upper jam nut c Lower jam nut 4...

Page 394: ...l Tilt 9A 4 15 20 EFI FourStroke Electric Start Remote Control 9A 5 15 20 EFI FourStroke with Electric Start Tiller Handle and Manual Tilt 9A 6 15 20 EFI FourStroke with Electric Start Tiller Handle a...

Page 395: ...Notes Color Diagrams Page 9A 2 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 396: ...Notes Color Diagrams 90 8M0125265 eng NOVEMBER 2017 2018 Mercury Marine Page 9A 3...

Page 397: ...14 Cowl mounted start switch not used 15 Not used 16 Tiller models Tiller handle stop push button 17 Tiller models Tiller handle E stop switch lanyard operated 18 Tiller models Tiller handle 14 pin ha...

Page 398: ...A B C D F G P LT GRN RED BLU BLU BLU GRN RED LT GRN BLK BLK WHT BLK YEL BLK GRN GRN WHT RED WHT BLK BLU GRN ORN RED WHT BLU WHT BLK BLU BLK BLU GRN YEL RED RED GRN RED BLK RED BLU YEL WHT RED RED RED...

Page 399: ...F G P LT GRN RED BLU GRN RED BLU BLU LT GRN BLK BLK WHT BLK YEL BLK GRN GRN WHT RED WHT BLK BLU GRN ORN RED WHT BLU WHT BLK BLU BLK BLU GRN YEL RED RED GRN RED BLK RED BLU YEL WHT RED RED RED GRN RED...

Page 400: ...unning 17 Cowl mounted start switch not used 18 Starter solenoid power start signal 19 14 pin connector for remote control harness 20 Power tilt models Cowl mounted power tilt switch 21 Power tilt mod...

Page 401: ...olenoid 15 Battery positive 16 15 amp fuse starting control circuit 17 Neutral start switch 18 Cowl mounted start switch 19 Not used 20 Tiller handle stop push button 21 Tiller handle E stop switch la...

Page 402: ...H J K L M N A B C D F G P LT GRN RED BLU BLU BLU GRN RED LT GRN BLK BLK WHT BLK YEL BLK GRN GRN WHT RED WHT BLK BLU GRN ORN RED WHT BLU WHT BLK BLU BLK BLU GRN YEL RED RED GRN RED GRN BLK RED BLU YEL...

Page 403: ...YEL GRN WHT GRA YEL BRN BRN WHT BLK BLU LT GRN E H J K L M N A B C D F G P LT GRN RED BLU GRN RED BLU BLU LT GRN BLK BLK WHT BLK YEL BLK GRN GRN WHT RED WHT BLK BLU GRN ORN RED WHT BLU WHT BLK BLU BL...

Page 404: ...l start switch 18 Cowl mounted start switch 19 Not used 20 Tiller handle stop push button 21 Tiller handle E stop switch lanyard operated 22 Tiller handle power tilt switch 23 Tiller handle 14 pin har...

Page 405: ...Color Diagrams Notes Page 9A 8 2018 Mercury Marine 90 8M0125265 eng NOVEMBER 2017...

Page 406: ...South Victoria 3175 Australia www mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium 90 8M0125265 NOVEMBER 2...

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