5/20 EFI FourStroke S E R VIC E M A NU AL
Notice to Users of This Manual Throughout this publication, safety alerts labeled WARNING and CAUTION (accompanied by the international hazard symbol ! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe these alerts carefully. These safety alerts alone cannot eliminate the hazards that they signal.
! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Manual Outline Important Information 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Installation E - General Troubleshooting 2 - Electrical A - Ignition B - Charging and Starting Systems 3 - Fuel System A - Fuel System Operation B - Troubleshooting 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 Tilt
90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page iv
Specifications Important Information 1 A Section 1A - Specifications Table of Contents Model Specifications.......................................................... 1A-2 Ignition Specifications at 20 °C (68 °F).............................. 1A-2 Charging and Starting Specifications.................................1A-3 Fuel System Specifications................................................1A-3 Cylinder Block/Crankcase Specifications...........................1A-3 Piston Specifications...............
Specifications Model Specifications Parameter Specification MH Weight 46.7 kg (103 lb) MRC 44 kg (97 lb) MLH 48.5 kg (107 lb) EH 50.3 kg (111 lb) ELH 51.7 kg (114 lb) E 47.6 kg (105 lb) EL 49 kg (108 lb) EPT ELPT 52.6 kg (116 lb) 54 kg (119 lb) ELHPT 57.6 kg (127 lb) ProKicker EXLPT 55.
Specifications Charging and Starting Specifications Parameter Specification Alternator type Single phase Alternator charge coil resistance 0.17–0.25 Ω Alternator output at 900 RPM 4.6 A Alternator output at 5000 RPM 11.5 A Type Bendix® Output 0.6 kW at 12 V Brush length 14.0 mm (0.551 in.) Brush length (service limit) Starter 11.0 mm (0.433 in.) Commutator undercut 0.95–1.05 mm (0.037–0.041 in.) Commutator diameter 28.3 mm (1.114 in.) Commutator diameter (service limit) 27.8 mm (1.
Specifications Parameter Connecting rod wrist pin bore diameter Specification 16.010–16.021 mm (0.6303–0.6307 in.) Connecting rod wrist pin bore diameter (service limit) Connecting rod crankshaft pin diameter 16.025 mm (0.6309 in.) 29.000–29.013 mm (1.1417–1.1422 in.) Connecting rod crankshaft pin diameter (service limit) Connecting rod side clearance 28.038 mm (1.1432 in.) 0.1–0.25 mm (0.004–0.01 in.) Connecting rod side clearance (service limit) 0.6 mm (0.0236 in.
Specifications Parameter Valve stem diameter Specification Intake 5.48 mm (0.216 in.) Intake (service limit) 5.46 mm (0.215 in.) Exhaust 5.46 mm (0.215 in.) Exhaust (service limit) 5.44 mm (0.214 in.) Cylindricity (maximum) 0.01 mm (0.0004 in.) Valve face width (intake and exhaust) 1.0 mm (0.04 in.) Valve face width (service limit) Valve margin thickness 2.0 mm (0.08 in.) Intake 0.55 mm (0.0217 in.) Exhaust 1.00 mm (0.0394 in.
Specifications Cooling System Specifications Parameter Thermostat Specification Start to open temperature 50–54 °C (122–129 °F) Full open temperature 60–64 °C (140–147 °F) Valve lift 4.0 mm (0.157 in.) Water pressure at idle 9–18 kPa (1.3–2.6 psi) Water pressure at WOT 59–118 kPa (8.6–17.
Maintenance Important Information 1 B Section 1B - Maintenance Table of Contents Cleaning Care.................................................................... 1B-2 Do Not Use Caustic Cleaning Chemicals................... 1B-2 Cleaning Care for Top and Bottom Cowls.................. 1B-2 Inspection and Maintenance Schedule.............................. 1B-2 Before Each Use.........................................................1B-2 After Each Use.....................................................
Maintenance Lubricant, Sealant, Adhesives Tube Ref No. Description Where Used Part No.
Maintenance Tube Ref No. 81 • Description Anti-Seize Compound Where Used Part No. Spark plug threads 92-898101389 Where Used Part No. Fuel tank 8M0047931 Add Quickleen to the fuel tank. Tube Ref No. Description Quickleen Engine & Fuel System Cleaner • Check the cowl seals to ensure that the seals are intact and not damaged. • Check that the idle relief muffler is in place, if equipped. • Inspect the thermostat for corrosion or a broken spring.
Maintenance Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages. 1. Remove the propeller. Refer to Propeller Replacement. 2. Remove the plug from the flush fitting, and attach a water hose.
Maintenance 3. Pull the filter assembly—including the rubber mount—off of the mounting bracket on the engine, and swing the assembly over the edge of the engine. 4. Loosen the drain valve until liquid flows out of the bottom. Empty the filter bowl's contents into an approved container. To protect the environment, immediately clean up spilled fluids and dispose of according to local laws and regulations.
Maintenance IMPORTANT: The filter is secured and sealed to the filter housing with an O‑ring. The O‑ring may remain on the filter housing. The O‑ring should be removed before installing the fuel filter. 63112 Fuel filter Filter Installation a b c d e 63113 1. abcde- Fuel filter O‑ring seal Fuel filter Red ring Sight bowl O‑ring seal Sight bowl Install the fuel filter O‑ring seal into the fuel filter. Verify the O‑ring does not have any folds or kinks. 63114 2.
Maintenance 5. Install the sight bowl onto the filter housing hand‑tight. 6. Verify the rubber mount is properly aligned with the filter housing and install the rubber mount. 63116 Rubber mount properly aligned 7. Install the filter assembly onto the mounting bracket. 8. Connect the fuel line to the engine and prime the engine fuel system. Inspect the fuel filter area for fuel leaks. Repair as needed.
Maintenance Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots. 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs for inspection.
Maintenance • Signs of wear on edges or outer surfaces of belt 62878 Engine Oil Changing the Oil Filter 62880 Oil filter 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 is in the full tilt position.
Maintenance 2. Remove the top cowl and remove the oil filter drain hose from it's storage location on the front of the engine. 64178 Oil filter drain hose 3. Tilt the engine up and lock the outboard in the full tilt position. Allow a few minutes for the oil in the filter to drain into the engine. 4. Route the oil filter drain hose into an approved container. a - Drain hose storage location b - Drain hose b a 64179 5. Remove the oil filter by turning the filter counterclockwise.
Maintenance 5. Inspect the drain plug seal and replace it if damaged. Lubricate the seal on the drain plug with oil and install. Tighten to the specified torque. 63034 4537 Description Nm lb‑in. lb‑ft Drain plug 24.0 – 17.7 Filling the Crankcase with Oil IMPORTANT: Do not try to fill the oil level to the top of the operating range (upper hole). The oil level is correct as long as it appears in the operating range between the upper and lower hole. 1.
Maintenance • One anode is mounted on the starboard side of the midsection, just above the anti‑ventilation plate. A screw and nut secure the anode to the midsection. 62958 • One anode is located on the underside of the lower engine mount. A screw secures it to the mount. 63263 • Two anodes are located near the bottom 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.
Maintenance Propeller Replacement ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. Removal 1. Remove the spark plug leads to prevent the engine from starting. 26899 2.
Maintenance Installation 1. Apply Extreme Grease or 2‑4‑C with PTFE to the propeller shaft. 31927 Tube Ref No. 95 Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 2. Install the front thrust hub onto the shaft so that the larger diameter end is facing the propeller. 3. Install the propeller, rear thrust washer, and propeller nut onto the shaft. 4.
Maintenance 1. Position a clean drain pan under the gear housing and remove the fill and vent screws with gaskets from the gear housing. a a - Vent screw b - Fill screw b 64165 2. 3. Inspect the gear lubricant for metal particles. Presence of a small amount of fine metal particles resembling powder indicates normal wear. Presence of larger particles or a large quantity of fine particles indicates a need for gear housing disassembly and component inspection. Note the color of the gear lubricant.
Maintenance 5. Remove the lubricant tube and install the cleaned fill/drain plug and new sealing washer. Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref No. 95 • Description Where Used Part No.
Maintenance ! WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. 2. Lubricate the following with lightweight oil. Steering link rod pivot points ‑ Lubricate points. • 63287 3. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref No. 95 • Description Where Used Part No.
Maintenance Protecting External Outboard Components • Lubricate all outboard components listed in the Inspection and Maintenance Schedule, preceding. • Touch‑up any paint nicks. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. 120 Description Corrosion Guard Where Used Part No.
Maintenance • The port side lower cowl has two bumpers to help reduce damage to the cowl when the engine is stored 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 of the top cowl also.
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General Information Important Information 1 C 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 ................................................................................
General Information Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. Model Number a b XXXXXXX abcd- Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) Serial Number XXXXX XX XXXX XXX HP XXX KW XXX LB XXX KG XXX Me rc ury Marine d Brunswick Corp.
General Information Engine Component Identification ‑ Manual Start Model 15/20 FourStroke EFI Manual Start Front View e d c f b a Tiller model shown a - Warning light b - Throttle cable (one of two) c - Recoil handle d - Air 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 - Tiller handle tilt lock lever o - Control cable from tiller han
General Information 15/20 FourStroke EFI Manual Start Starboard View i j k l h m g f n d e d c o p b a 62791 Tiller model shown, remote control model similar a - Oil drain screw b - Water pump indicator c - Vapor separator tank (VST) assembly d - Fuel injector (2) e - Fuel rail f - Fuel rail service port with cap g - Throttle body h - Throttle position sensor (TPS) connector ijklmnop- NOTE: The TPS is behind (on the port side of) the throttle body.
General Information 15/20 FourStroke EFI Manual Start Port View c d e f g h i b a j k l j m n 62792 Tiller model shown, with air box and recoil starter removed a - Engine control module (ECM) b - Diagnostic connector 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 pressure switch n - Flush connector 90-8M0125265 eng NOVEMBER
General Information 15/20 FourStroke EFI Manual Start Aft View f g h e i d j c k Tiller model shown a - Idle exhaust port b - Spark plug cap (2) c - Crankcase ventilation hose d - Camshaft gear cover/vent tank e - 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 pump (behind driveshaft housing covers and cowl latch) b l a 6279
General Information Engine Component Identification ‑ Electric Start Model 15/20 FourStroke EFI Electric Start Front View Remote control (RC) model shown, with control cables and steering hardware removed a - Carry handle 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 14‑pin connector j - Fuel line connector k - Power tilt pump wires l - S
General Information 15/20 FourStroke EFI Electric Start Starboard View j k i h l g m f d e d c b a 63009 Remote control (RC) model shown a - Oil drain screw b - Water pump indicator hose c - Vapor separator tank (VST) assembly d - Fuel injector (2) e - Fuel rail f - Fuel rail service port with cap g - Throttle body h - Throttle position sensor (TPS) connector ijklm- NOTE: The TPS is behind (on the port side of) the throttle body.
General Information 15/20 FourStroke EFI Electric Start Port View g h i j k l f m e d n c b a o p q r 63010 Remote control (RC) model shown a - Engine control module (ECM) b - Oil filter c - 15‑amp fuse housing d - Diagnostic connector e - Starter solenoid f - Crankshaft position sensor (CPS) g - Tilt up relay (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 -
General Information 15/20 FourStroke EFI Electric Start Aft View g f e h i j d c k b Remote control (RC) model shown a - Idle exhaust port b - Spark plug cap (2) c - Crankcase ventilation hose d - Camshaft gear cover/vent 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 k - Oil fill cap l - Fuel hose from fuel pump (behind cowl) l a 6
General Information Following Complete Submersion Engine Submerged while Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. After the engine is recovered, remove the spark plugs. If the engine fails to turn over freely when turning the flywheel, the possibility of internal damage (bent connecting rod or bent crankshaft) exists. The powerhead must be disassembled for inspection.
General Information Methanol and Ethanol Fuel Blends IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).
General Information 1. Sand the entire area to be painted with 3M™ 120 Regalite™ Polycut™ or coarse Scotch‑Brite™ disc or belts. 2. Feather the edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG DX330 Wax and Grease Remover or equivalent (xylene or M.E.K.). 4. If bare metal has been exposed, use Mercury Light Gray Primer. 5. Allow a minimum of one hour dry time and no more than one week before applying the finish coat. 6.
General Information ! WARNING Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure that the work area is properly ventilated and wear protective eyewear, clothing, and respirators. 1. Wash and degrease the cowl with a water‑based cleaning solution. Simple Green® Aircraft & Precision Cleaner or Stewart Systems EkoClean are suggested at a 10:1 mix ratio with clean water. Rinse with clean water. 2.
General Information Oxides of Nitrogen – NOx NOx is a slightly different by‑product of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine's combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog.
General Information The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following location: EPA INTERNET WEB SITE: http://www.epa.gov/otaq/marinesi.
General Information Shipping of Hazardous Material (HazMat) and Engine/Components Containing Hazardous Material Outboard Service Bulletin 2008‑07 There are a number of United States regulations regarding the shipment of hazardous material. These regulations apply not only to shipments within the United States, but to import and export shipments as well. It is important to comply with all of these regulations.
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Outboard Installation Important Information 1 D Section 1D - Outboard Installation Table of Contents Start in Gear Protection..................................................... 1D-2 Lifting the Outboard........................................................... 1D-2 Installing Outboard.............................................................1D-2 Boat Transom Height Requirement............................ 1D-2 Installing Outboard on Transom.................................
Outboard Installation Lubricants, Sealants, Adhesives Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Steering cable end 92-802859A 1 Start in Gear Protection ! WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting in gear.
Outboard Installation This product must be secured to the transom with the required mounting hardware. If the outboard strikes an underwater object, the required mounting hardware prevents the outboard from propelling off the transom. A decal on the swivel bracket reminds the installer of the potential hazard. WARNING Avoid serious injury or death. Secure engine to transom with bolts. 37-896853-007 52375 1. Place the outboard on the centerline of the transom. 27005 2.
Outboard Installation Steering Cable Installation 1. Lubricate the entire cable end with Mercury or Quicksilver 2‑4‑C with PTFE. 28722 Tube Ref No. 95 Description 2-4-C with PTFE 2. Insert the steering cable into the tilt tube. 3. Tighten the steering cable nut to the specified torque. 4. Thread the steering cable seal onto the end of the tilt tube. Where Used Part No. Steering cable end 92-802859A 1 a - Steering cable nut b - Steering cable seal a b 63262 Description Nm lb‑in.
Outboard Installation Assemble the steering link rod to the engine with bolt, locknut, spacer, and flat washers. Tighten the locknut to the specified torque. d b e c b b a abcdef- Bolt Flat washer Spacer Nylon insert locknut Steering bracket Nylon insert locknut ‑ tighten until it seats, then back off 1/4 turn f 63289 Description Nylon insert locknut "d" Nm lb‑in.
Outboard Installation 2. Position the remote control handle into neutral. 3. Attach the shift cable to the shift lever with a washer and bow‑tie retainer. 4. Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle. a b abcd- d Bow‑tie retainer Flat washer Shift cable Cable barrel c 63123 5. Check shift cable adjustments as follows: a. Shift the remote control into forward.
Outboard Installation c. Make a center mark (c), midway between marks (a and b). Align the end guide with this center mark when installing the cable onto the engine. a b c 6098 3. Attach the throttle cable end guide to the throttle lever with a washer and bow‑tie retainer. 4. Adjust the cable barrel so the installed throttle cable will maintain alignment. 5. Position the throttle cable into the barrel receptacle. abcd- a c d b 6.
Outboard Installation Battery Connections Connecting Outboard Battery Cables First, connect the red battery cable to the (+) positive battery terminal and then 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 battery cable from the (+) positive terminal.
General Troubleshooting Important Information 1 E Section 1E - General Troubleshooting Table of Contents Conditions Affecting Performance..................................... 1E-2 Bottom of Boat ........................................................... 1E-2 Cavitation....................................................................1E-2 Detonation.................................................................. 1E-3 Elevation, Weather, and Climate................................
General Troubleshooting Lubricant, Sealant, Adhesives Tube Ref No. 25 Description Liquid Neoprene Where Used Part No. All ring terminal connections 92- 25711 3 Special Tools Cylinder Leakage Tester Snap‑On EEPV309A Aids in checking cylinder leakdown. 11604 CDS G3 Diagnostic Tool Kit 8M0114141 Interfaces CDS G3 software to SmartCraft network. NOTE: This kit includes download instructions and a license key.
General Troubleshooting Detonation Detonation in a 4‑cycle engine resembles the pinging heard in an automobile engine. It can be otherwise described as a tin‑like rattling or plinking sound. Detonation is the explosion of the unburned fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine. These shock waves often find or create a weakness: the dome of a piston, cylinder head or gasket, piston rings or piston ring lands, piston pin, and roller bearings.
General Troubleshooting • Generally increases speed and engine RPM • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane • At extremes, can cause the boat to porpoise Shifting weight to front (bow): • Improves ease of planing • Improves rough water ride • At extremes, can cause the boat to veer back and forth (bow steer) Compression Check 1. Remove spark plugs. 2. Install compression gauge in spark plug hole. 3.
General Troubleshooting Guardian Protection System The Guardian Protection System monitors critical engine functions and will reduce engine power accordingly in an attempt to keep the engine running within safe operating parameters. IMPORTANT: The Guardian Protection System cannot guarantee that powerhead damage will not occur when adverse operating conditions are encountered.
General Troubleshooting If a caution state is detected, the warning system will sound the horn for six one‑second intervals, and then remain silent. The warning light will flash six times, in sync with the horn, and then will repeat every five minutes.
General Troubleshooting Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRA Gray GRN Green ORN Orange PNK Pink PPL Purple RED Red TAN Tan WHT White YEL Yellow LT Light DK Dark Warning System Wiring Diagram 18 1 a 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 a - Engine control module (ECM) b - Warning horn c - Warning light b BLU YEL J6 2 YEL 4 BLU 33 LT GRN J1 1 2 WHT/RED 1 2 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 J1
General Troubleshooting This manual assumes that you have successfully installed CDS G3 on your computer and have updated it to the most current version. For installation instructions, refer to the user manual loaded onto the computer diagnostic system laptop (in the Windows® Start menu > All Programs > Mercury Marine > User Manual). Connecting CDS G3 CDS G3 Diagnostic Tool Kit 1. 2. 8M0114141 Insert the CDS G3 SmartCraft diagnostic interface USB connector into a USB port on your computer.
General Troubleshooting CDS G3 Cable Kit 8M0137534 • CDS G3 requires the technician to select the specific engine to which it is connected. Accurate engine identification is important, because in many cases, the available testing options depend on the engine identified. • The diagnostic cable connection supplies power to the ECM. • Fault codes can be displayed active or historic. View Faults displays the code number, description, and the source of the faults.
General Troubleshooting CDS G3 Diagnostics Screen Use the Diagnostics screen to confirm proper operation of various system components. To perform one of the listed diagnostics, click the appropriate button, and follow the on‑screen instructions.
General Troubleshooting Engine Control Module Pinout Connector 34 17 18 1 64636 Pin Wire Color Function 1 Orange Ignition coil 2 Yellow Warning horn 3 Black/red Stator coil H 4 Blue 12 VDC 5 Blue Stator coil L 6 Green/orange MAP sensor 7 Red/white Sensor power 5 VDC 8 Red/white CPS (signal) 9 Black CPS (ground) 10 Black Ground 11 White Diagnostics (Rx) 12 Red/white Communication power 5 VDC 13 Red Battery input (diagnostics) 14 Blue Boot mode 15 Black/gree
General Troubleshooting For CDS G3 users this means that instead of seeing a fault such as INJ1_OutputFault, the fault will now appear as 201 (Fuel injector circuit 1), 16 (The ECU has detected a problem when trying to output a signal to this device.).
General Troubleshooting Fault Code Type Code Code Description Type Description Possible Root Cause 511 13 Intake manifold air temperature Lost communication with device. Faulty TMAP sensor 541 22 Seawater temperature Relative to a specified threshold, the value is too high. Faulty ECT sensor 621 5 System voltage The signal received is valid but is lower than the expected range.
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Ignition Electrical Section 2A - Ignition 2 Table of Contents Ignition Specifications at 20 °C (68 °F).............................. 2A-2 Ignition Theory of Operation ............................................. 2A-3 General Troubleshooting................................................... 2A-3 Engine Control Module (ECM)........................................... 2A-3 ECM Systems Control Matrix......................................2A-4 Troubleshooting...................................................
Ignition Lubricants, Sealants, Adhesives Tube Ref No. Description 6 Dielectric Grease 9 Loctite® 567 PST Pipe Sealant Where Used Part No. Oil pressure switch electrical connection 92-823506 1 Threads of the oil pressure switch 92-809822 Special Tools CDS G3 Diagnostic Tool Kit 8M0114141 Interfaces CDS G3 software to SmartCraft network. NOTE: This kit includes download instructions and a license key.
Ignition Parameter Specification ECM RPM limiter (Guardian) 2800 RPM Overtemperature 85 °C (185 °F) Low oil pressure (over 10 seconds) 26.3 kPa (3.8 psi) Crankshaft position sensor Ignition coil 148–222 Ω Primary 0.26–0.35 Ω Secondary (with plug wires and caps) 16.8–20.2 kΩ Spark plug lead (without spark plug cap) 3.0–7.5 kΩ Ignition Theory of Operation The ignition system uses a microcomputer‑controlled capacitor discharge ignition (CDI) system.
Ignition ECM Systems Control Matrix ECM Control Item Description Ignition timing Controls the optimum ignition timing according to the current operating conditions Fuel injection Controls the fuel injection pulse width (duration) for optimum efficiency according to current operating condition Idle air control (IAC) Stabilizes the engine RPM when idling and during quick engine RPM deceleration by managing the duty cycle driving the IAC in order to control bypass air entering the intake manifold Tach
Ignition Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRA Gray GRN Green ORN Orange PNK Pink PPL Purple RED Red TAN Tan WHT White YEL Yellow LT Light DK Dark Sensors Crankshaft Position Sensor The crankshaft position sensor (CPS) is a hall effect switch, which senses the collapse of a magnetic field. The CPS is located at the top of the cylinder block, next to the flywheel.
Ignition Crankshaft Position Sensor Test With the engine not running, disconnect the CPS from the engine harness, and measure the sensor's resistance with a DMT 2004 Digital Multimeter, or equivalent. 33966 DMT 2004 Digital Multimeter 91‑892647A01 Meter Test Leads Red Black Red/white Black Meter Scale Reading Ω 148–222 Ω CPS Removal 1. Remove the air box and recoil starter. • It is easiest to remove and install these two items together.
Ignition Engine Coolant Temperature (ECT) Sensor The engine coolant temperature sensor is located at the top of the cylinder block. The ECT sensor monitors the temperature of the cooling water that has passed through the engine as controlled by the thermostat. The ECM uses the data from the ECT sensor in its calculations for the amount of fuel to inject into the combustion chamber to achieve optimum fuel economy, based on the engines RPM.
Ignition 3. Measure the resistance when the specified temperature is reached. If out of specification, replace the sensor. DMT 2004 Digital Multimeter 91‑892647A01 a - Engine coolant temperature sensor a 22587 Meter Test Leads Red Black Black/blue Green/yellow Meter Scale Temperature Reading 5 °C (41 °F) 4.24 kΩ–4.86 kΩ Auto 25 °C (77 °F) 1.90 kΩ–2.10 kΩ 100 °C (212 °F) 166 Ω–204 Ω ECT Sensor Installation 1. With a new O‑ring in place, thread the ECT sensor into the engine.
Ignition Oil Pressure Switch The oil pressure switch is located at the bottom port side of the powerhead. It is a pressure sensitive switch that will show either continuity or no continuity. 21122 If the engine oil pressure drops below 24.5 kPa (3.5 psi) for more that 0.5 seconds, the ECM will limit engine power, generate a failure code, and complete the circuit for the warning horn and warning light, informing the operator of potential engine damage.
Ignition 2. Using a controllable air pressure source, apply air pressure to the oil pressure switch. Check for continuity specifications. 3119 Meter Test Leads Red Black Switch terminal Switch body Meter Scale Applied pressure Reading Resistance Auto 24.5 kPa (3.55 psi) or higher Open 0 kPa (0 psi) Continuity Installation 1. Apply Loctite® 567 PST Pipe Sealant to the threads of the oil pressure switch. Tube Ref No. 9 2. 3. 4. Loctite® 567 PST Pipe Sealant Where Used Part No.
Ignition The temperature and manifold absolute pressure (TMAP) sensor combines the manifold absolute pressure sensor and manifold air temperature sensor into a single unit. The TMAP sensor is positioned in the throttle body, downstream of the throttle plate.
Ignition Throttle Position Sensor (TPS) The throttle position sensor (TPS) is located on the throttle body and is in direct contact with the throttle shaft. The TPS transmits throttle angle information to the ECM, which regulates the fuel injector volume (pulse width) and ignition timing. 63004 TPS Replacement To replace the TPS: 1. Remove the throttle body from the engine. Refer to Section 3C ‑ Throttle Body Removal. 2.
Ignition Ignition Components Flywheel The flywheel is weighted and balanced to improve engine running characteristics. The flywheel is secured to the crankshaft with a washer and nut. The flywheel has a ring gear that is used with the optional starter motor to start the engine electrically. The top of the flywheel is cast with notches to engage the recoil starter, for manual starting. Below the ring gear, the flywheel is cast with a timing key.
Ignition Flywheel Installation 1. Inspect the flywheel key. Replace if required. Place the flywheel key into the crankshaft keyway. a a - Flywheel key 33838 2. Align the flywheel key with the flywheel slot. 3. Carefully install the flywheel. 4. While pushing down on the flywheel, rock the flywheel back and forth to ensure that the flywheel key has not fallen out of the crankshaft keyway. 5. Install the washer and flywheel nut. 6.
Ignition Ignition System Wiring Diagram 18 1 a 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ORN BLK 1 ORN 3 BLK/RED 5 BLU 10 BLK BLK/RED BLU c BLK/RED BLU WHT YEL J4 d 34 17 abcd- b BLK 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 62886 ECM Ignition coil Stator (white and yellow wires are not part of the ignition circuit) Ground Stator Resistance Test IMPORTANT: Perform this test with the engine not running. NOTE: Readings may vary slightly due to temperature changes.
Ignition 5. Remove the three screws that secure the stator to the coil bracket. Remove the stator. a a - Screws (3) 10117 Stator Installation 1. Install the stator with the stator wires facing toward the front starboard side of the engine. 2. Secure the stator to the coil bracket with three screws. Tighten the screws to the specified torque. a a - Screws (3) 10117 Description Nm lb‑in. lb‑ft Stator screws 6.0 53.1 – 3.
Ignition Timing Belt Installation Ensure that the timing marks on the crankshaft drive gear and the camshaft driven gear are still aligned with the corresponding marks on the engine. a c b d 2 1 1. e 63876 Timing marks (shown with starter bracket removed, for clarity) a - Crankshaft drive gear timing mark b - Timing mark on the cylinder block for the crankshaft c - Timing mark on the cylinder block for the camshaft d - Timing mark for #1 cylinder e - Timing mark for #2 cylinder 2.
Ignition Primary Coil Resistance Disconnect the coil leads from the engine harness, and measure the resistance of the primary coil with a DMT 2004 Digital Multimeter or equivalent. 33964 DMT 2004 Digital Multimeter 91‑892647A01 Meter Test Leads Red Black Orange Black Meter Scale Reading Ω 0.26–0.35 Ω Secondary Coil Resistance 1. Remove the spark plug leads from the spark plugs. 2. Measure the resistance between the two high tension leads (spark plug boots). 65049 Meter Test Leads 3.
Ignition 4. Remove the two screws that secure the ignition coil to the engine, and remove the coil. e d c abcdef- Ignition coil Screw (2) Cable tie Orange and black coil input wires Spark plug wire (2) Clip on upper spark plug wire (2) f b b a e 62968 Installation 1. Install the ignition coil onto the engine using two screws. Tighten the screws to the specified 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.
Ignition Notes: Page 2A-20 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Charging and Starting Systems Electrical Section 2B - Charging and Starting Systems 2 Table of Contents Charging and Starting Specifications.................................2B-2 General Troubleshooting................................................... 2B-2 Starter Motor Components.................................................2B-4 Starter Motor and Solenoid Electrical Components........... 2B-6 Wire Color Code Abbreviations..........................................2B-8 Charging System.................
Charging and Starting Systems Lubricant, Sealant, Adhesives Tube Ref No. 80 Description SAE® Engine Oil 30W Where Used Part No. Starter end cap bushing Armature shaft Starter armature shaft, and helix Obtain Locally Special Tools DMT 2004 Digital Multimeter 91‑892647A01 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.
Charging and Starting Systems Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 2B-3
Charging and Starting Systems Starter Motor Components 2 1 3 5 4 6 10 11 12 14 13 9 8 7 33809 Page 2B-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Charging and Starting Systems Starter Motor Components Torque Ref. No. Qty. Description 1 1 2 1 Pinion assembly 3 1 Washer 4 1 Brush card 5 2 Screw (M4 x 8) 6 1 Bushing 7 2 Screw 8 2 Lockwasher 9 2 Washer 10 1 O‑ring 11 1 Bushing 12 1 Washer 13 2 Lockwasher (M6) 14 2 Nut Nm lb‑in. lb‑ft 1.5 13.3 – 6.0 53.1 – 4.0 35.
Charging and Starting Systems Starter Motor and Solenoid Electrical Components 1 1 2 5 16 6 15 14 3 4 7 13 8 9 10 12 11 Page 2B-6 64407 10 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Charging and Starting Systems Starter Motor and Solenoid Electrical Components Torque Ref. No. Qty.
Charging and Starting Systems Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRA Gray GRN Green ORN Orange PNK Pink PPL Purple RED Red TAN Tan WHT White YEL Yellow LT Light DK Dark Charging System e 15A 20A 1 2 1 2 RED RED a d RED RED Charging System Wiring Diagram g h f b c RED RED RED WHT YEL WHT YEL BLU BLK/RED BLK GRN BLK J5 62916 abcdefgh- Battery Positive battery cable Starter solenoid 15‑amp fuse 20‑amp fuse Eng
Charging and Starting Systems • Check for loose or corroded battery connections. • Visually inspect the wiring between the stator and battery for cuts, chafing, loose, corroded, or disconnected connection. • Excessive electrical load from too many accessories will cause battery to run down. Testing the Stator Charge Windings NOTE: The test readings listed were taken at 20 °C (68 °F). NOTE: The stator windings can be tested with the stator mounted to the engine. 1.
Charging and Starting Systems DMT 2004 Digital Multimeter 91‑892647A01 NOTE: Due to manufacturing differences, meter internal polarity may vary from manufacturer to manufacturer. As a result, the test readings may be a direct reversal of the readings specified. If so, reverse the meter leads and perform the test again. A slight variance from the listed specification does not necessarily indicate a defective component.
Charging and Starting Systems Starting System Starting System Description The battery supplies energy to spin the starter motor. When the start button or key switch is activated, the starter solenoid is energized and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when the engine is in gear.
Charging and Starting Systems Starting System Wiring Diagrams Use these wiring diagrams in conjunction with the Starting System Troubleshooting Chart, following. The numbers indicate test points identified in the troubleshooting chart.
Charging and Starting Systems Starting System Troubleshooting Chart Location of test points (TP) called out in the chart are numbered in the preceding diagrams. DMT 2004 Digital Multimeter 91‑892647A01 Starter Does Not Work Test Number Procedure Reading: Action Continuity: The ground connection is good. Proceed to Test 2. Test 1 – Test the ground connection: Connect the leads of an ohmmeter (R x 1 scale) between the negative (–) battery post (TP1) and a common powerhead ground. 1.
Charging and Starting Systems Starter Motor Removal 1. Disconnect the battery cables from the battery. 2. 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 and Section 8A ‑ Recoil Starter. 3. Move the rubber boot out of the way, and remove the positive lead from the starter. 4. Remove the negative lead from the starter.
Charging and Starting Systems 6. Remove the armature from the bottom end cap. Do not lose the thrust washer on end of armature. b c e d abcde- a Armature Top end cap Field frame Starter motor support insulator Bottom end cap 10504 7. Remove the nut securing the power stud to the end cap insulator. 8. Remove the two screws securing the brush card to the end cap. Remove the brush card.
Charging and Starting Systems 4. Assemble the power stud O‑ring, insulator, washer, lockwasher, and nut onto the power stud. Tighten the nut to the specified torque. a abcdefg- b c d e f g End cap Power stud Power stud O‑ring Insulator Washer Lockwasher Power stud nut 10508 Description Nm lb‑in. lb‑ft Power stud nut 4.0 35.4 – 5. Insert a starter assembly screw through the end cap to ensure the brush card alignment. 6. Tighten the brush card screws to the specified torque.
Charging and Starting Systems 10. Lubricate the end cap bushing with a drop of SAE® Engine Oil 30W. b a abcd- c Brush spring Drill bit Brush card End cap bushing b d Tube Ref No. 80 10520 Description SAE® Engine Oil 30W Where Used Part No. Starter end cap bushing Obtain Locally 11. Insert the armature into the end cap. Ensure the armature is seated in end cap. 12. Remove the two drill bits to engage the brushes to the commutator. 13. Install the field frame to the end cap.
Charging and Starting Systems 16. Install two starter assembly screws. Tighten the screws to the specified torque. 10502 Description Nm lb‑in. lb‑ft Starter assembly screw 6.0 53.1 – 17. Lubricate the armature shaft and helix with SAE Engine Oil 30W. 10541 Tube Ref No. 80 Description SAE® Engine Oil 30W Where Used Part No. Starter armature shaft, and helix Obtain Locally 18. Install the starter bendix, bendix spring, and pinion stopper. Secure the starter bendix assembly with a circlip.
Charging and Starting Systems 7. Description Nm lb‑in. lb‑ft Starter motor cable nuts (2) 4.0 35.4 – Cover the positive electrical connection with the red rubber boot. Some items shown removed for clarity a - Positive cable with rubber boot covering the connection b - Isolator bracket screw (2) d d NOTE: The port side isolator bracket screw is not shown in this view.
Charging and Starting Systems Notes: Page 2B-20 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Fuel System Operation Fuel System Section 3A - Fuel System Operation Table of Contents Theory of Operation........................................................... 3A-2 Air Induction System...................................................3A-2 Fuel System................................................................3A-2 Fuel Pump.................................................................. 3A-2 Vapor Separator Tank................................................ 3A-2 Throttle Body...............
Fuel System Operation Theory of Operation Air Induction System The air induction system consists of an intake manifold with an intake runner to each cylinder for a smooth air flow to the combustion chamber. Each runner has a single fuel injector controlled by the ECM. The fuel injector has several very small holes in the fuel injector nozzle tip, to help atomize the fuel when injected into the runner as the cylinder intake valve opens.
Fuel System Operation A fuel cooler is integrated within the lower housing of the VST. 62987 Throttle Body The throttle body is connected to the intake manifold. It controls the amount of air that is allowed into the intake manifold. The throttle body affects the manifold absolute pressure (MAP). When the throttle body valve is closed (idle), the air pressure inside the intake manifold is in a vacuum state.
Fuel System Operation Troubleshooting For troubleshooting information, refer to: • • Section 1E ‑ Accessing ECM Information with CDS G3 The appropriate engine wiring diagram in Section 9A ‑ Color Diagrams Additional Information For additional information on the ECM, including removal and installation procedures, refer to Section 2A ‑ Engine Control Module (ECM). Sensors This engine uses sensors to monitor various aspects of engine operation.
Fuel System Operation • Functions as an electronic dashpot by providing additional bypass air as the throttle quickly closes during a rapid deceleration, preventing engine stalling. 62991 Fuel Injector The fuel injector is an electrically‑operated, spring‑loaded solenoid that delivers a metered amount of fuel into the intake manifold runner, just ahead of the intake valve. The injectors are electrically charged by the ECM through the stator assembly when the flywheel starts to rotate.
Fuel System Operation Notes: Page 3A-6 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Troubleshooting and Diagnostics Fuel System Section 3B - Troubleshooting and Diagnostics Table of Contents General Troubleshooting................................................... 3B-2 Testing Fuel System Inlet Vacuum.................................... 3B-2 Fuel Pressure Test.............................................................3B-2 90-8M0125265 eng NOVEMBER 2017 Wire Color Code Abbreviations..........................................3B-3 Fuel System Wiring Diagram..............................
Troubleshooting and Diagnostics Special Tools Fuel Pressure Gauge Kit 91‑881833A03 Tests the fuel pump pressure; can be used to relieve fuel pressure. 2807 Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1 Tests fuel and air pressure; the dual gauges allow the viewing of both pressures simultaneously. 5822 General Troubleshooting For general troubleshooting information, including connecting and using the CDS G3 diagnostic tool, refer to Section 1E ‑ General Troubleshooting.
Troubleshooting and Diagnostics 2. Start the engine. The fuel pressure should be within specification. 62834 Fuel Pressure Specification All operating conditions 256 ± 25 kPa (37.1 ± 3.
Troubleshooting and Diagnostics Sensor Wiring Diagram 18 1 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 34 17 1 2 3 RED/WHT BLU/WHT BLK/BLU c 1 2 BLK/BLU GRN/YEL 1 2 3 4 GRN/WHT RED/WHT BLK/BLU GRN/ORN 1 2 3 15/20 EFI sensor wiring diagram a - Temperature and manifold absolute pressure (TMAP) sensor b - Throttle position sensor (TPS) c - Engine coolant temperature (ECT) sensor d - Crankshaft position sensor (CPS) e - Engine control module (ECM) J
Service Procedures Fuel System Section 3C - Service Procedures Table of Contents Fuel System Specifications................................................3C-2 Fuel System Components................................................. 3C-4 Vapor Separator Tank Components.................................. 3C-6 Air Intake Components...................................................... 3C-8 Fuel Lift Pump..................................................................3C-10 Fuel Lift Pump Removal ............
Service Procedures Special Tools Fuel Pressure Gauge Kit 91‑881833A03 Tests the fuel pump pressure; can be used to relieve fuel pressure. 2807 Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1 Tests fuel and air pressure; the dual gauges allow the viewing of both pressures simultaneously. 5822 Clamp Tool 91‑803146T Used to clamp high‑pressure (Oetiker®) hose clamps. Part of Clamp Tool Kit (91‑803146A04).
Service Procedures Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 3C-3
Service Procedures Fuel System Components 4 17 16 5 26 18 19 6 7 21 20 8 22 2 1 9 3 2 21 27 10 1 23 20 24 25 28 11 28 29 15 13 14 10 30 11 30 31 32 9 12 32 33 34 35 36 36 37 38 40 39 41 42 43 42 44 64410 Page 3C-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Service Procedures Fuel System Components Torque Ref. No. Qty.
Service Procedures Vapor Separator Tank Components 4 2 4 3 1 5 6 7 8 9 11 10 12 13 14 15 16 23 17 18 23 22 19 21 20 Page 3C-6 © 2018 Mercury Marine 64412 90-8M0125265 eng NOVEMBER 2017
Service Procedures Vapor Separator Tank Components Torque Ref. No. Qty.
Service Procedures Air Intake Components 9 8 7 10 11 6 5 2 3 1 4 12 13 16 2 14 1 15 17 19 18 14 15 64529 Page 3C-8 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Service Procedures Air Intake Components Torque Ref. No. Qty. Description Nm lb‑in. lb‑ft 1 2 Washer 2 2 Screw 6.0 53.1 – 3 4 1 Screw 6.0 53.1 – 1 Air box 5 1 Hose 6 1 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 Breather hose 17 1 Hose clamp 18 2 Nut 6.0 53.
Service Procedures Fuel Lift Pump Fuel Lift Pump Removal ! WARNING Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components. ! WARNING Fuel is flammable and explosive.
Service Procedures 4. Install the driveshaft housing covers. Refer to Section 5A ‑ Driveshaft Housing Covers. Be certain to tighten the screws to the specified torque. Description Nm lb‑in. lb‑ft Driveshaft housing cover screws (11) 6.0 53.1 – Vapor Separator Tank (VST) VST Removal ! WARNING Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting.
Service Procedures 7. Remove the hose clamp securing the low‑pressure fuel supply hose to the assembly. c b a a - Hose clamp securing the low‑pressure fuel supply hose b - High‑pressure fuel pump wire harness connector c - Screws (2) d - VST drain screw e - VST drain hose d e 62923 8. Disconnect the fuel cooler water supply and water pump indicator hoses from the fittings located in the driveshaft housing. a - Water pump indicator hose fitting b - Fuel cooler water supply hose fitting a b 62924 9.
Service Procedures VST Disassembly 1. Remove the four screws that secure the two halves of the VST assembly. Be careful to not spill any fuel that may remain in the tank. Empty any fuel into an appropriate container and dispose of it according to local regulations. 63127 2. Gently pull on the high‑pressure fuel pump to remove it from the cover. 3. Remove the float pin from the assembly. The float and the fuel inlet needle will come free.
Service Procedures 8. Remove the seal from the cover, and discard. a - Clip b - Seal a b 63134 VST Reassembly 1. Ensure that the O‑ring is in place on the fuel pump electrical connector, feed the red, yellow, and white wires through the opening on the top of the VST cover, and firmly seat the connector in position. NOTE: When viewing the electrical connector from the terminal side, the clockwise order of the wires should be white, yellow, and red.
Service Procedures NOTE: When viewing the fuel pump electrical terminals from the top, the clockwise order of connection is white, yellow, and red. abcde- Wires routed outside of screw boss White wire spade terminal Yellow wire spade terminal Red wire spade terminal O‑ring c d a b e 63139 7. Insert the fuel inlet needle into the VST cover, place the float in position, and secure it with the float pin. 8.
Service Procedures 2. Remove the seal. a c b d e f 63140 abcdef- Screw (4) Fuel cooler cover Seal Cooling water chamber Water outlet (water pump indicator hose) Water inlet VST Installation 1. Feed the water pump indicator hose and the fuel cooler supply hose through their respective 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.
Service Procedures 4. Connect the fuel cooler water supply and water pump indicator hoses to the fittings located in the driveshaft housing. a - Water pump indicator hose fitting b - Fuel cooler water supply hose fitting a b 62924 5. Attach the low‑pressure fuel supply hose to the VST assembly, and secure it with a hose clamp. 6. Attach the VST assembly to the cylinder block with two screws. Tighten the screws to the specified torque. Description Nm lb‑in. lb‑ft VST mounting screws 6.0 53.
Service Procedures 4. Lift the cover assembly to remove it from the two pins that secure it to the engine. a abcdef- b Pin (2) Crankcase breather hose VST hose with white mark VST hose without white mark Clip Vent hose c f d e 63142 Installation 1. Position the cover assembly onto the engine. Ensure that the grommets do not become dislodged from the cover assembly. 2. Route the crankcase breather hose across the tray and secure it to the valve cover with a spring clamp. 3. 4.
Service Procedures 6. Remove the two nuts securing the throttle assembly to the intake manifold, and remove the throttle body assembly from the intake manifold. 63036 7. Remove the grommet from the throttle body assembly. 8. Remove the idle air control (IAC) valve from the throttle body assembly. 9. Remove the gasket. c a abcd- b Gasket IAC valve Throttle position sensor (TPS) Grommet d 63037 Throttle Body Installation 1. Install a gasket onto the throttle body studs. 2.
Service Procedures • Refer to Section 8A ‑ Recoil Starter and Air Box Installation. a e b abcde- f c Air box Recoil starter assembly IAC valve harness connector Throttle link TPS harness connector d 63035 Fuel Rail Fuel Rail Removal ! WARNING Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting.
Service Procedures 7. Remove the fuel hose from the fuel rail inlet tube. Clean up any spilled fuel after removing the fuel hose. abcd- a Fuel injector harness connectors Fuel rail screws (2) Clamp Oetiker® clamp c b d a 62996 Fuel Rail Disassembly 1. Remove the screw securing the fuel inlet tube to the fuel rail. Remove the fuel inlet tube. 2. Remove the fuel injectors from the fuel rail. a - Screw securing the fuel inlet tube b - Fuel injectors (2) b a 63059 Fuel Rail Reassembly 1.
Service Procedures 5. Secure the fuel inlet tube to the fuel rail with a clamp and screw. Tighten the screw to the specified torque. a - Screw b - Inlet tube clamp b a 11645 Description Nm lb‑in. lb‑ft Screw 6.0 53.1 – 6. Inspect the fuel injector filter screen. 7. NOTE: The fuel injector filter screen is a nonserviceable component, but can be cleared of debris. Install new O‑rings and seals onto the fuel injectors. a - O‑ring b - Seal b a 63291 8.
Service Procedures 6. Connect the fuel injector harness connectors to the fuel injectors. abcd- a Fuel injector harness connectors Fuel rail screws (2) Spacer Oetiker® clamp c b d a 62996 Air Box Air Box Removal 1. Remove the three screws that secure the air box to the engine. 2. Remove the recoil starter assembly. Refer to Section 8A ‑ Recoil Starter. 3. Pull the air box off the end of the throttle body. 4. Disconnect the crankcase breather hose from the air box. 5.
Service Procedures Idle Air Control (IAC) The idle air control (IAC) is an electrically operated, spring‑loaded solenoid valve that controls the amount of air bypassing the closed throttle shutter. Signals from the ECM regulate the duty cycle for which the IAC valve remains open. The duty cycle ranges from 0% to 100% open. IAC Removal 1. Remove the air box. Refer to Air Box Removal. 2. Remove the two screws that secure the IAC to the throttle body assembly, and remove the IAC. 3.
Service Procedures DMT 2004 Digital Multimeter 6. 91‑892647A01 Measure the resistance of the IAC with the DMT 2004 Digital Multimeter tool. The IAC is not polarity sensitive. NOTE: The IAC resistance values are for reference only. Meter Test Leads Red Black Right terminal pin Left terminal pin Meter Scale Reading Auto 21.0–27.0 Ω IAC Installation 1. Apply clean engine oil to the O‑ring on the IAC. 2. Insert the IAC into the throttle assembly, and attach with two screws.
Service Procedures Notes: Page 3C-26 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Block/Crankcase Powerhead Section 4A - Cylinder Block/Crankcase Table of Contents Cylinder Block/Crankcase Specifications...........................4A-2 Piston Specifications..........................................................4A-3 Cylinder Block and Crankcase Components..................... 4A-4 Crankshaft Components.................................................... 4A-6 Powerhead Removal..........................................................4A-8 Cylinder Block Disassembly.............
Cylinder Block/Crankcase Lubricants, Sealants, Adhesives Tube Ref No. Description Where Used Part No.
Cylinder Block/Crankcase Parameter Connecting rod crankshaft pin diameter Specification 29.000–29.013 mm (1.1417–1.1422 in.) Connecting rod crankshaft pin diameter (service limit) Connecting rod side clearance 28.038 mm (1.1432 in.) 0.1–0.25 mm (0.004–0.01 in.) Connecting rod side clearance (service limit) 0.6 mm (0.0236 in.
Cylinder Block/Crankcase Cylinder Block and Crankcase Components 64413 Page 4A-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Block/Crankcase Cylinder Block and Crankcase Components Torque Ref. No. Qty. Description 1 1 2 1 Oil filter fitting 3 1 Hose 4 2 Dowel pin 5 4 Screw (M8 x 50) 6 6 Screw (M6 x 30) 7 6 Washer 8 1 Oil filter 9 1 Lifting eye Nm lb‑in. lb‑ft 30 – 22.1 First 10.0 88.5 – Final 23.5 – 17.3 First 6.0 53.1 – Final 11.5 101.8 – 18.0 159.3 – 13.0 115 – 9.0 79.7 – First 6.0 53.1 – Final 9.0 79.7 – First 15.0 132.7 – Final 30.0 – 22.
Cylinder Block/Crankcase Crankshaft Components 64577 Page 4A-6 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Block/Crankcase Crankshaft Components Torque Ref. No. Qty. 1 2 2 2 3 1 Crankshaft assembly 1 Plain shaft bearing, blue (set of 2) 4 Description Nm lb‑in. lb‑ft First 6.0 53.1 – Final 10.0 88.
Cylinder Block/Crankcase Powerhead Removal ! WARNING Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components. ! WARNING Fuel is flammable and explosive.
Cylinder Block/Crankcase d. Remove the one screw and washer that secures the relay bracket to the stator/starter bracket. b c a - CPS connector b - Screw and washer for 14‑pin connector bracket c - Screws and washers for ground terminals (2 each) d - Screw and washer securing relay bracket to stator/starter bracket d a 63936 e. Remove the four screws and washers that secure the stator/starter bracket to the powerhead, and remove the stator/ starter bracket.
Cylinder Block/Crankcase f. Release the reusable cable tie. abcd- c Fuel pump Fuel pump inlet hose (from fuel filter) Fuel pump outlet hose (to VST) Reusable cable tie d b a 63886 g. Remove the vapor separator tank (VST). Refer to Section 3C ‑ VST Removal. h. Remove the fuel rail. Refer to Section 3C ‑ Fuel Rail Removal. NOTE: It is not necessary to remove the high‑pressure fuel hose that connects the VST to the fuel rail. 11.
Cylinder Block/Crankcase 5. Remove the yellow fuse housing from the electrical bracket and the black fuse housing from its pocket on the ECM. 6. Remove the rubber boot from the oil pressure switch, and remove the single screw that secures the ring terminal to the switch. 7. Remove a single screw to remove the ground terminal from the engine block. NOTE: If you are servicing the cylinder head only, steps 6 through 11 may be skipped.
Cylinder Block/Crankcase 12. Power tilt models: Remove the two remaining screws to remove the tilt relay/start solenoid bracket from the engine. a - ECM bracket screws (2) b - Relay/solenoid bracket screws (2 + 1 previously removed) b a 63941 13. Electric start models: Remove two screws to remove the voltage regulator/rectifier and bracket from the engine. a - Bracket screws (2) b - Voltage regulator/rectifier a a b 63942 Throttle Body Removal 1. Remove two nuts to remove the throttle body. 2.
Cylinder Block/Crankcase 3. Remove the lockwasher, belt guide, timing gear, and timing gear key from the crankshaft. a abcde- b c d Crankshaft Nut Lockwasher Belt guide Timing gear e 63944 Thermostat and Exhaust Cover Removal 1. Remove the oil filter. Be certain to wipe up any spills, and dispose of oil, filter, and oil‑soaked rags according to local regulations. 2. Remove the two screws securing the thermostat cover and electrical bracket. 3. Remove the engine coolant temperature sensor. 4.
Cylinder Block/Crankcase Oil Strainer Removal Remove the oil strainer and hose from the cylinder block. b a - Hose b - Cable tie c - Oil strainer c a 64049 Crankcase and Crankshaft Removal 1. Remove the ten crankcase cover screws and remove the crankcase cover. a - Screw (M8 x 50) (4) b - Screw (M6 x 30) (6) a b 64051 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.
Cylinder Block/Crankcase 5. Remove the crankshaft seals. abcd- a Upper crankshaft seal Cap screw (4) Connecting rod cap (2) Lower crankshaft seal b c d 64146 6. Mark the connecting rod cap screws with paint to identify them as used. 7. Install the connecting rod caps onto their respective connecting rods. Tighten the connecting rod cap screws finger‑tight. b a a - Piston and connecting rod b - Connecting rod cap c - Cap screws c 64147 8.
Cylinder Block/Crankcase 9. Remove the main bearings from the cylinder block and crankcase cover. 64149 Piston Disassembly IMPORTANT: Disassemble each piston separately to ensure the components will not be intermixed. After disassembly, place the components into a container that identifies the cylinder location. 1. Remove the piston pin clips, and piston pin. Separate the connecting rod from the piston. 2. Use a piston ring expander to remove the top ring and the second ring. 3.
Cylinder Block/Crankcase Crankshaft Timing Gear Inspect the crankshaft timing gear and key. Replace if damaged or worn. 3117 Timing Belt Inspect the timing belt. Replace if worn, stretched, or damaged. 3118 Anode Replace the engine water jacket anode if partially consumed. Measuring Cylinder Bore Measure the cylinder walls for taper, out of round, or excessive ridge at the top of the ring travel. This should be done with a cylinder bore dial indicator or an inside micrometer.
Cylinder Block/Crankcase Piston Diameter 1. Measure the piston at a point 9 mm (0.35 in.) from the bottom, 90° to the piston pin. Replace the piston if out of specification. a a - Piston diameter b - Measure point 9 mm (0.35 in.) b 22022 Piston 2. Diameter (standard) 60.96 mm (2.400 in.) Diameter (service limit) 60.90 mm (2.3976 in.) Measure the piston to cylinder clearance. If out of specification examine the piston and cylinder bore further to determine repair/replacement.
Cylinder Block/Crankcase NOTE: The ring must be level for measurement. Push the ring 4 mm (0.157 in.) into the bore with the crown of a piston. a - 4 mm (0.157 in.) a 22024 Piston Ring End Gap Top 0.15–0.30 mm (0.0059–0.0118 in.) Top (service limit) 0.50 mm (0.020 in.) Second 0.35–0.50 mm (0.0138–0.0197 in.) Second (service limit) 0.70 mm (0.028 in.) Oil 0.20–0.70 mm (0.008–0.028 in.) Piston Wrist Pin Measure the piston wrist pin diameter. Replace the piston wrist pin if out of specification.
Cylinder Block/Crankcase Connecting Rod 29.000–29.013 mm (1.1417–1.1422 in.) Crankshaft pin journal diameter Crankshaft pin journal diameter (service limit) 28.038 mm (1.1432 in.) 16.010–16.021 mm (0.6303–0.6307 in.) Piston pin bore diameter Piston pin bore diameter (service limit) 16.025 mm (0.6309 in.) Crankshaft Crankshaft Runout 1. 2. Thoroughly clean the crankshaft and inspect the bearing surfaces. Replace the crankshaft if the bearing surfaces are pitted, scored, or discolored.
Cylinder Block/Crankcase 3. 4. 5. • Main bearing surfaces on the cylinder block and crankcase cover • Main bearings • Crankshaft bearing surfaces Install the main bearing halves into the cylinder block. NOTE: Align each bearing projection with the notch in the cylinder block. Install the crankshaft onto the cylinder block. Place a piece of gauging plastic onto each of the crankshaft bearing surfaces. NOTE: Do not put gauging plastic over the oil hole on the bearing surface of the crankshaft.
Cylinder Block/Crankcase 9. Remove the bolts and the crankcase cover. 10. Measure the gauging plastic at its maximum compressed width. a a - Compressed gauging plastic b - Gauging plastic scale b 11637 11. If the oil clearance is out of specification limit, measure the inside diameter of the cylinder block and crankcase cover main bearing journals. Selecting New Main Bearings 1. Locate the main bearing code on the cylinder block. 2.
Cylinder Block/Crankcase Connecting Rod Oil Clearance Measure the connecting rod oil clearance using the measurement steps outlined following. Connecting Rod Oil clearance 0.015–0.041 mm (0.0006–0.0016 in.) Connecting Rod Oil Clearance Measurement IMPORTANT: Do not interchange connecting rod caps. Reinstall connecting rod caps in their original positions. 1. Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. 2.
Cylinder Block/Crankcase 7. If the oil clearance is out of specification limit, measure the diameter of the connecting rod and crankpin journal. Replace as needed. Powerhead Assembly Piston Assembly 1. Insert the connecting rod into the piston. IMPORTANT: Ensure that the "UP" indicators on the connecting rod and piston are facing the same direction. 2. Lubricate the piston pin with 4‑Stroke 10W‑30 Outboard Oil. 3. Install the piston pin, and secure it with new piston pin clips.
Cylinder Block/Crankcase 2. Lubricate the rings with 4‑Stroke 10W‑30 Outboard Oil, after the rings are installed on the piston. a e b c 110 d 110 T f 45 o 45 o g UP c b a d e h i T 3150 abcdefghi- Top oil control ring Expander Bottom oil control ring Second ring Top ring End gap ‑ Top ring End gap ‑ Bottom oil control ring End gap ‑ Second ring End gap ‑ Top oil control ring Tube Ref No. 110 Description Where Used Part No.
Cylinder Block/Crankcase 5. Ensure the UP mark on the top of the piston is towards the flywheel. Push the piston down into the cylinder bore until the rings have entered the cylinder. a - Piston b - Ring compressor tool firmly seated against the cylinder block a b 21019 Tube Ref No. Description 10W-30 4-Stroke Marine Engine Oil 110 Where Used Part No. Piston, piston rings, and cylinder bore 92-8M0078625 Piston Ring Compressor 6. FT2997 Repeat the procedure for the remaining cylinders.
Cylinder Block/Crankcase Tube Ref No. 110 Description Where Used 10W-30 4-Stroke Marine Engine Oil Part No. Crankshaft seal and main bearing area, crankshaft main and connecting rod journals, connecting rod bearing area, upper 92-8M0078625 and lower oil crankshaft seal lips 4. Carefully place the crankshaft onto the cylinder block main bearings. 5. Ensure the crankshaft seals are parallel with the crankshaft and centered in the seal area of the cylinder block. 6.
Cylinder Block/Crankcase 14. Tighten the bolts to the specified torque in sequence in two steps. 1 2 9 9 5 1 5 8 8 4 2 10 10 6 6 37 7 3 4 64052 Description Main bearing bolts (1–4) (M8 x 50) Crankcase cover bolts (5–10) (M6 x 30) Nm lb‑in. lb‑ft First 10.0 88.5 – Final 23.5 – 17.3 First 6.0 53.1 – Final 11.5 101.8 – Crankshaft Timing Gear Installation 1. Install the timing gear key into the crankshaft. 2. Install the timing gear. 3.
Cylinder Block/Crankcase 4. Install the thermostat, thermostat cover gasket, thermostat cover, and electrical bracket. 5. Tighten all seven screws (five M6 x 25 and two M6 x 50 screws) in the indicated sequence to the specified torque.
Cylinder Block/Crankcase 10. Lubricate the oil filter gasket with clean engine oil. Install the oil filter and tighten to the specified torque. c a - Oil filter b - Thermostat cover/electrical bracket mounting screws c - Engine coolant temperature sensor d - Cylinder head assembly e - Anode f - Exhaust cover g - Oil pressure switch d b e a f g 63992 Description Nm lb‑in. lb‑ft ECT sensor 4.0 35.4 – Anode screw 2.0 17.7 – Anode plug 18.0 159.3 – Oil pressure switch 8.0 70.
Cylinder Block/Crankcase 4. Install the throttle body, and secure it with two nuts and washers. Tighten the nuts to the specified torque. a - Dipstick extension tube screw b - Throttle body nuts a b 63943 Description Nm lb‑in. lb‑ft Dipstick extension tube screw 6.0 53.1 – Throttle body nuts 6.0 53.
Cylinder Block/Crankcase 3. Install the ECM bracket, using two screws with washers. Tighten the screws to the specified torque. a - ECM bracket screws (2) b - Relay/solenoid bracket screws (2 + 1 to be installed later) b a 63941 Description Nm lb‑in. lb‑ft Tilt relay/start solenoid bracket screws 6.0 53.1 – ECM bracket screws 6.0 53.1 – 4. Install the ECM onto its bracket, and connect the ECM to the engine harness. 5.
Cylinder Block/Crankcase 12. Electric start models: Connect the engine harness red bullet connector to the voltage regulator/rectifier. a f e c b d a - 2‑pin ECT sensor connector b - Voltage regulator/rectifier red bullet connector c - Yellow fuse housing d - Oil pressure switch with rubber boot installed (behind harness) e - Ground terminal f - Black fuse housing 63939 Description Nm lb‑in. lb‑ft Ground terminal screw 6.0 53.1 – Oil pressure switch screw 1.5 13.3 – 13.
Cylinder Block/Crankcase c. Install six screws to secure the powerhead to the driveshaft housing assembly. Tighten the screws to the specified torque in two stages. 63076 Powerhead screws (three on each side, starboard shown) Description Powerhead screws (M8 x 35) 2. Nm lb‑in. lb‑ft First 15.0 132.7 – Final 30.0 – 22.1 Install the fuel system components onto the engine: a. Install the vapor separator tank and the fuel rail.
Cylinder Block/Crankcase g. Connect the fuel inlet hose to the fuel filter. Secure the connection with a hose clamp. Route the hose to the front of the engine and attach it to the engine harness with a cable tie, as shown—do not tighten the cable tie. Secure the hose to the upper spark plug lead with a clip, as shown. Electric start, power tilt model shown, other models similar a - Cable tie b - Fuel inlet hose c - Fuel filter d - Fuel filter outlet hose c d b a 63877 3.
Cylinder Block/Crankcase 5. Description Nm lb‑in. lb‑ft Stator/starter bracket screws (5 ‑ 4 top, 1 side) 6.0 53.1 – Engine harness ground screws (2) 6.0 53.1 – 14‑pin connector bracket screw 6.0 53.1 – On electric start models: a. Install the starter motor. Refer to Section 2B ‑ Starter Motor Installation. b. Connect the negative battery cable to the starter motor and the positive battery cable to the starter solenoid. Tighten the screws to the specified torque.
Cylinder Block/Crankcase Tube Ref No. 110 Description 10W-30 4-Stroke Marine Engine Oil Where Used Part No. Engine crankcase 92-8M0078625 11. For electric start models, connect the battery cables to the battery.
Cylinder Block/Crankcase Notes: Page 4A-38 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Head Powerhead Section 4B - Cylinder Head Table of Contents Cylinder Head Specifications............................................. 4B-2 Cylinder Head Components...............................................4B-4 Intake/Exhaust Valve Components....................................4B-6 Camshaft and Oil Pump Components............................... 4B-8 Valve Adjustments........................................................... 4B-10 Cylinder Head Removal.........................................
Cylinder Head Lubricant, Sealant, Adhesives Tube Ref No. Description Where Used Part No. 51 Loctite® 222 Threadlocker Camshaft gear screw threads 92-809818 110 4-Stroke 10W-30 Outboard Oil Valve stems Rocker shaft components and camshaft lobes 92-8M0078625 Special Tools Lock‑Ring Pliers Snap‑On SRP‑4 Aids in the removal of lock rings. 4799 Valve Spring Compressor 91‑809494A1 Removes and installs valve springs.
Cylinder Head Parameter Specification Valve face width (intake and exhaust) 1.0 mm (0.04 in.) Valve face width (service limit) Valve margin thickness 2.0 mm (0.08 in.) Intake 0.55 mm (0.0217 in.) Exhaust 1.00 mm (0.0394 in.) Intake and exhaust 5.51 mm (0.217 in.) Intake valve guide bore (service limit) 5.55 mm (0.218 in.) Exhaust valve guide bore (service limit) 5.57 mm (0.219 in.) Intake 0.008–0.04 mm (0.0003–0.0016 in.
Cylinder Head Cylinder Head Components 19 4 20 3 21 5 5 5 2 6 7 13 8 18 11 1 14 6 7 2 18 12 13 15 9 16 10 15 17 64414 Page 4B-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Head Cylinder Head Components Torque Ref. No. Qty. Description 1 1 Cylinder head gasket 2 2 Dowel pin 3 1 Cylinder head 4 1 Oil seal 5 6 Screw (M8 x 60) 6 2 Screw (M6 x 25) 7 3 Washer 8 1 Screw (M6 x 40) Nm lb‑in. lb‑ft First 10.0 88.5 – Final 30.0 – 22.1 First 6.0 53.1 – Final 10.0 88.5 – First 6.0 53.1 – Final 10.0 88.5 – 2.0 17.7 – 9 1 Screw 10 1 Anode 11 1 O‑ring 12 1 Anode plug 18.0 159.3 – 13 2 Spark plug 18.0 159.
Cylinder Head Intake/Exhaust Valve Components 9 8 6 5 7 4 3 2 10 1 8 5 4 3 9 7 6 15 13 12 11 14 9 8 5 6 7 4 3 2 10 1 8 3 4 5 6 9 7 13 11 14 12 64539 Page 4B-6 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Head Intake/Exhaust Valve Components Torque Ref. No. Qty. Description 1 2 Intake valve 2 2 Intake valve stem 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 10 2 Collar 11 2 Exhaust valve 12 2 Exhaust valve stem seal 13 2 Rocker shaft spring 14 2 Washer 15 1 Rocker arm shaft 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Nm lb‑in. lb‑ft 7.
Cylinder Head Camshaft and Oil Pump Components 6 7 5 8 4 9 3 10 2 1 11 12 13 14 15 64415 Page 4B-8 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cylinder Head Camshaft and Oil Pump Components Torque Ref. No. Qty. Description 1 1 Key 2 1 Drive gear 3 1 Belt guide 4 1 Lockwasher 5 1 Nut 6 1 Timing belt 7 1 Screw (M6 x 20) 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 assembly 15 3 Screw (M6 x 35) 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Nm lb‑in. lb‑ft 64.0 – 47.2 11.5 101.8 – 6.0 53.
Cylinder Head Valve Adjustments IMPORTANT: The timing belt and gears must be installed in the correct position or valve damage may occur. 1. Remove the following components: • • It is easiest to remove and install these two items together. • Refer to Section 3C ‑ Air Box Removal and Section 8A ‑ Recoil Starter. • Camshaft gear cover/vent tank. Refer to Section 3C ‑ Camshaft Gear Cover/Vent Tank. • Disconnect the inlet and outlet fuel pump hoses. Refer to Section 4A ‑ Powerhead Removal.
Cylinder Head • Turn the driven gear and align the dot on the driven gear with the timing mark on the cylinder block. • Adjust the intake and exhaust valve clearance for #1 cylinder. • Turn the crankshaft 360° and align the second dot on the driven gear with the timing mark on the cylinder block. • Adjust the intake and exhaust valve clearance for #2 cylinder. • Tighten the locknuts to the specified torque.
Cylinder Head 7. Carefully pry on both sides of the camshaft gear to remove the gear from the camshaft. b a a - Camshaft gear retaining screw (M6 x 20) and washer b - Camshaft gear pry points 64023 b 8. Remove the four cylinder head cover screws. a - Screw (M6 x 30) (4) b - Cylinder head cover a a b a a 64032 9. Remove the camshaft key. 10. Remove the three cylinder head perimeter screws. 11. Remove the six cylinder head retaining screws.
Cylinder Head Cylinder Head Disassembly 1. Loosen all of the valve adjusting locknuts and screws. Turn the valve adjusting screws out several turns. b a - Adjusting screw b - Locknut a 64120 2. Use a lock‑ring pliers to remove the rocker shaft. 3. Remove the springs, rocker arms, spacers, and washers. abcde- Rocker shaft Washer (2) Spring (2) Rocker arm (4) Spacer (2) e d c b a 64121 Lock‑Ring Pliers 4. Snap‑On SRP‑4 Remove the camshaft. Be careful to not damage the decompression valves.
Cylinder Head 5. Remove the camshaft oil seal. 64123 6. Compress the valve springs using a valve spring compressor. 3198 Valve Spring Compressor 7. 91‑809494A1 Remove keepers, upper seats, springs, seals, lower seats, and intake/exhaust valves. NOTE: Valve seals are not reusable.
Cylinder Head Cleaning and Inspection Camshaft 1. Measure the cam lobe at its maximum valve lift. Replace the cam if any of the cam lobe dimensions are out of specification. 21391 Cam Lobe 2. Intake 23.63 mm (0.9303 in.) Exhaust 23.80 mm (0.9370 in.) Measure the outer diameter of the upper and lower bearing journals. Replace the cam if the journal dimensions are out of specification.
Cylinder Head Valve Stem Outside Diameter 3. Intake 5.46–5.48 mm (0.215–0.216 in.) Exhaust 5.44–5.46 mm (0.214–0.215 in.) Measure the margin thickness of the valve. Replace the valve if out of specification. 20972 Valve Margin thickness Intake 0.55 mm (0.0217 in.) Exhaust 1.00 mm (0.0394 in.) Valve Springs 1. Check the free length of each valve spring. Replace the valve springs if they are out of specification. 20973 Valve Spring Free length 2. 31.50–32.85 mm (1.240–1.293 in.
Cylinder Head 4. Thoroughly clean all sanding grit from the cylinder head. 3007 Valve Guides Measure the valve guide inner diameter. Replace the cylinder head if the valve guide inner diameter is out of specification. a - Valve guide inside diameter a 20975 Valve Guide Inside Diameter Intake 5.51–5.55 mm (0.217–0.218 in.) Exhaust 5.51–5.57 mm (0.217–0.219 in.) Rocker Arm and Rocker Arm Shaft Inspection 1. Measure the rocker arm inside diameter. Replace if out of specification. 2.
Cylinder Head 6. To reface a valve seat, use a 30°, 45°, and 60° valve seat cutting tool. a b a - 30° angle b - 45° angle c - 60° angle c 20964 7. NOTE: When twisting the cutter, keep an even downward pressure to prevent chatter marks. NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Start with the 45° cutting tool to clean up any pitting or rough surface of the valve seat. 45° a - Rough surface of valve seat a 20954 8.
Cylinder Head 11. If the valve seat contact area is too narrow and situated near the top of the valve face, use the 30° cutting tool to cut the top edge of the valve seat. If necessary, use the 45° cutting tool to center the area of contact and set its width. 30° a - Previous contact width a 20980 12. If the valve seat contact area is too narrow and situated near the bottom of the valve face, use the 60° cutting tool to cut the bottom edge of the valve seat.
Cylinder Head 2. Compress the springs using a valve spring compressor. Insert the keepers and release the valve spring compressor. 3198 Valve Spring Compressor 3. 91‑809494A1 Install the camshaft oil seal. NOTE: Install the camshaft seal 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 camshaft lobes with 4‑Stroke 10W‑30 Outboard Oil. 6.
Cylinder Head 7. Insert the rocker shaft until it is fully seated in the cylinder head. abcde- Rocker shaft (1) Washer (2) Spring (2) Rocker arm (4) Spacer (2) e d c b a 64129 Tube Ref No. 110 Description 4-Stroke 10W-30 Outboard Oil Where Used Part No. Rocker shaft components and camshaft lobes 92-8M0078625 Cylinder Head Installation 1. Rotate the crankshaft so the top pistons are at TDC and the drive gear on the crankshaft points to the timing mark on the cylinder block. 2.
Cylinder Head 7. Install the key into the keyway on the camshaft. a 5 6 abcd- Camshaft key Cylinder head screw (M8 x 60) (6) Perimeter screw (M6 x 40) and washer (1) Perimeter screw (M6 x 25) and washer (2) d 8 1 2 b d 7 c 9 3 4 64136 Description Cylinder head screw (M8 x 60) (6) Perimeter screw (M6) (3) Nm lb‑in. First 10.0 88.5 lb‑ft – Final 30.0 – 22.1 First 6.0 53.1 – Final 10.0 88.5 – 8. Slide the camshaft gear onto the camshaft, with the notch over the camshaft key.
Cylinder Head a abcde- c b d 2 1 11. Ensure that the timing marks on the crankshaft drive gear and the camshaft driven gear are still aligned with the corresponding marks on the engine. e 63876 Crankshaft drive gear timing mark Timing mark on the cylinder block for the crankshaft Timing mark on the cylinder block for the camshaft Timing mark for #1 cylinder Timing mark for #2 cylinder 12. Install the timing belt. 13. Adjust the valve clearance. Refer to Valve Adjustments. 14.
Cylinder Head Description Nm lb‑in. lb‑ft Cylinder head cover screws (M6 x 30) 6.0 53.1 – 16. Install two spark plugs. Tighten them to the specified torque. Description Nm lb‑in. lb‑ft Spark plugs 18.0 159.3 – 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 Installation) 18. Install the powerhead onto the driveshaft housing.
Oil Pump Powerhead Section 4C - Oil Pump Table of Contents Oil 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.....................
Oil Pump Lubricants, Sealants, Adhesives Tube Ref No. 110 Description Where Used Part No. 4-Stroke 10W-30 Outboard Oil I.D. and O.D. of the mounting hub, oil pump inlet/outlet, cylinder head oil pump bore, camshaft 92-8M0078625 Oil System Specifications Parameter Specification All temperatures FC‑W® 10W‑30 Oil pump type Oil type Trochoid Alternate viscosity above 4 °C (40 °F) FC‑W® 25W‑40 Oil capacity Engine oil pressure at 75 °C (167 °F) 1.0 L (1.1 U.S. qt) At 950 RPM 50 kPa (7.
Oil Pump 2. Push the oil pump shaft out of the oil pump housing. 3. Remove the inner rotor and outer rotor from the oil pump housing. 4. Remove the pressure relief valve from its bore. NOTE: Do not reuse the cover seal. a abcdefgh- b c d e f Oil pump housing Cover seal Outer rotor Shaft Drive pin Inner rotor Pressure relief spring Pressure relief valve h g 64057 Oil Pump Inspection 1. Inspect oil pump components for pitting or scratches. Replace if necessary. 2.
Oil Pump 7. Install the pressure relief valve and spring. a b c d e f abcdefgh- Oil pump housing Cover seal Outer rotor Shaft Drive pin Inner rotor Pressure relief spring Pressure relief valve h g 8. 64057 Install the cover. Tighten the oil pump cover screws to the specified torque. 64055 Description Nm lb‑in. lb‑ft Cover screws 4.0 35.4 – Oil Pump Installation 1. Lubricate the inside and outside diameter (I.D. and O.D.) of the mounting hub with 4‑Stroke 10W‑30 Outboard Oil. 2.
Oil Pump Tube Ref No. 110 6. Description 4-Stroke 10W-30 Outboard Oil Where Used Part No. I.D. and O.D. of the mounting hub, oil pump inlet/outlet, cylinder head oil pump bore, camshaft 92-8M0078625 Fasten the oil pump to the cylinder head with three M6 x 35 screws. Tighten the screws to the specified torque. a a - Cylinder head b - Screw (M6 x 35) b 64017 Description Nm lb‑in. lb‑ft Oil pump mounting screws 6.0 53.
Oil Pump Oil Flow Diagram i 1 n 1 o 1 p 1 l 1 m 1 e j 2 n 2 o 2 p h 2 m 2 k g f 2 e d l c b a 64333 abcdefghijklmnop- Sump Screen Hose Pump Camshaft journal Regulator valve Filter Main gallery Oil pressure switch Camshaft faces Rocker arm shaft and valve Crankshaft main bearing Crankshaft rod journal Cylinder wall Piston Piston pin Page 4C-6 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Cooling System Powerhead Section 4D - Cooling System Table of Contents Cooling System Specifications.......................................... 4D-2 Cooling System Description...............................................4D-2 General Troubleshooting................................................... 4D-2 Thermostat.........................................................................4D-2 Thermostat/Electrical Bracket Removal..................... 4D-2 Testing the Thermostat.............................
Cooling System Cooling System Specifications Parameter Thermostat Specification Start to open temperature 50–54 °C (122–129 °F) Full open temperature 60–64 °C (140–147 °F) Valve lift 4.0 mm (0.157 in.) Water pressure at idle 9–18 kPa (1.3–2.6 psi) Water pressure at WOT 59–118 kPa (8.6–17.2 psi) Cooling System Description Water enters the cooling system through the lower unit water inlets.
Cooling System 4. Slowly heat the water while observing the thermostat and thermometer. 5. Measure the thermostat opening when the specified water temperature is achieved. a 3120 a - Minimum thermostat valve lift Parameter Specification Start to open temperature 50–54 °C (122–129 °F) Full open temperature 60–64 °C (140–147 °F) Valve lift 4.0 mm (0.157 in.) Thermostat/Electrical Bracket Installation The thermostat housing and electrical bracket are secured to the engine with the same screws. 1.
Cooling System Water Flow Diagram e d f g abcdefgh- Water inlet Water pump Water tube Cylinder block Thermostat Cylinder head Fuel cooler (part of the vapor separator tank) Water pump indicator outlet h c b a 64794 Page 4D-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Clamp/Swivel Bracket and Driveshaft Housing Midsection Section 5A - Clamp/Swivel Bracket and Driveshaft Housing Table of Contents Clamp Bracket Components (Power Tilt)...........................5A-4 Clamp Bracket Components (Manual Tilt)......................... 5A-6 Steering Arm and Copilot Components........................... 5A-10 Driveshaft Housing Components..................................... 5A-12 Driveshaft Housing Cover Components...........................5A-14 Driveshaft Housing Covers.......
Clamp/Swivel Bracket and Driveshaft Housing Lubricants, Sealants, Adhesives Tube Ref No. Description Where Used Part No.
Clamp/Swivel Bracket and Driveshaft Housing Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 5A-3
Clamp/Swivel Bracket and Driveshaft Housing Clamp Bracket Components (Power Tilt) 40 41 20 21 13 14 9 10 11 22 14 18 19 23 45 44 12 8 43 15 16 17 7 6 4 1 30 22 24 5 2 42 31 25 32 3 6 26 6 2 10 27 33 16 34 28 6 15 35 14 29 38 37 36 9 12 3 4 38 11 24 7 8 39 63491 Page 5A-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Clamp/Swivel Bracket and Driveshaft Housing Clamp Bracket Components (Power Tilt) Torque Ref. No. Qty. Description Nm lb‑in. lb‑ft 1 1 Carrying handle 2 3 Grease fitting 3 2 Screw (M6 x 16) 4 2 Anode 6.0 53.1 – 5 1 Starboard clamp bracket 6 4 Bushing 7 2 Washer 8 2 Screw (M8 x 20) 9 2 Cap 13 115 – 10 1 Tilt tube assembly 11 2 Locknut (M8) 13 115 – 12 2 Washer 13 1 Ground wire (starboard clamp bracket to swivel bracket) 14 3 15 2 Screw (M6 x 12) 6.
Clamp/Swivel Bracket and Driveshaft Housing Clamp Bracket Components (Manual Tilt) 46 43 41 40 44 39 38 37 16 48 49 47 48 42 36 32 31 17 20 15 35 34 33 30 29 14 13 4 11 18 17 22 26 5 16 21 22 27 28 1 12 45 20 23 25 19 24 2 7 8 8 6 3 10 6 5 8 9 4 8 7 63293 Page 5A-6 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Clamp/Swivel Bracket and Driveshaft Housing Clamp Bracket Components (Manual Tilt) Torque Ref. No. Qty.
Clamp/Swivel Bracket and Driveshaft Housing Torque Ref. No. Qty. 47 2 Transom screw (M8 x 85) 48 4 Washer 49 2 Nut Page 5A-8 Description © 2018 Mercury Marine Nm lb‑in. lb‑ft 13.
Clamp/Swivel Bracket and Driveshaft Housing Clamp Bracket Components (Manual Tilt) 42 41 40 44 39 38 37 16 48 49 47 48 46 43 36 32 31 17 20 15 35 34 33 30 29 14 13 4 11 18 17 22 26 5 16 21 22 27 28 1 12 45 20 23 25 19 24 2 7 8 8 6 3 10 9 6 5 8 4 8 7 63293 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 5A-9
Clamp/Swivel Bracket and Driveshaft Housing Steering Arm and Copilot Components 18 25 26 19 20 17 20 21 27 22 28 29 30 18 17 24 30 23 22 31 32 1 29 33 34 2 3 3 5 16 4 6 8 2 15 9 8 6 13 7 10 Page 5A-10 14 © 2018 Mercury Marine 12 11 64416 90-8M0125265 eng NOVEMBER 2017
Clamp/Swivel Bracket and Driveshaft Housing Steering Arm and Copilot Components Torque Ref. No. Qty.
Clamp/Swivel Bracket and Driveshaft Housing Driveshaft Housing Components 29 28 29 27 25 24 5 26 26 7 2 15 16 1 22 23 19 9 18 20 4 17 3 8 22 14 13 6 21 6 11 10 21 12 64417 Page 5A-12 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Clamp/Swivel Bracket and Driveshaft Housing Driveshaft Housing Components Torque Ref. No. Qty.
Clamp/Swivel Bracket and Driveshaft Housing Driveshaft Housing Cover Components 64676 Page 5A-14 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Clamp/Swivel Bracket and Driveshaft Housing Driveshaft Housing Cover Components Torque Ref. No. Qty.
Clamp/Swivel Bracket and Driveshaft Housing Driveshaft Housing Covers Removal 1. Remove the top cowl. 2. Remove the cowl seal. 3. Loosen, but do not remove the screw that secures the cowl latch to the driveshaft housing covers. 63041 4. Loosen the seven captive screws that secure the starboard driveshaft cover, and remove the cover. 63039 5. NOTE: To remove the port cover without removing the starboard cover, loosen only the three captive screws at the rear of the cover.
Clamp/Swivel Bracket and Driveshaft Housing 6. b. Cut the cable tie that secures the power tilt wires to the electrical bracket. c. Pull the power tilt pump wires through the grommet in the port cover. d. If the engine has a cowl‑mounted tilt switch, disconnect the switch from the engine harness. Loosen the three captive screws that secure the port cover, and remove the cover.
Clamp/Swivel Bracket and Driveshaft Housing 2. Remove the two screws that secure the front cowl to the shift lever brackets. d c e abcdef- Screws (2) Rubber plug (optional start push‑button) Diagnostic light Top cowl catch Fuel connection Upper shift shaft boot b a a f 63482 3. Disconnect the two bullet connectors for the diagnostic light. 4. Disconnect the two bullet connectors for the start switch, if equipped. 5. Remove the fuel inlet hose from the fuel inlet fitting. 6.
Clamp/Swivel Bracket and Driveshaft Housing Idle Exhaust Port Cover Removal and Inspection 1. Remove the six screws securing the idle exhaust port cover, and remove the cover. a - Vent tank vent hose fitting b - Screws (6) 3 a 4 b b 2 1 6 5 62947 2. Remove the gasket. 3. Remove the three screws securing the idle exhaust port plate. 62948 4. Inspect and clean the idle exhaust port cover. Installation NOTE: Refer to the illustrations in the Removal and Inspection procedure, as required. 1.
Clamp/Swivel Bracket and Driveshaft Housing Description Nm lb‑in. lb‑ft Idle exhaust port cover screws 6.0 53.1 – Powerhead/Midsection Assembly Separation Several procedures require the separation of the powerhead/midsection assembly from the clamp/swivel bracket assembly. Refer to the following procedures as required.
Clamp/Swivel Bracket and Driveshaft Housing a. With the gearcase in neutral, disconnect the upper shift shaft from the shift lever by pulling the upper shift shaft toward starboard. Pull the upper shift shaft toward starboard a - Upper shift shaft b - Shift lever b a 63486 b. Disconnect the upper shift shaft from the lower shift shaft by turning the jam nut (down) and the coupler (up). a b abcd- Upper shift shaft Coupler Jam nut Lower shift shaft c d 62825 c. 5.
Clamp/Swivel Bracket and Driveshaft Housing 7. Remove the locknuts and washers from the ends of the long upper mount screws (one each side). Carefully remove the engine from the steering arm/swivel bracket. a - Locknut and washer on long upper mount screw b - Screw head a b 62941 Installation For the following procedure, refer to the illustrations in the Removal procedure as required. 1. Ensure that the rubber damper is in place on the steering arm/swivel bracket. 63001 2.
Clamp/Swivel Bracket and Driveshaft Housing Engine Mount Replacement Upper Mount IMPORTANT: The upper mounts cannot be replaced without removing the engine from the steering arm/swivel bracket, including removing the lower mounts. Starboard mount shown, port mount similar a - Arrow pointing toward the transom b - Notch rotated for access to screw head c - Upper mount screws c b a c 62999 Removal 1. Separate the engine and driveshaft housing from the steering arm/swivel bracket.
Clamp/Swivel Bracket and Driveshaft Housing NOTE: Inspect the anode. Replace if necessary; otherwise, it need not be removed. a - Anode b - Screw c - Continuity wire (from swivel bracket to lower mount) d - Lubrication fitting e - Continuity wire (from lower mount to driveshaft housing) d c e b a 2. 62942 Remove the two screws that attach the two halves of the lower mount bracket. 62943 3. Remove the lower mount bracket halves and three rubber mounts. 4. Inspect the rubber mounts for wear.
Clamp/Swivel Bracket and Driveshaft Housing 3. 4. Slide the starboard half of the lower mount bracket into position. Secure the bracket halves with two screws. Tighten the screws to the specified torque. Description Nm lb‑in. lb‑ft Lower mount screws 13 115 – Attach the two continuity wires to the port side of the lower mount with a screw and washer. Tighten the screw to the specified torque. Description Nm lb‑in. lb‑ft Screw 6.0 53.
Clamp/Swivel Bracket and Driveshaft Housing 9. Remove the port clamp bracket from the tilt tube, feeding the power tilt pump wires out through the hole in the bracket. abcdefgh- c b d a e h d g Cap Locknut P‑clip Cable ties (2) Tilt lock pin, locknut, and washer Lower pivot pin screw (M8 x 20) and washer Ground cable screw on power tilt unit Port clamp bracket f 63659 10. Inspect the tilt lock pin, lower pivot pin bushing, and anode.
Clamp/Swivel Bracket and Driveshaft Housing 6. Align the lower pivot pin with the port clamp bracket bushing and push the clamp bracket onto the lower pivot pin. a - Lower pivot pin b - Clamp bracket bushing a b 35067 7. Install the lower pivot pin screw and washer. Tighten the screw to the specified torque. 8. Lubricate the plastic washer on the tilt tube with 2‑4‑C with PTFE. 9. Install the tilt tube locknut. Tighten the locknut to the specified torque. 10. Install the cap.
Clamp/Swivel Bracket and Driveshaft Housing 12. Connect the green and blue power tilt wires to the tilt relays. Cover the connections with the red boots. a b a - Blue (up) tilt relay terminal and wire b - Green (down) tilt relay terminal and wire 63064 13. Secure the wires to the electrical bracket with a cable tie. Starboard Bracket Removal 1. Remove the power tilt lower pivot screw and washer. 2. Remove the screw securing the ground cable. 3. Remove the port tilt tube cap. 4.
Clamp/Swivel Bracket and Driveshaft Housing 8. Inspect the tilt lock pin, lower pivot pin bushing, and anode. a f e d c abcdef- b Ground cable Screw (M6 x 12) Tilt lock pin Lower pivot pin bushing Anode Screw (M6 x 16) 63490 Starboard Bracket Installation 1. Install the lower pivot pin bushing. 2. Install the tilt lock pin. Tighten the locknut to the specified torque. 3. Install the anode and ground cable. Tighten the anode screw to the specified torque.
Clamp/Swivel Bracket and Driveshaft Housing 12. Install the cap. a b abcde- Ground cable screw Nut Cap Lower pivot pin screw (M8 x 20) and washer Tilt lock pin, locknut, and washer c e d 63485 Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Tilt tube washer 92-802859A 1 Description Nm lb‑in. Lower pivot pin screw (M8 x 20) 13 115 – 24.0 – 17.7 Tilt tube locknut lb‑ft Steering Arm Removal 1.
Clamp/Swivel Bracket and Driveshaft Housing 3. Remove the steering arm. 63814 Power Tilt Removal 1. Remove the steering arm. Refer to Steering Arm Removal. 2. Remove the P‑clip that secures the power tilt pump wires to the outside of the port clamp bracket. 3. Cut the cable ties securing the power tilt pump wires to the inside of the port clamp bracket. 4. Pull the power tilt pump wires through the opening in the clamp bracket. 5.
Clamp/Swivel Bracket and Driveshaft Housing Swivel Bracket Removal IMPORTANT: This procedure assumes the following prerequisite procedures have been completed: 1. Powerhead/driveshaft housing/gearcase assembly removed from the clamp bracket/swivel bracket/steering arm assembly. Refer to Powerhead/Midsection Assembly Separation. 2. Steering arm removed from the swivel bracket. Refer to Steering Arm Removal. 3. Power tilt unit removed from the swivel bracket. Refer to Power Tilt Removal.
Clamp/Swivel Bracket and Driveshaft Housing 5. Install the bushings into the swivel bracket. a Power tilt model a - Thrust plate b - Swivel bracket bushing (2) c - Swivel bracket d - O‑ring e - Lower pivot bushings (2) f - Carrying handle g - Washer (2) b g c e f b d a Tube Ref No. 35131 Description 2-4-C with PTFE 95 Where Used Part No. Swivel bracket bushings 92-802859A 1 Tilt Lock Lever 1. Remove the tilt spring from the swivel bracket. 2. Remove the spring pin from the tilt lock pin.
Clamp/Swivel Bracket and Driveshaft Housing 5. Install a washer and the starboard clamp bracket onto the tilt tube. a b c d c e abcdef- f Tilt tube Port clamp bracket Washer Carrying handle Starboard clamp bracket Swivel bracket 35140 6. Install the nut onto the tilt tube. Tighten the port side locknut to the specified torque. 7. Attach the starboard ground cable to the swivel bracket. Tighten the screw to the specified torque. 8. Install the tilt tube caps.
Clamp/Swivel Bracket and Driveshaft Housing 7. Install the screw and washer that secure the upper pivot pin. Tighten the screw to the specified torque. a abcd- b d Screw and washer Upper pivot pin Lower pivot pin screw and washer Power tilt unit c 35122 Description Nm lb‑in. lb‑ft Lower pivot pin screw (M8 x 20) 13 115 – Upper pivot pin screw (M6 x 12) 6.0 53.1 – 8. Route the power tilt pump wires through the port clamp bracket. 9.
Clamp/Swivel Bracket and Driveshaft Housing a. Install the copilot threaded rod into the swivel bracket. b. Install one disc and washer (item c, shown following) onto the threaded rod. c. Attach the plate to the steering arm with two screws and washers. d. Install a disc, handle, washer, and locknut onto the threaded rod. Tighten the locknut to the specified torque.
Clamp/Swivel Bracket and Driveshaft Housing Clamp Brackets, Swivel Bracket ‑ Manual Tilt Models Clamp Brackets ‑ Manual Tilt NOTE: To remove the clamp brackets: • Use an overhead hoist to support the outboard by the lifting eye, or • Lay the outboard on its back side. Port Bracket Removal 1. Remove the tilt tube cap and locknut. 2. Remove the tilt pin. 3. Remove the nut and washer from the port end of the clamp bracket spacer. 4. Remove the port clamp bracket from the tilt tube. 5.
Clamp/Swivel Bracket and Driveshaft Housing 4. Ensure that the guide bar of the tilt lock is aligned in the channels of the clamp brackets. 5. Install the washer and nut onto the clamp bracket spacer. Tighten the nut to the specified torque. 6. Install the tilt tube locknut. Tighten the locknut to the specified torque. 7. Install the tilt tube cap. 8. Install the tilt pin.
Clamp/Swivel Bracket and Driveshaft Housing 8. Inspect the anode. a abcdef- b Tilt tube Nut Spacer Nut and washer Tilt pin Anode f e c d 63319 Starboard Bracket Installation 1. Ensure that a good anode is installed on the starboard clamp bracket. a - Anode b - Channel for tilt lock b a 63340 2. Install the clamp bracket partially onto the tilt tube. 3. Lubricate the plastic washer on the tilt tube with 2‑4‑C with PTFE. Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No.
Clamp/Swivel Bracket and Driveshaft Housing 9. Install the tilt pin. a abcdef- b Tilt tube Nut Spacer Nut and washer Tilt pin Anode f e d Tube Ref No. 95 c 63319 Description 2-4-C with PTFE Where Used Part No. Tilt tube washer 92-802859A 1 Description Nm lb‑in. lb‑ft Tilt tube locknut Spacer nut 24.0 – 17.7 6.0 53.1 – Steering Arm Removal 1. 2. 3. Separate the powerhead/driveshaft housing/gearcase assembly from the clamp bracket/swivel bracket/steering arm assembly.
Clamp/Swivel Bracket and Driveshaft Housing 4. Remove the steering arm. 63342 Swivel Bracket Removal 1. 2. Remove the steering arm. Refer to Steering Arm Removal. Remove the tilt tube port side cap and locknut, spacer bar nut and washer, and tilt pin. abcd- a b c 3. Tilt tube cap Tilt tube port side locknut Spacer bar nut and washer Tilt pin d 63343 Remove the swivel bracket and bushings from the tilt tube. a - Bushing b - Swivel bracket a a b 63344 Swivel Bracket Inspection 1. 2.
Clamp/Swivel Bracket and Driveshaft Housing 3. Clean the swivel bracket. 4. Apply 2‑4‑C with PTFE to the bushings. 5. Install the bushings into the swivel bracket. a b abcdef- c d Thrust plate (2) Swivel bushing (2) Tilt bushing (2) Swivel bracket Grease fitting O‑ring e c b f a Tube Ref No. 35211 Description 2-4-C with PTFE 95 Where Used Part No.
Clamp/Swivel Bracket and Driveshaft Housing Description Nm lb‑in. lb‑ft Shoulder screw 13 115 – Reverse Lock c g f e abcdefghij- d b h i a j Reverse lock spring Reverse lock link Reverse lock rod Split pin E‑clip (2) Reverse lock spring (2) Pin (2) Reverse lock Reverse lock arm Reverse lock shaft 63346 Swivel Bracket Installation 1. Clean the tilt tube and clamp brackets. 2. Insert the tilt tube through the starboard clamp bracket. 3.
Clamp/Swivel Bracket and Driveshaft Housing 7. Install the locknut onto the tilt tube. Tighten the locknut to the specified torque. 8. Install the washer and nut onto the clamp bracket spacer. Tighten the nut to the specified torque. 9. Install the tilt pin. 10. Install the tilt tube caps. abcd- a Tilt tube cap (one each end) Locknut Clamp bracket spacer nut and washer Tilt pin b c d 63343 Description Nm lb‑in. lb‑ft Tilt tube locknut 24.0 – 17.7 Clamp bracket nut 6.0 53.
Clamp/Swivel Bracket and Driveshaft Housing d. Install a disc, handle, washer, and locknut onto the threaded rod. Tighten the locknut to the specified torque. a c i b h g e f d abcdefghi- 63351 Threaded rod Disc Washer Plate Screws and washers Disc Copilot handle Washer Locknut Description Nm lb‑in. lb‑ft Copilot 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.
Clamp/Swivel Bracket and Driveshaft Housing Tube Ref No. Description Loctite® 271 Threadlocker 7 Where Used Part No. Tiller handle screw threads 92-809819 Description Nm lb‑in. lb‑ft Upper mount locknut 27.0 – 19.9 Tiller handle screws 40.0 – 29.5 Driveshaft Housing Removal 1. Completely remove the driveshaft housing covers, including disconnecting the cowl‑mounted tilt switch (if equipped) and the power tilt pump wires (if equipped). Refer to Driveshaft Housing Covers. 2.
Clamp/Swivel Bracket and Driveshaft Housing 11. Remove one screw to remove the water pump indicator tube. a - Water pump indicator tube b - Screw b a 64268 Driveshaft Housing Installation 1. Using one screw, attach the water pump indicator tube to the driveshaft housing. Tighten the screw to the specified torque. a - Water pump indicator tube b - Screw b a 64268 Description Nm lb‑in. lb‑ft Screw 6.0 53.1 – 2. Install the rubber seal onto the driveshaft housing. 3.
Clamp/Swivel Bracket and Driveshaft Housing 6. Install the two upper mount locknuts. Tighten the locknuts to the specified torque. b a - Locknut (one each side) b - Steering arm a 64100 Description Nm lb‑in. lb‑ft Locknuts 27.0 – 19.9 7. Install the lower mount. Refer to Lower Mount. 8. Install the powerhead. Refer to Section 4A ‑ Powerhead Installation. 9. Install the gear housing. Refer to Section 6A ‑ Gear Housing Installation. 10. Install the front cowl. Refer to Front Cowl. 11.
Clamp/Swivel Bracket and Driveshaft Housing The ProKicker tiller handle model is equipped with kicker straps located on each side of the outboard. The straps prevent the outboard from pivoting when the outboard is tilted up. When the outboard is in the full up position, the kicker straps should be tight and center the outboard. 63832 Shown with starboard driveshaft housing cover removed Removal 1. 2. 3. 4. 5. Remove the driveshaft housing cover for easier access to the kicker strap retaining hardware.
Clamp/Swivel Bracket and Driveshaft Housing Notes: Page 5A-50 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Power Tilt Midsection Section 5B - Power Tilt Table of Contents Power Tilt Specifications....................................................5B-2 General Troubleshooting................................................... 5B-2 Power Tilt ‑ General Information........................................ 5B-2 Power Tilt Components......................................................5B-4 Theory of Operation........................................................... 5B-6 Power Tilt Hydraulic Diagram..............
Power Tilt Lubricant, Sealant, Adhesives Tube Ref No. 114 Description Power Trim and Steering Fluid Where Used Part No. Power tilt system Lubrication of O-rings Lubrication of power tilt O-rings 92-858074K01 Special Tools DMT 2004 Digital Multimeter 91‑892647A01 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.
Power Tilt Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 5B-3
Power Tilt Power Tilt Components 19 22 20 23 1 2 21 7 8 9 5 4 10 3 6 24 13 11 14 14 15 12 16 25 17 26 18 27 33822 Page 5B-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Power Tilt Power Tilt Components Torque Ref. No. Qty. Description 1 1 2 1 3 1 4 1 5 1 6 1 C‑ring 7 1 Seal 8 1 Down orifice assembly 9 1 10 2 O‑ring 11 1 Pump 12 1 Up relief valve assembly 13 1 Nm lb‑in. lb‑ft Cap assembly O‑ring Manual release valve assembly O‑ring O‑ring O‑ring O‑ring 14 2 Bolt (M5 x 20) 5.2 46.0 – 15 1 Bolt (M5 x 25) 5.2 46.
Power Tilt Theory of Operation Power Tilt Hydraulic Diagram m l n o i j k h p f g e c a abcdefghijklmnop- b d 9180 Reservoir Filter Electric motor Tilt up inlet check valve Tilt down inlet check valve Up circuit relief valve Down circuit relief orifice Hydraulic pump Tilt up pressure operated check valve Shuttle valve Tilt down pressure operated check valve Impact relief valve Tilt cylinder Up circuit thermal relief valve Down circuit thermal relief valve Manual release valve Operation Tilt Ci
Power Tilt Tilt Circuit - Down When the down circuit is activated, the electric motor rotates in the opposite direction. As the pump’s gears rotate, fluid is drawn through a check valve and into the pump’s inlet. The pump flow passes through a check valve and to the top of the tilt cylinder. The fluid pushes the cylinder piston down and lowers the engine. Oil, from the bottom side of the cylinder, returns to the inlet side of the pump.
Power Tilt The adjustment of the tilt‑in stop pins will set the vertical operating angle of your outboard. Proper adjustment allows the boat to run stable, achieve optimum performance, and minimize steering effort. a a a - Tilt‑in stop pins 32192 NOTE: Refer to the following when adjusting the operating angle of your outboard. The tilt‑in stop pins should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed.
Power Tilt 2. Remove the fill plug and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF). 4531 Tube Ref No. 114 3. Description Where Used Part No. Power Trim and Steering Fluid Power tilt system 92-858074K01 Reinstall the fill plug.
Power Tilt • The switch should be positioned with the harness at the bottom. • Ensure that the switch is vertical before tightening the screws. abcd- d Foam gasket Flange on tilt switch housing Flat edge of mounting bracket Switch harness exits at the bottom of the switch c a a b 63476 3. Install the port‑side driveshaft housing cover. Refer to Section 5A ‑ Driveshaft Housing Covers. 4. Confirm proper up/down operation of the tilt switch.
Power Tilt Method 2 1. Extend the power tilt cylinder to the full up position. 2. Mark the tilt cylinder rod 55 mm (2.2 in.) above the cylinder cap with an indelible marker. 3. Wait 24 hours. 4. If the marked line is visible, the power tilt unit is within specifications for leakage. Power Tilt System Leakage Specification Cylinder rod leak‑down in 24 hour period Less than 55 mm (2.2 in.
Power Tilt Problem/Solution No. Problem Solution 1. Battery low or discharged 2. Wiring reversed in remote control, handle switch, or tilt leads Verify connections. Check battery. 3. Open circuit in tilt wiring Check for an open connection. 4. Wire harness corroded through Replace wire harness. 5. Internal motor problem (brushes, shorted armature) Check for open connection. Replace motor. 6. Tilt switch failure Replace switch. 7.
Power Tilt Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRA Gray GRN Green ORN Orange PNK 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 following Tilt System Troubleshooting Charts.
Power Tilt Power Tilt Electrical Circuit - Tiller Handle a 3, 9 15A b c RED RED RED RED RED BLK GRN BLK RED 1 2 J5 7, 8 LT BLU BLK BLK J8 PNK RED f e d RED A B C D E F G H J K L M N P GRN BLU BLK BLK BLK BLK LT BLU PNK 1, 4 2 RED LT BLU PNK 6 10 5 J7 E F G A H UP DN P D N C B J g M L K h i LT BLU/WHT GRN/WHT RED/PPL GRN/WHT LT BLU/WHT RED/PPL A B C D E F G H J K L M N P 63522 abcdefghi- Starter solenoid Battery 15‑amp fuse Tilt up relay Tilt down relay Powe
Power Tilt Power Tilt Electrical Circuit - Remote Control a 3, 9 15A b c RED RED RED RED RED BLK GRN BLK RED 1 2 J5 8 LT BLU BLK BLK J8 PNK RED 1 2 3 LT BLU PNK A B C D E F G H J K L M N P GRN BLU BLK BLK BLK BLK RED f e d RED LT BLU PNK 1 2 RED LT BLU PNK 6 10 5 J7 E F g DN 1 2 3 UP G P D A H N C B J h M L K i j 4 RED BLU/WHT GRN/WHT BLU/WHT GRN/WHT 7 RED GRN/WHT LT BLU/WHT RED/PPL A B C D E F G H J K L M N P 63523 Typical (side mount remote cont
Power Tilt Step Step 1: Check for battery voltage at point 1. Test Procedure 1. Connect voltmeter red lead to point 1 and black lead to ground. 2. Press the down tilt button. Test Result Battery voltage measured: • Go to step 2. No battery voltage measured: • Go to step 3. Battery voltage measured: Step 2: Check for battery voltage at point 3. Step 3: Check for battery voltage at point 4. Connect voltmeter red lead to point 3 and black lead to ground. 1.
Power Tilt Step Test Procedure Test Result Battery voltage measured: Step 4: Check for battery voltage at point 5. Step 5: Check for battery voltage at point 6. Connect voltmeter red lead to point 5 and black lead to ground. 1. Connect voltmeter red lead to point 6 and black lead to ground. 2. Press the up tilt button. • Tilt switch is faulty. No battery voltage measured: • Check for loose or corroded wire at point 5. • Open circuit in wire supplying current to point 5.
Power Tilt Step Test Procedure Test Result Check that voltage is being supplied to control by performing the following checks: Step 5: Check 1. voltage. 2. 3. No voltage measured: • Red wire is open between point 3 and red terminal on back of ignition switch. Do not start engine. • Turn ignition switch to "RUN" position. Check for loose or corroded connections. • Check for open in wire. Battery voltage measured: Check for voltage at any instrument • using a voltmeter.
Power Tilt 8. Remove the port side screw from the power tilt pivot pin. a - Pivot pin retaining screw b - Power tilt assembly a b 8357 9. Using a drift punch, remove the pivot pin from the power tilt assembly. a - Drift punch b - Pivot pin bore c - Power tilt assembly b a c 8360 10. Remove the power tilt assembly from the clamp brackets. Manual Release Valve Removal and Repair IMPORTANT: The power tilt system is pressurized.
Power Tilt 5. Remove the manual release valve by turning the valve counterclockwise. b c d a b 8397 abcd- Power tilt assembly Manual release valve Snap ring Reservoir fill plug 6. Remove and discard the two O‑rings from the valve. 7. Remove and discard the sealing washer from inside the manual release valve cavity. a c b c a - Sealing washer b - Manual release valve c - O‑ring 8402 8. Install a new sealing washer in the manual release valve cavity.
Power Tilt 6. Separate the motor assembly from the power tilt pump and cylinder assembly. b abcde- c Wire harness retaining screw Power tilt pump and cylinder assembly Motor assembly 4 mm internal hex screw Reservoir fill plug a d e 8455 Power Tilt Motor Disassembly, Inspection, and Repair 1. Remove the two cross slotted screws securing the motor housing to the bracket assembly. a a - Motor cover b - Screws (2) c - Motor bracket b c 8438 2. Remove the armature from the motor housing.
Power Tilt Test for Ground Use a DMT multimeter (R x 1 scale). Place one lead of the meter on the armature shaft and the other lead on the commutator. If continuity is indicated, armature is grounded and must be replaced.
Power Tilt 3. Remove the brush holder and brush. h i a g b c c f d d f abcdefghi- Blue wire Green wire Screw Brush holder Brush Spring Breaker Motor bracket O‑ring e e c 8425 Power Tilt Motor Reassembly 1. Install the breaker into the motor bracket. 2. Install the breaker holder and secure with a screw. 3. Attach the blue wire to the terminal post of the breaker. 4. Route the green wire along the inside diameter of the bracket. 5. Install the brush holder and secure with a screw. 6.
Power Tilt 10. Install the O‑ring. a b abcde- Armature Motor bracket Brush Brush O‑ring e c d 8433 11. Install the motor cover. Secure with two cross slotted screws. a a - Motor cover b - Screws (2) c - Motor bracket b c 8438 Power Tilt Pump Power Tilt Pump Disassembly ! CAUTION Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering components can result in injury or product damage.
Power Tilt 7. Separate the motor assembly from the power tilt pump and cylinder assembly. b abcde- c Wire harness retaining screw Power tilt pump and cylinder assembly Motor assembly 4 mm internal hex screw Reservoir fill plug a d e 8455 8. Remove the pump/motor coupling. 9. Remove the pump filter from the power tilt assembly. a - Filter b - Pump/motor coupling a b 9199 NOTE: Relief valve components are held in place by the power tilt pump.
Power Tilt 11. Remove the up relief valve components, down relief orifice, and O‑rings from the power tilt housing. a - Up relief valve components b - Down relief orifice c - O‑ring a c b 8442 12. Inspect the down orifice screen and up relief valve seat. a - Up relief valve seat b - Down orifice screen a b 8452 Power Tilt Pump Reassembly 1. Install two new lubricated O‑rings in the power tilt housing. 2. Install a new lubricated O‑ring on orifice. 3. Install the filter and orifice.
Power Tilt 4. Install the up relief valve components in the power tilt housing. b c d e i j f a k h g 8448 abcdefghijk- Up relief valve assembly O‑ring Valve seat Ball Spring guide Spring Down orifice assembly Filter O‑ring Orifice O‑ring Tube Ref No. 114 5. Description Where Used Part No. Power Trim and Steering Fluid Lubrication of power tilt O-rings 92-858074K01 Assemble the pump with three internal hex screws. Tighten the screws to the specified torque.
Power Tilt 7. Install the pump/motor coupling into the pump. a - Pump filter b - Pump/motor coupling a b 9199 8. Assemble the motor assembly to the power tilt pump and cylinder assembly. 9. Install the wire harness retaining screw. 10. Install the two 4 mm internal hex screws securing the motor assembly to the power tilt pump and cylinder assembly. Tighten the screws to the specified torque. 11. Fill the power tilt system with Power Trim and Steering Fluid.
Power Tilt Power Tilt Installation 1. Tilt the outboard to the full up position and engage the tilt support lever. a - Tilt support lever a 31919 2. Install the bushing into the tilt cylinder rod eye. a a - Power tilt cylinder b - Tilt cylinder rod eye c - Bushing c b 11462 3. Install the pivot pin bushings in the clamp bracket. 4. Place the power tilt assembly between the clamp brackets. 5. Install the tilt cylinder pivot pin through the clamp brackets and the power tilt unit. 6.
Power Tilt 7. Install the ground strap and retaining screws. Tighten the screws to the specified torque. abcd- Clamp bracket Ground strap screw on power tilt unit Ground strap screw on clamp bracket Ground strap a b c d 8815 8. Description Nm lb‑in. lb‑ft Ground strap screw 6.0 53.1 – Connect the power tilt electrical wires to the power tilt relays. a b a - Blue (up) tilt relay terminal and wire b - Green (down) tilt relay terminal and wire 63064 9.
Power Tilt 12. Align the tilt cylinder rod eye between the swivel brackets. 13. Install the tilt cylinder rod pin. 14. Install the tilt cylinder rod pin retaining screw and washer. Tighten the screw to the specified torque. a a - Tilt cylinder rod pin retaining screw and washer b - Tilt cylinder rod pin b 63702 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.
Power Tilt Notes: Page 5B-32 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Gear Housing (2.15:1) Lower Unit Section 6A - Gear Housing (2.15:1) Table of Contents Gearcase Specifications.................................................... 6A-4 Gear Housing and Driveshaft.............................................6A-6 Propeller Shaft................................................................... 6A-8 General Service Recommendations................................ 6A-10 Bearings....................................................................6A-10 Shims.....................
Gear Housing (2.15:1) Lubricants, Sealants, Adhesives Tube Ref No. Description Where Used Part No.
Gear Housing (2.15:1) Universal Puller Plate 91‑37241 Removes bearings from gears and the driveshaft. 8505 Pinion Bearing Installation Tool Assembly 8M0038865 Guides the removal and installation of the pinion bearing 37832 Bearing Mandrel Kit 91‑ 83166M Aids in the removal and installation of bearings and bearing races. 3421 Spring 8M0011503 Applies upward force to the driveshaft for checking forward gear backlash.
Gear Housing (2.15:1) Backlash Indicator Arm 91‑803133 12 Aids in determining the forward gear backlash; use with a dial indicator. 12512 Dial Indicator 91‑ 58222A 1 Used to obtain a variety of measurements including gear backlash, pinion gear location, and TDC. 9479 Dial Indicator Adapter 91‑83155 Dial indicator holding fixture. 2999 Gearcase Specifications Parameter Specification Gear ratio 2.15:1 Gearcase capacity 460 ml (15.
Gear Housing (2.
Gear Housing (2.
Gear Housing (2.15:1) Gear Housing and Driveshaft Torque Ref. No. Qty.
Gear Housing (2.
Gear Housing (2.15:1) Propeller Shaft Torque Ref. No. Qty. Description 1 1 Ball bearing 2 1 Forward gear 3 1 Push rod 4 1 Retainer spring 5 1 Clutch pin 6 1 Clutch 7 1 Spring 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 15 1 Oil seal 16 2 Screw 17 1 Propeller 18 1 Propeller hardware kit 19 1 Front thrust hub 20 1 Washer 21 1 Propeller nut 22 1 Cotter pin Nm lb‑in.
Gear Housing (2.15:1) General Service Recommendations There may be more than one way to disassemble or reassemble a particular part. It is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub‑assembly may not be necessary, until cleaning and inspection reveals that disassembly is required for replacement of one or more components.
Gear Housing (2.15:1) 1. Position a clean drain pan under the gear housing and remove the fill and vent screws from the gear housing. a a - Vent screw b - Fill screw b 62824 2. Inspect the gear lubricant for metal particles. Presence of a small amount of fine metal particles resembling powder indicates normal wear. Presence of larger particles or a large quantity of fine particles indicates a need for gear housing disassembly and component inspection. 3. Note the color of the gear lubricant.
Gear Housing (2.15:1) 4. Remove the jam nut from the lower shift shaft. a b abcd- Upper shift shaft Coupler Jam nut Lower shift shaft c d 62825 5. Remove the four screws securing the gear housing to the driveshaft housing, and remove the gearcase. 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 appearance. Bearing Carrier Disassembly 1.
Gear Housing (2.15:1) 2. Use prybars at the indicated pry points to aid in the removal of the bearing carrier assembly from the gearcase. a - Pry points a a 6542 3. Remove the bearing carrier and propeller shaft assembly from the gearcase. a - Propeller shaft b - Bearing carrier assembly b a 6545 NOTE: The cam follower is free to slide out of the propeller shaft.
Gear Housing (2.15:1) 4. Remove the propeller shaft from the reverse gear/bearing carrier assembly. a b c a - Reverse gear/bearing carrier assembly b - Thrust washer c - Propeller shaft 62932 5. Replace the reverse gear if the gear teeth or clutch teeth are chipped or worn. a b a - Clutch teeth b - Gear teeth 34377 6. If the reverse gear must be replaced, use a bearing puller assembly to remove the reverse gear from the reverse gear bearing.
Gear Housing (2.15:1) 7. Inspect the reverse gear bearing for roughness, catches, pits, or discoloration from lack of lubricant. If the bearing must be replaced, use a torch lamp to warm the bearing carrier assembly to aid in removal. Remove the O‑ring from the carrier to prevent heat damage. Use a bearing puller assembly to remove the bearing from the bearing carrier. a - Torch lamp b - Reverse gear bearing c - Bearing puller assembly a b c 6554 Bearing Puller Assembly 91‑ 83165T Torch Lamp 8.
Gear Housing (2.15:1) 9. Use a suitable mandrel to press the needle bearing out of the bearing carrier. b a - Needle bearing b - Bearing carrier a 34382 a - Mandrel b - Needle bearing (hidden) c - Bearing carrier b a c 34383 Propeller Shaft Disassembly 1. Inspect the cam follower for wear. Replace the follower if it is worn. b a c 62931 a - Propeller shaft b - Bearing carrier assembly c - Cam follower 2. Remove the clutch pin retainer spring from the clutch.
Gear Housing (2.15:1) ! CAUTION The spring‑loaded clutch pin can disengage from the clutch and propel through the air, causing possible eye injury. Always wear protective eye equipment when disassembling the clutch assembly. 3. Remove the clutch pin from the sliding clutch/propeller shaft. Removal of the clutch pin allows the clutch spring to discharge. Wear appropriate eye protection. Discard the clutch pin after removal. b a - Clutch pin (under spring) b - Retainer spring c - Sliding clutch a c 4.
Gear Housing (2.15:1) • Oil seal surface is grooved • Shaft has a noticeable wobble or is bent more than 0.15 mm (0.006 in.) a b c d b d a - Check shaft for wobble b - Check for twisted splines c - Check for seal surface grooves d - Check for needle bearing surface pits or wear 6567 Water Pump, Driveshaft, and Shift Shaft Disassembly 1. Remove the four screws and four washers from the water pump cover. a b a - Screws (4) and washers (4) b - Water pump cover 62846 2.
Gear Housing (2.15:1) 4. Remove the faceplate. a a - Drive key b - Faceplate b 62848 5. Remove the water tube grommet from the pump cover. Inspect the grommet for wear or damage. Replace the grommet as required. When installing the grommet into the pump cover, align the grommet tabs with the holes in the pump cover. b c d abcd- Hole (2) Tab (2) Grommet Water pump cover a 62849 6. Inspect the pump cover for damage from excessive heat; charring, blistering, or discoloration.
Gear Housing (2.15:1) NOTE: Be careful to not lose the two dowel pins. a - Screw and clamp b - Pry point (one each side of base) a b 62852 11. Remove the gasket from the gear housing. a b a - Shift shaft b - O‑ring c - Gasket c 62853 12. Lift the shift shaft until the spring pin aligns with the notch in the shift shaft bracket. Rotate the shift shaft 90 degrees, and slide the shift shaft out of the water pump base. 13. Remove the water pump base seal with a seal puller.
Gear Housing (2.15:1) 15. Inspect the shift cam for wear. If the cam follower is worn, replace the shift cam. a - Shift cam a 6607 a. Use a spring pin removal tool to remove the retainer pin securing the shift cam to the shift shaft. Discard the retainer pin. a - Spring pin removal tool b - Retainer pin c - Shift cam a b c 62860 Spring Pin Removal Tool b. 91‑853996‑6 Use a spring pin removal tool to secure the shift cam to the shift shaft with a new retainer pin.
Gear Housing (2.15:1) Driveshaft Holding Tool 2. 91‑804762 Remove the driveshaft from the gearcase. Retain the shims located above the upper driveshaft bearing. a b a - Driveshaft b - Shims (retained) c - Upper driveshaft bearing c 65058 3. Inspect the pinion gear teeth for breakage, rust, chipping, or excessive wear. a a - Pinion gear teeth 6616 4. If the pinion gear teeth are damaged, inspect the forward and reverse gears for damage. Forward Gear and Reverse Gear Inspection 1.
Gear Housing (2.15:1) 4. Use a bearing puller to remove the forward gear bearing assembly. c a abcd- Puller shaft Puller nut Plate Screw and washer b d 34629 Bearing Puller Assembly 5. 91‑ 83165T 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.
Gear Housing (2.15:1) 6. If the forward gear ball bearing must be replaced, use a suitable mandrel, press, and universal puller plate to remove the bearing from the forward gear. abcd- c b Universal puller plate Ball bearing Mandrel Forward gear a d 7046 Universal Puller Plate 7. 91‑37241 Inspect the propeller shaft forward gear bushing surface to determine the condition of the forward gear bushing.
Gear Housing (2.15:1) 3. If the pinion bearing must be replaced, use the pinion bearing tool to remove the pinion bearing. 65060 Pinion bearing Pinion Bearing Installation Tool Assembly a. 8M0038865 With the sleeve installed on the end of the tool, push the tool into the driveshaft bore until the flange of the tool guide rests against the surface of the gear housing. a a - Pinion bearing tool guide b - Sleeve b 65063 b. Tap on the head of the tool until the head seats against the tool flange.
Gear Housing (2.15:1) 2. Inspect the driveshaft for grooves where the water pump base oil seals contact the shaft. Replace the driveshaft if grooves are found. a a - Water pump oil seal surface 6708 Upper Driveshaft Bearing Inspection IMPORTANT: Do not remove the upper driveshaft ball bearing from the driveshaft unless replacement is necessary. The removal process will damage the bearing. 1. Inspect the upper driveshaft ball bearing for rust, roughness, or excessive wear. 2.
Gear Housing (2.15:1) 3. Insert the pinion bearing tool with the new pinion bearing into the driveshaft housing bore. a a - Pinion bearing tool b - Pinion bearing c - Driveshaft housing bore b c 65067 Pinion Bearing Installation Tool Assembly 4. 8M0038865 Tap on the head of the tool until the tool head seats against the tool flange. The pinion bearing will then be installed at the correct height in the driveshaft housing bore.
Gear Housing (2.15:1) 3. Use the pinion bearing tool to install the bearing and forward gear assembly into the gearcase. a - Pinion bearing tool b - Bearing and forward gear assembly c - Torch lamp a c b 65074 Torch Lamp 91‑ 63209 Pinion Bearing Installation Tool Assembly 8M0038865 Bearing Carrier Assembly 1. Apply 2‑4‑C with PTFE to the bearing carrier seal lips. Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Bearing carrier seal lips 92-802859A 1 2.
Gear Housing (2.15:1) 4. When installing the new needle bearing, press on the letter side of the bearing until the bearing is just below the ledge. a - Letter side of bearing b - Ledge b a 11461 5. Using a mandrel that contacts the inner diameter of the bearing race, press the new bearing onto the reverse gear. a - Mandrel b - Reverse gear bearing c - Reverse gear a b c 6766 IMPORTANT: Do not install the bearing carrier O‑ring if the torch lamp will be used on the bearing carrier.
Gear Housing (2.15:1) 7. Apply 2‑4‑C with PTFE to the new bearing carrier O‑ring. Install the O‑ring onto the bearing carrier. a - Bearing carrier b - O‑ring b a 62933 Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Bearing carrier O-ring 92-802859A 1 Water Pump Base Assembly 1. Using a suitable mandrel, 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.
Gear Housing (2.15:1) Propeller Shaft Assembly 1. Slide the clutch onto the propeller shaft with the ring on the clutch facing toward the forward gear. Ensure the hole in the clutch aligns with the slot in the propeller shaft. b a abcd- Clutch Ring faces toward forward gear Cross pin hole Slot d c 2. 34630 Install the clutch spring and cam follower into the propeller shaft. a c b d 62934 abcd- Propeller shaft Clutch Clutch spring Cam follower 3.
Gear Housing (2.15:1) 6. Install the retainer spring onto the clutch. Do not overlap the retainer spring coils. a a - Clutch retainer spring b - Clutch pin b 7. 7245 Install the propeller shaft assembly into the bearing carrier assembly. a b c a - Reverse gear/bearing carrier assembly b - Thrust washer c - Propeller shaft 62932 Pinion Gear and Driveshaft Installation IMPORTANT: Remove any lubricant from the driveshaft pinion nut threads. 1.
Gear Housing (2.15:1) IMPORTANT: Install the pinion nut with the step side of the nut against the pinion gear. a b c 4. a - Pinion gear b - Pinion nut c - Step side (install toward pinion gear) 7378 Use the driveshaft holding tool and a suitable wrench to tighten the pinion nut to the specified torque. a a - Pinion gear b - Pinion nut b 7394 Driveshaft Holding Tool Tube Ref No. 7 91‑804762 Description Loctite® 271 Threadlocker Where Used Part No.
Gear Housing (2.15:1) 5. Slide the spring and clamp over the driveshaft. Compress the spring approximately 6 mm (0.25 in.), and tighten the fastener on the clamp. abcdefg- f g e c Water pump base Water pump guide plate (with gasket) M6 x 1 screw (4) Spring, compress 6 mm (0.25 in.) Clamp Driveshaft Backlash indicator arm (install later) d b a 64955 6. Spring 8M0011503 Clamp 8M0033741 NOTE: It may be easier to rotate the gearcase nose down, while preloading the forward gear.
Gear Housing (2.15:1) Dial Indicator 91‑ 58222A 1 Dial Indicator Adapter 9. 91‑83155 Position the dial indicator tip so that it is perpendicular to and touching the notch in the indicator arm, as shown. Adjust the angle of the backlash indicator arm, as required. Tighten the fasteners on the dial indicator adapter so that the dial indicator does not move. NOTE: Ensure that the dial makes at least one full revolution as the tip is compressed into the dial indicator.
Gear Housing (2.15:1) 3. Position the shift shaft such that the spring pin is level with the notch in the shift shaft bracket. Rotate the shift shaft so that the spring pin rides along the edges of the bracket and the cam is facing in the correct direction (ramped face towards the cam follower, when installed into the gearcase). a - Shift cam ramped face a 6607 4. Place a new water pump gasket onto the gearcase housing. 5. Install the water pump base assembly onto the gearcase housing.
Gear Housing (2.15:1) Water Pump Cover Assembly 1. Align the locating tab on top of the water pump liner with the slot in the pump cover. Insert the liner into the pump cover. a - Slot in the water pump cover b - Tab on top of the water pump liner b a 62865 2. Install the water pump drive key. Use 2‑4‑C with PTFE to hold the key to the driveshaft. Tube Ref No. Description 2-4-C with PTFE 95 Where Used Part No.
Gear Housing (2.15:1) 5. Slide the pump cover onto the driveshaft. While pushing down on the water pump cover, rotate the driveshaft clockwise to install the pump cover over the impeller. 62867 6. Secure the water pump cover with four screws. Tighten the screws to the specified torque. a b a - Screws (4) b - Water pump cover 62846 Description Nm lb‑in. lb‑ft Water pump cover screws 6.0 53.1 – Propeller Shaft and Bearing Carrier Installation 1.
Gear Housing (2.15:1) 2. Rotate the driveshaft while seating the bearing carrier assembly into the gear housing, to ensure that the pinion and reverse gears are in mesh. a - Propeller shaft b - Bearing carrier assembly b a 6545 Tube Ref No. 2-4-C with PTFE 95 3. Description Where Used Part No. Bearing carrier O-ring 92-802859A 1 Secure the bearing carrier with two screws. Tighten the screws to the specified torque. a - Screws (2) a 6532 Description Nm lb‑in.
Gear Housing (2.15:1) NOTICE Installing the gear housing to the powerhead without adequately cleaning the top of the driveshaft can result in severe product damage. Any lubricant trapped in the space between the driveshaft and the crankshaft prevent the two from properly engaging. Always clean the top of the driveshaft before installing the gear housing. Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Driveshaft splines 92-802859A 1 5.
Gear Housing (2.15:1) Propeller Installation ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Coat the propeller shaft splines with one of the following Mercury products: Tube Ref No.
Gear Housing (2.
Throttle and Shift Linkage Attachments Section 7A - Throttle and Shift Linkage Table of Contents Throttle and Shift Components (Tiller Models).................. 7A-4 Remote Control Components............................................ 7A-6 Tiller Handle Models.......................................................... 7A-8 Throttle and Shift Linkage Removal............................7A-8 Shift Detent.................................................................
Throttle and Shift Linkage Lubricants, Sealants, Adhesives Tube Ref No. 95 Page 7A-2 Description 2-4-C with PTFE Where Used Part No.
Throttle and Shift Linkage Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 7A-3
Throttle and Shift Linkage Throttle and Shift Components (Tiller Models) 1 3 2 4 3 8 6 12 13 17 19 10 7 14 13 11 9 5 18 15 12 18 12 13 20 16 26 25 27 25 26 28 31 29 30 32 24 29 33 21 34 22 23 35 36 Page 7A-4 © 2018 Mercury Marine 64682 90-8M0125265 eng NOVEMBER 2017
Throttle and Shift Linkage Throttle and Shift Components (Tiller Models) Torque Ref. No. Qty.
Throttle and Shift Linkage Remote Control Components 13 15 12 13 12 15 8 26 22 19 25 24 14 22 23 16 14 11 11 21 20 18 11 17 10 18 9 7 5 29 28 27 1 2 5 3 5 4 Page 7A-6 6 © 2018 Mercury Marine 64681 90-8M0125265 eng NOVEMBER 2017
Throttle and Shift Linkage Remote Control Components Torque Ref. No. Qty.
Throttle and Shift Linkage Tiller Handle Models Throttle and Shift Linkage Removal 1. Remove the starboard driveshaft housing cover. Refer to Section 5A ‑ Driveshaft Housing Covers. 2. Remove the tiller handle control cable. Refer to Section 7B ‑ Tiller Handle Removal. 3. 4. 5. 6. 7. NOTE: It is not necessary to remove the tiller handle from the engine. Remove the air box and recoil starter. • It is easiest to remove and install these two items together.
Throttle and Shift Linkage Shift Detent Inspect the shift detent hardware. Replace any worn or damaged components. c abcd- b Shift detent springs Short detent spring Screw Port shift lever bracket a d 63463 Throttle and Shift Linkage Installation 1. 2. 3. Ensure the gearcase is in neutral. Install the vertical shift shaft, if it was removed. Apply 2‑4‑C with PTFE to the shift shaft assembly detents and contact surfaces. Tube Ref No. 95 4. 5. Description 2-4-C with PTFE Where Used Part No.
Throttle and Shift Linkage 11. Attach the shift link to the shift lever using a retaining clip and washer. 12. Install the throttle and shift bracket. Tighten the three screws to the specified torque. Description Nm lb‑in. lb‑ft Throttle and shift bracket screws 6.0 53.1 – 13. Attach the end of the neutral interlock cable to the shift lever. Temporarily secure the cable to the starter mounting bracket with the two jam nuts.
Throttle and Shift Linkage 4. Loosen one of the interlock cable jam nuts, and remove the interlock cable from the shift lever. a - Jam nuts b - Interlock cable anchored in the shift lever a b 63455 5. Remove the bow‑tie retainers and washers from the throttle and shift cables. a b d c a c b abcd6.
Throttle and Shift Linkage 10. Remove one screw, two washers, and a bushing to remove the shift link from the engine. b a a - Throttle link b - Throttle and shift bracket screws (3) c - Retaining clip and washer d - Screw, two washers, and bushing e - Shift link e d c 63465 11. Remove the starter motor. Refer to Section 2B ‑ Starter Motor Removal. 12. Remove the four screws securing the two shift lever shaft brackets. The front cowl will come loose with the brackets. 13.
Throttle and Shift Linkage 3. Install the shift shaft lever, being certain to engage the vertical shift shaft. 4. Secure the shift shaft lever with two brackets and four screws. 5. Ensure that the front cowl properly engages the midplate and the vertical shift shaft boot. 6. Tighten the four shift shaft lever bracket screws (two per bracket) and the shift detent screw to the specified torque. NOTE: If the front cowl was removed from the shift lever brackets, install it now.
Throttle and Shift Linkage 12. Attach the interlock cable to the shift arm, and temporarily secure the cable to the starter bracket with the two jam nuts. a - Jam nuts b - Interlock cable anchored in the shift arm a b 63455 13. Install the shift and throttle cables. Refer to Section 1D ‑ Remote Wiring Harness and Control Cable Installation. 14. Install the recoil starter and air box. • It is easiest to install the recoil starter and air box together.
Tiller Handle Attachments Section 7B - Tiller Handle Table of Contents Tiller Handle Features........................................................7B-2 Tiller Handle Components................................................. 7B-4 Tiller Handle Yaw...............................................................7B-8 Tiller Handle Removal........................................................7B-9 Tiller Handle Disassembly................................................. 7B-9 Throttle Cable Case...........
Tiller Handle Lubricants, Sealants, Adhesives Tube Ref No. Description Where Used 7 Loctite® 271 Threadlocker 95 2-4-C with PTFE Part No. Exposed threads of the pivot screw Tiller handle mounting screws Throttle cable end barrels, pulley face, and pulley O.D. Shift handle bushings Shift cable input rod and eyelet Throttle shaft bracket I.D. Friction knob shaft threads Tiller handle plastic bushing I.D.
Tiller Handle • Tiller handle yaw can be adjusted to change the angle of the handle to the engine. Refer to Tiller Handle Yaw. • The tiller handle is equipped with a lanyard stop switch and a spare lanyard stop switch clip. a - Lanyard stop switch b - Spare lanyard stop switch clip c - Lanyard a b c 63083 • A stop switch at the end of the tiller handle allows the operator to easily stop the engine.
Tiller Handle Tiller Handle Components 8 6 5 12 7 16 15 9 17 63 4 10 1 2 3 28 27 26 30 32 18 6 33 29 34 14 36 35 36 25 23 24 21 20 37 39 59 58 40 9 64 57 42 41 56 19 22 38 60 55 17 11 29 28 30 31 61 13 39 43 54 52 44 50 53 51 49 48 45 47 46 62 62 64701 Page 7B-4 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Tiller Handle Tiller Handle Components Torque Ref. No. Qty.
Tiller Handle Torque Ref. No. Qty. 47 1 Throttle handle outer grip 48 1 Inner throttle handle 49 1 Throttle shaft 50 1 Tension clamp 51 1 Compression spring 52 1 Plain washer 53 1 Cotter pin 54 1 Washer 55 1 Tiller handle adjusting nut 56 1 Tiller handle bracket 57 1 58 1 59 1 Pulley cover 60 1 Throttle cable pulley 61 1 Throttle cable case 62 1 63 1 Grommet 64 1 Plastic nut Page 7B-6 Description Nm lb‑in. lb‑ft Pan head screw 2.3 20.
Tiller Handle Tiller Handle Components 8 6 5 12 7 16 15 9 17 63 4 10 1 2 3 28 61 13 29 28 30 27 26 30 32 18 6 31 29 33 34 14 36 35 36 25 23 24 21 20 37 39 59 58 40 9 64 57 42 41 56 19 22 38 60 55 17 11 39 43 54 52 44 50 53 51 49 48 45 47 46 62 62 64701 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 7B-7
Tiller Handle Tiller Handle Yaw The tiller handle yaw allows the operator to change the angle of the handle up to 18° left or right of center. Each increment demarcation is 6°. 1. Remove the rubber boot covering the clamp screw nut. 2. Remove the 15 mm locknut. a - Locknut b - Rubber boot b a 63258 3. Loosen the 6 mm Allen socket head pivot screw. 63259 4. Apply Loctite® 271 Threadlocker to the exposed threads of the pivot screw.
Tiller Handle 7. Description Nm lb‑in. lb‑ft Locknut 50.0 – 36.9 Description Nm lb‑in. lb‑ft 6 mm Allen socket head pivot screw 24.0 – 17.7 Tighten the 6 mm Allen socket head pivot screw to the specified torque. Tiller Handle Removal 1. Remove the starboard driveshaft housing cover. Refer to Section 5A ‑ Driveshaft Housing Covers. 2. Undo the shift cable bracket clip by rotating the top away from the engine. 3. Remove the shift linkage clip.
Tiller Handle 2. Remove six screws from the underside of the tiller handle, and remove the top cover. a a - Screws (6) b - Lanyard stop switch b 63427 3. Remove the two grommets from the tiller handle, and remove the screw, Belleville washer, flat washer, flange spacer, and locknut that secure the tiller handle mount.
Tiller Handle 7. Cut the cable ties that secure the tiller handle harness. a - Screw b - Throttle shaft bracket c - Cable tie (2) b c c a 63429 8. Pull the throttle handle out far enough to gain access to the stop switch electrical connector. Disconnect and depin the 2‑pin male connector. 9. Pull the throttle handle and lift to remove it from the tiller handle housing. 10. Remove the locknut that secures the shift cable to the shift lever. Lift the shift cable from the retaining slot.
Tiller Handle 2. Remove the cables and pulley from the cable case. 3. Inspect the pulley for cracks. Inspect the cables for kinks, frayed or broken cables. Ensure that the cables slide freely in the outer jacket. 4. If any defects are found, replace the component. a d b c e abcde- 3008 Cable case Pulley Cover Cables Screw and washer Assembly 1. Install the cable end barrel into the slot on the pulley. b a a - Throttle cable b - Cable end barrel in slot c - Pulley c a 2.
Tiller Handle 4. Ensure that the cable ends are fully installed in the case. a - Cable ends installed in case a a 5. 6. 3010 Hold the cables in place and install the cover with a screw. Tighten the screw to the specified torque. Description Nm lb‑in. lb‑ft Pulley cover screw 2.0 17.7 – Rotate the pulley, and ensure that the cables move freely. a b a a - Throttle cable (2) b - Pulley cover screw c - Pulley cover c 64753 Tiller Handle Assembly 1.
Tiller Handle 5. Insert the lanyard stop switch through the tiller handle housing and secure it from below with a plastic nut. Tighten the nut to the specified torque. a a - Lanyard stop switch b - Nut b 63441 6. Description Nm lb‑in. lb‑ft Plastic nut 2.0 17.7 – Apply 2‑4‑C with PTFE to the shift cable input rod and eyelet. Tube Ref No. 95 Description 2-4-C with PTFE Where Used Part No. Shift cable input rod and eyelet 92-802859A 1 7.
Tiller Handle d. Feed the stop switch wires through the throttle cable pulley housing, attach the 2‑pin male connector to the wires, and connect the connector to the tiller handle harness.
Tiller Handle 11. Install the friction knob: a. Apply 2‑4‑C with PTFE to the threads of the friction knob shaft. Tube Ref No. Description 2-4-C with PTFE 95 b. c. d. e. Where Used Part No. Friction knob shaft threads 92-802859A 1 Insert the friction knob through the tiller handle housing. Place the large washer, small washer, and spring on the friction knob shaft. Thread the shaft into the throttle shaft clamp until it stops.
Tiller Handle 15. Attach the cover to the tiller handle, using six screws. Ensure that the tiller harness grommet is correctly seated between the cover and the tiller handle housing. Tighten the screws to the specified torque. Description Nm lb‑in. lb‑ft Tiller handle cover screws 2.3 20.3 – 16. Attach the lanyard cord to the lanyard stop switch. a a - Screws (6) b - Lanyard stop switch b 63427 Tiller Handle Installation 1.
Tiller Handle Shift Cable Installation 1. Release the tension on the neutral interlock cable by pulling it out and away from the recoil housing. a a - Neutral interlock cable tension spring b - Neutral interlock cable b 9696 2. Remove the single screw that secures the 14‑pin connector bracket, and remove the bracket. 64461 3. Loosen the shift detent screw. abcd- b Fuel inlet hose Horizontal shift shaft Shift shaft detent springs Shift detent screw c d a 64462 4.
Tiller Handle c. Push the lower shift shaft down to the reverse stop. a - Coupler on upper shift shaft b - Lower shift shaft in reverse (full down) c - Jam nut all of the way down a b c 64466 d. Press the shift linkage aft to rotate the outboard’s horizontal shift shaft to the full reverse stop. 64465 e. Maintain alignment of the upper and lower shift shafts while threading the coupler at least five turns onto the lower shift shaft. f. Use two wrenches to lock the jam nut against the coupler.
Tiller Handle 6. 7. Verify the detent spring position: a. Verify no engagement or clutch drag when the horizontal shift shaft is rotated to neutral (detent spring fully seated in the neutral detent). b. Verify forward gear engagement when the horizontal shift shaft is rotated to forward (detent spring fully seated in the forward detent). c. Adjust the detent spring position as required. Determine the center of the lost motion of the shift cable: a. Shift the tiller handle to neutral. b.
Tiller Handle c. • Verify the recoil starter interlock is disengaged. • Verify the electric neutral start switch allows the engine to fire. Shift the tiller into reverse. • Verify clutch/gear engagement. • Verify the detent spring is fully seated in the horizontal shift shaft cam notch. • Lightly coat the unthreaded portion of the shift cable output rod with 2‑4‑C with PTFE. Tube Ref No. 95 d. Description 2-4-C with PTFE Where Used Part No.
Tiller Handle 4. Insert the anchor of the bottom cable into the lower slot in the throttle drum. Insert the anchor of the top cable into the upper slot in the throttle drum. Coat both anchors with 2‑4‑C with PTFE. Tube Ref No. Description 2-4-C with PTFE 95 Where Used Part No. Throttle cable anchors 92-802859A 1 5. Rotate the throttle grip to the idle position. 6. Slide the throttle cables into the slots on the throttle bracket. Temporarily secure the cables so as to allow throttle grip rotation.
Tiller Handle 3. Rotate the tiller twist grip to the wide‑open throttle (WOT) position. Ensure that the wide‑open throttle stop on the throttle drum rests against the throttle stop.
Tiller Handle Notes: Page 7B-24 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Recoil Starter Manual Starter Section 8A - Recoil Starter Table of Contents Recoil Starter Components................................................8A-4 Recoil Starter Removal...................................................... 8A-6 Recoil Starter Disassembly................................................8A-6 Recoil Starter Assembly.....................................................8A-7 Recoil Starter Installation.................................................
Recoil Starter Lubricant, Sealant, Adhesives Tube Ref No. Description Where Used 7 Loctite® 271 Threadlocker 95 2-4-C with PTFE Page 8A-2 Part No.
Recoil Starter Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 8A-3
Recoil Starter Recoil Starter Components 6 5 8 7 9 9 10 14 4 13 3 2 1 11 12 17 16 18 15 19 20 26 21 25 24 23 Page 8A-4 © 2018 Mercury Marine 22 64650 90-8M0125265 eng NOVEMBER 2017
Recoil Starter Recoil Starter Components Torque Ref. No. Qty.
Recoil Starter Recoil Starter Removal 1. 2. Remove the three screws that secure the air box to the engine, and remove the air box or position it out of the way. Refer to Section 3C ‑ Air Box Removal. NOTE: Due to the routing of the crankcase breather hose behind the throttle body, it is easiest to not fully remove the air box, if no other components are being removed. Remove the three screws securing the recoil starter assembly to the engine. 62950 Shown with air box removed 3.
Recoil Starter 5. Remove the screw securing the recoil friction plate to the recoil housing. Remove the recoil friction plate. b c d a abcd- Recoil rope Sheave Screw securing recoil friction plate Rotate sheave clockwise 63303 6. Carefully remove the sheave. 7. Remove the recoil spring if replacement is needed. 8. Disengage the interlock lever spring from the recoil lock. 9. Pinch the recoil lock retainer and push the recoil lock out of the recoil housing.
Recoil Starter 1. Using 2‑4‑C with PTFE, lubricate the area of the recoil housing where the recoil spring is located. 2. Install the recoil spring into the recoil housing. a a - Recoil spring b - Lubricate with 2‑4‑C with PTFE b 9726 Tube Ref No. 95 3. Description 2-4-C with PTFE Where Used Part No. Recoil housing 92-802859A 1 Attach the recoil rope to the sheave: a. Tie a knot on one side of the recoil rope and insert the recoil rope through the sheave. b.
Recoil Starter d. Install the starter pawl onto the sheave. a a - Starter pawl b - Starter pawl return spring b 9730 Tube Ref No. 95 e. Description 2-4-C with PTFE Where Used Part No. Starter pawl bore on the sheave 92-802859A 1 Secure the starter pawl with the E‑ring retained during disassembly. 9725 5. Install the sheave onto the recoil housing. The sheave catch must interlock with the recoil spring for the recoil to function properly. a a - Recoil spring b - Sheave catch b 9732 6.
Recoil Starter Tube Ref No. 2-4-C with PTFE 95 b. c. d. Description Where Used Part No. Friction plate 92-802859A 1 Insert the friction plate spring through the wire loop. Align the tabs on the recoil housing with the holes on the friction plate. Apply Loctite® 271 Threadlocker to the threads of the friction plate retaining screw. Tighten the friction plate retaining screw to the specified torque.
Recoil Starter 9. Install the recoil lock: a. Insert the recoil lock into the recoil housing. b. Push the recoil lock until it snaps into place. b a a - Recoil lock b - Sheave c - Recoil lock bore c 9749 c. Place the interlock lever spring onto the recoil lock. a b a - Recoil lock b - Interlock lever spring c - Recoil lock retainer c 9723 Recoil Starter Installation 1. Place the recoil starter into position on the engine. 2.
Recoil Starter 6. Secure the recoil starter assembly to the engine with the three screws. Tighten the screws to the specified torque. 62950 7. Description Nm lb‑in. lb‑ft Recoil starter assembly screws (3) 6.0 53.1 – Complete the air box installation. Refer to Section 3C ‑ Air Box Installation. Neutral Interlock Cable Adjustment 1. On tiller models: Ensure the tiller handle shift cable is properly adjusted. Refer to Section 7B ‑ Shift Cable Installation. 2. Ensure the outboard is in neutral.
Color Diagrams Color Diagrams Section 9A - Color Diagrams Table of Contents 15/20 EFI FourStroke, Manual Start, Manual 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, and Power Tilt................................................................
Color Diagrams Notes: Page 9A-2 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
Color Diagrams Notes: 90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 9A-3
Color Diagrams 15/20 EFI FourStroke, Manual Start, Manual Tilt 12345678910 11 12 13 14 15 16 - Page 9A-4 Injector #1 Injector #2 Idle speed control valve (idle air control) Vapor separator tank/high‑pressure fuel pump Temperature and manifold absolute pressure (TMAP) sensor Throttle position sensor (TPS) Engine coolant temperature (ECT) sensor 20‑amp fuse (not used) Not used (weather capped) Stator Stator yellow and white wires (not used) Not used 15‑amp fuse (not used) Cowl‑mounted start switch (not use
15/20 EFI FourStroke Manual Start, Manual Tilt 1 2 1 2 1 2 LT GRN/BLK BLU GRN/RED BLU BLK/WHT BLK/YEL BLK/GRN GRN/WHT RED/WHT BLK/BLU GRN/ORN RED/WHT BLU/WHT BLK/BLU 17 1 2 BLK BLK 1 2 3 BLK BLK/YEL 1 2 3 4 GRN 1 2 3 1 2 14 15 RED RED 15A RED 1 2 13 12 20A RED RED 1 2 9 RED 8 2 1 2 LT GRN/RED BLU 1 16 1 2 3 1 2 1 2 1 2 3 6 WHT YEL BLU BLK/RED 1 2 3 4 RED 3 BLK/BLU GRN/YEL 2 10 7 1 2 1 5 4 J2 J1 BLU/WHT GRN/YEL GRN/WHT J6 J2 BLK/BLU YEL BRN BRN/WHT J1
15/20 EFI FourStroke Electric Start, Remote Control 13 12 RED RED/WHT BLU/WHT BLK/BLU 1 2 RED RED GRN/WHT RED/WHT BLK/BLU GRN/ORN 17 15A RED BLK/WHT BLK/YEL BLK/GRN 1 2 BLK GRN/RED BLU 1 2 BLK 1 2 3 BLK 1 2 3 4 WHT YEL BLU BLK/RED 1 2 3 BLK RED YEL WHT 1 2 RED RED 1 2 LT GRN/BLK BLU 2 1 2 16 15 14 20A LT GRN/RED BLU 1 1 2 1 2 9 8 2 1 1 2 3 RED 1 2 3 4 1 2 3 RED 3 7 6 BLK GRN BLK RED 4 2 10 BLK/BLU GRN/YEL 1 5 J2 J1 RED BLU BLK/RED J3 36 18 1 18 19 20 21
Color Diagrams 15/20 EFI FourStroke, Electric Start, Remote Control 12345678910 11 12 13 14 15 16 17 18 - Injector #1 Injector #2 Idle speed control valve (idle air control) Vapor separator tank/high‑pressure fuel pump Temperature and manifold absolute pressure (TMAP) sensor Throttle position sensor (TPS) Engine coolant temperature (ECT) sensor 20‑amp fuse (stator output) Voltage rectifier/regulator Stator Starter solenoid ground Battery negative (–) Starter Starter solenoid Battery positive (+) 15‑amp fu
Color Diagrams 15/20 EFI FourStroke with Electric Start, Tiller Handle, and Manual Tilt 12345678910 11 12 13 14 15 16 17 - Page 9A-6 Injector #1 Injector #2 Idle speed control valve (idle air control) Vapor separator tank/high‑pressure fuel pump Temperature and manifold absolute pressure (TMAP) sensor Throttle position sensor (TPS) Engine coolant temperature (ECT) sensor 20‑amp fuse (stator output) Voltage rectifier/regulator Stator Starter solenoid ground Battery negative (–) Starter Starter solenoid Ba
15/20 EFI FourStroke with Electric Start, Tiller Handle, and Manual Tilt 12 1 2 21 19 GRN GRN RED GRN GRN BLK BLK/YEL 1 2 RED RED RED/WHT BLU/WHT BLK/BLU RED GRN/WHT RED/WHT BLK/BLU GRN/ORN 18 15A 1 2 BLK BLK/WHT BLK/YEL BLK/GRN 1 2 BLK GRN/RED BLU 1 2 BLK 1 2 3 WHT YEL BLU BLK/RED 1 2 3 4 16 15 14 BLK RED YEL WHT 1 2 3 RED RED 1 2 BLK/BLU GRN/YEL 1 2 LT GRN/BLK BLU 2 1 2 17 BLK BLK 9 20A LT GRN/RED BLU 1 8 1 2 3 1 2 1 2 1 2 3 20 RED 1 2 3 4 RED 3 7 6 BL
15/20 EFI FourStroke with Electric Start, Tiller Handle, and Power Tilt 1 13 5 4 2 3 7 1 2 3 4 20 9 8 2 1 12 17 16 15 14 20A 2 1 6 1 2 3 1 2 1 1 2 3 2 10 18 15A 1 2 19 21 22 UP RED/PPL LT BLU/WHT GRN/WHT BLK BLK BLK BLK/YEL GRN RED GRN RED GRN GRN GRN GRN 1 2 RED RED RED RED/WHT BLU/WHT BLK/BLU RED GRN/WHT RED/WHT BLK/BLU GRN/ORN RED BLK/WHT BLK/YEL BLK/GRN 1 2 BLK GRN BLK RED GRN/RED BLU 1 2 BLK LT GRN/BLK BLU 1 2 BLK 1 2 3 BLK 1 2 3 4 WHT YEL BLU BLK/RED
Color Diagrams 15/20 EFI FourStroke with Electric Start, Tiller Handle, and Power Tilt 12345678910 11 12 13 14 15 16 17 18 19 20 - Injector #1 Injector #2 Idle speed control valve (idle air control) Vapor separator tank/high‑pressure fuel pump Temperature and manifold absolute pressure (TMAP) sensor Throttle position sensor (TPS) Engine coolant temperature (ECT) sensor 20‑amp fuse (stator output) Voltage rectifier/regulator Stator Starter solenoid ground Battery negative (–) Starter Starter solenoid Batte
Color Diagrams Notes: Page 9A-8 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
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