Outboard OptiMax I Technician’s Guide 1
Table of Contents Section 1 – General Information Section 2 – Powerheads Section 3 – Air Systems Section 4 – Fuel Systems Section 5 – Oil Injection Systems Section 6 – Electrical Systems Section 7 – Warning System and Diagnostics Section 8 – Tools for OptiMax Section 9 – Service Bulletins 3 2
Section 1 - General Information 1-1 90-898305 3
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 Installation .....................................................................................................5 14 Pin Adapter and Control Harnesses .........................................................5 Adapter Harnesses (Key/Choke)...........................
Hydrocarbons – HC..................................................................................... 50 Carbon Monoxide – CO .............................................................................. 50 Oxides of Nitrogen - NOx ............................................................................ 50 Controlling Emissions.................................................................................. 50 Stoichiometric (14.7:1) Air/Fuel Ratio ....................................................
Installation Notes _______________________ 14 Pin Adapter and Control Harnesses _______________________ Models Affected _______________________ 4-stroke models 9.9 thru 225 HP V-6 EFI (Excluding Verado) _______________________ 2-stroke V-6 Outboards 135 thru 250 HP (Excluding Jet Drive) The 2006 models listed above will be changing to a 14 pin connector for the main engine to boat control harness connection.
Notes _______________________ _______________________ _______________________ Adapter Harness 84-896542T_ Adapts 2006 model year and newer engines that use the 14 pin harness to the old round 8 pin control or key/choke harness. Use with engines not being equipped with SmartCraft gauges.
Analog Instrument Harness Notes _______________________ 84-892990T01 connects to the 10 pin/J-box connection on new 14 pin key/choke harness, to operate analog gauges _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ New Test Key Switch 14 pin15000A12 Service tool to isolate the boat from the engine.
Notes _______________________ IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be 7.6 cm (3 in.) for the final wiring installation. _______________________ 1. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness. _______________________ 2. Install cable pulling tool to data harness. _______________________ _______________________ _______________________ 3. Secure pulling tool with 2 cable ties.
1. Standard (original) cable length and wire gauge size.
Notes _______________________ _______________________ _______________________ Battery Information All OptiMax • Do not use deep cycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA or 180 Ah. • When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.
Connecting Battery Cables and DTS Power Harness Notes _______________________ _______________________ _______________________ _______________________ _______________________ • Install DTS power harness directly to the starting battery only. _______________________ • Do not extend lead length of harness. _______________________ • See accessory manual for optional lead connection kit.
Notes Single Engine - Battery At Stern _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________
Single Engine - Battery At Helm 1-13 90-898305 14
Notes Dual Engine - Battery At Stern _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Important: Make sure twin applications have the common ground.
Dual Engine - Battery At Helm Important: Make sure twin applications have the common ground. If missing can result in open DTS fuse.
Notes _______________________ Connecting 04 DTS 10 Pin Data Harness Single Engine Single Helm • SC5000 data cable (yellow) with termination resistor at engine end is required. _______________________ • Install termination resistor in the junction box. _______________________ • Fasten cable connections within 25.4 cm (10 in.) of the junction box.
Command Module Installation 1. Plug the command module connector into the command module. Notes _______________________ _______________________ 2.
Notes _______________________ Single Helm Command Module Harness Installation _______________________ 1. Connect the 14 pin Deutch connector on the command module harness to the 14 pin data harness. _______________________ 2. Ensure the CAN 1 and CAN 2 connectors have terminator resistors installed, and the CAN 3 connector is sealed with a weather cap.
Panel Mount Control Wiring Connections Notes 1. Connect the trim harness and lever harness. _______________________ 2. Insert the bayonet end of the lever harness into the bracket hole. This will prevent the connector from pulling out. See illistration below _______________________ 3. Connect the lanyard stop switch bullet connectors. _______________________ IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle movement.
Notes _______________________ Wiring Guidelines for Electrical Boat Accessories ! _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ IMPORTANT: Do not connect boat accessories to 12 volt or ignition key switch DTScircuits. Use a separate switched 12 volt source for wiring boat accessories.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Key Switch Options _______________________ • Key Switch Three Position (Off, Run, and Start) has shorter key and mounting length 3/4 inch cut out. Without mounting hardware.
Notes _______________________ Wiring Instructions for Non-Mercury Marine Ignition Key Switch _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ • The ignition key switch must comply with Mercury specifications for key switches and controller input switches (897741-5 or 89
• CDS version 5.09 or higher for 06 DTS System • CDS version 3.23 or higher for 05 DTS System • CDS version 3.12 or higher for 04 DTS System • For step by step instructions reference the Help Icon (purple book with question mark) on top row of CDS.
TERMINATION RESISTOR PLACEMENT Notes _______________________ _______________________ _______________________ _______________________ _______________________ NOTE: Termination resistors are designed to reduce noise and provide proper DC voltage levels on the C.A.N. Bus circuit. 1. Each system must include exactly two (2) termination resistors. 2. Termination resistors must be located at the furthest ends of the main C.A.N. Bus trunk. 3. The main C.A.N. Bus trunk may not exceed 36.6 m (120 ft.
Harness Termination Resistor (One End) Some of the SmartCraft wiring harnesses (84-879981T_) are designed with the termination resistor at one end. Harness termination resistors are used primarily for installations which do not require a junction box in the rear of the boat. Harness Termination Resistor (Both Ends) Harness (84-879982A20, 30) include termination resistors at both ends and may be used to connect System Monitor or System tachometer directly to the engine without junction boxes.
Notes System Tachometer/Speedometer Wiring Configurations _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ____________________
Notes Dual Engine _______________________ IMPORTANT: The location of the junction box termination resistors are critical forproper system function. All unused junction box ports must be sealed with a weathercap. Disconnect the power harness on the port engine. _______________________ _______________________ _______________________ If running a single CAN bus (blue data cable) on dual or more engine installations, only one engine is used to supply 12 volt power.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ IMPORTANT: When using single CAN line make sure to disconect one 8 pin po
Notes Installing Standard Analog Tachometer to Digital Optimax Engines This procedure allows a standard analog tachometer to be connected to the tachometer plug that is incorporated into the key switch harness. _______________________ NOTE: SmartCraft speedometer or tachometer communicate with the engine through the gray lead and the brown/white lead in the key switch harness.
Notes Installing Standard Analog Trim Indicator Gauge to Digital Optimax Engines _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ NOTE: SmartCraft speedometer or tachometer communicate with the engine through the gray lead and the brown/white lead in the key switch harn
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ NOTE: If none of the digital sensors (oil level, fuel level, paddle wheel, speedo, and trim) are used, digital harness P/N 84-859244T1 could be removed from the engine. The 8-pin connection on the engine should then be capped with P/N 877613A1. Installing Standard Analog Temperature Gauge to Digital Optimax Engines 1.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Installing Standard Speedometer Gauge to Digital Optimax Engines NOTE: The digital speedometer sensor must be disconnected to connect the analog speedometer.
Installing Standard Water Pressure Gauge to Digital Optimax Engines 1. Remove the RED plug P/N 22-859732 from the connector at the end of the water pressure hose (gray color). This will allow a direct connection of later style Mercury water pressure gauge. NOTE: If older Mercury or after market water pressure gauge is used, barb fitting adapter P/N 22-859731 must be installed into the coupler.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ IMPORTANT: Most vessels have Coast Guard and/or static grounds on their fuel tank. Do not add additional grounds. This is to prevent ground loop problems (power feeding back on sensor grounds) which can cause high idle and potential faults. See bulletin 2000-13.
System Wiring Installation Checklist Notes Data Cable • • Verify the data harness is not routed near sharp edges, hot surfaces or moving parts. Verify data harness is not routed near ignition components (coils, spark plug leads, and spark plugs), high power VHF coax or radios. • • Verify the data harness is not routed near sharp edges, hot surfaces or moving parts. Ensure the harness connections are fastened within 25.4 cm (10 in.) of the junction box.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Remote Control Cables Remote control cables are the mechanical connection between the control box and engine, selection and use of the high quality cables are imperative in maintaining this connection. Control cables are designed with a hard composite outer shell (casing) and with a solid inner core (wire).
Console Mount Remote Controls Notes 1. When measuring cable length for a console mount remote control, measure along theactual selected cable routing path and add 18 inches (457 mm) to the total. _______________________ _______________________ _______________________ 2. Divide by 12 in. (304 mm). _______________________ _______________________ 3. This is the length of the throttle and shift cables in feet.
Notes _______________________ _______________________ _______________________ _______________________ SHIFT EFFORT TOOL Part Numbers (current at time of print) • MPC 4000 Gen II 91-892535A01 • MCC 4500 Gen II, 91-892539A01 • MSC Commander 4000 Side Mount Tool OB, 91-892542A01 • MPC 4000 Gen II Panel Mount Tool with lock bar 91-892547A01 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ____________________
2. Remove the throttle only button covering the hex nut in the base of the remote control using a screwdriver or similar tool. Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 3. Move the remote control into the NEUTRAL (N) position.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ b. If the neutral lock button is on the side of the handle, firmly push the clip down. You may feel some resistance as the button is pushed in.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Torque Specifications Engine Not Running _______________________ _______________________ CABLES NOT CONNECTED (OUTBOARD MODELS) NOTE: The torque specifications do not reflect the force required to move the handle through the detent. 1. Measure the torque by moving the remote control handle to the detent.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 4. There are three methods for activating the priming process. • CDS-Oil Pump Prime in ACTIVE TEST will activate the priming process. • DDT-Oil Pump Prime in SPECIAL FUNCTIONS will activate the priming process.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Priming the Oil Injection Pump Before starting engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ PRIMING THE OIL INJECTION PUMP a. Connect the fuel hose. Fill the fuel system by squeezing the primer bulb. Squeeze the fuel line primer bulb until it feels firm. b. Turn the ignition key switch to the “ON” position for three seconds. This operates the electric fuel pump. c.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ a- Fill Cap _______________________ Propeller Installation _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Flow Torqu
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ The Flo-Torq III plastic drive sleeve assembly has a small forward/aft clearance so that it or the prop is not locked to the prop shaft. This allows the two hub pieces to rotate ± 10° relative to each other, and allows the springs to absorb the impacts from the combustion cycles instead of the clutch dogs.
Notes _______________________ Emissions Information _______________________ Models Affected _______________________ MERCURY/MARINER/FORCE/SPORT JET _______________________ 1998 and Later 2.
The responsibilities listed above are general, and are 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 EPA at the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St.
Notes _______________________ Hydrocarbons – HC _______________________ Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons.
Outboard Hydrocarbon Emissions Reductions 8 1/3% _ PER YEAR OVER 9 MODEL YEARS Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ __________________
Engine Emission Certification Label Notes Your outboard has been labeled on the cowl with one of the following star labels. _______________________ The Star Label means Cleaner Marine Engines. _______________________ _______________________ _______________________ _______________________ _______________________ The Symbol for Cleaner Marine Engines Means: Cleaner Air and Water – for a healthier lifestyle and environment.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ __
Speed/Density Operation Notes To determine the density of the air in the intake manifold, we need to know the intake manifold vacuum, which we measure with the MAP (Manifold Absolute Pressure) sensor. It is important to remember that a MAP sensor measures the manifold pressure above absolute zero (like a barometer), while a conventional vacuum gauge measures the manifold pressure below the current atmospheric pressure.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Stratified VS Homogenized Charge OptiMax engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge.
Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1.
Notes _______________________ _______________________ _______________________ _______________________ Theory of Operation - V6 Models Air Induction Through Crankcase Combustion air enters the cowl through holes located in the top aft end of the cowl. The cowl liner directs this air to the bottom of the powerhead. This limits the exposure of salt air to the components inside the engine cowl.
Air Compressor System Air from inside the engine cowl is drawn into the compressor through the flywheel cover or air plenum. This cover acts like a muffler to quiet compressor noise and contains a filter to prevent the ingestion of debris into the compressor. A restrictor is located between the filter and compressor.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ __
Oil Notes Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil is stored inside a standard remote oil reservoir. Crankcase pressure will force oil from the remote oil reservoir into the oil storage tank on the side of the powerhead. Oil will flow from the oil storage tank into the oil pump. The oil pump is a solenoid design. It is activated by the ECM and includes pistons with corresponding discharge ports. The oil pump is mounted directly onto the powerhead.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ Compressor Notes: To aid in starting when the air rail pressure is low and before the compressor has time to build pressure, the direct injector is held open by the ECM. This allows the compression from inside the cylinders to pressurize the air rail faster (1 or 2 strokes, or 60° of crankshaft rotation). Idle Notes: Idle quality is controlled by fuel volume and fuel timing.
Theory of Operation - 3 Cylinder Models Air Induction Through Crankcase Combustion air enters the cowl through holes located in the top aft end of the cowl. The cowl liner directs this air to the bottom of the powerhead. This limits the exposure of salt air to the components inside the engine cowl. Once inside the cowl the air enters the plenum through the throttle shutter which is located in the plenum assembly. The air then continues through the reed valves and into the crankcase.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Fuel Fuel for the engine is stored in a typical fuel tank. A primer bulb is installed into the fuel line to allow priming of the fuel system.
Electrical Notes The electrical system consists of the PCM, crank position sensor (flywheel speed & crankshaft position), throttle position sensor (TPS), MAP sensor, engine temperature sensor, ignition coils and injectors (fuel & direct). The engine requires a battery to start (i.e. the ignition and injection will not occur if the battery is dead). The system will run off of the alternator.
3 Cylinder/1.5 Liter Notes _______________________ 75/90/115 HP _______________________ Cowls (Upper & Lower) _______________________ • One piece light weight upper cowl. _______________________ • Two piece lower cowls that extend down the drive shaft housing. The extended lower cowls have sound blankets to reduce engine noise. _______________________ • Removable panel on lower Port cowl to allow installation of control cables.
Notes Emissions & Noise Levels _______________________ • Three star emission levels _______________________ • Operator ear sound pressure level (ICOMIA 39/94: 83.2 dBA _______________________ Powerhead _______________________ • Three Cylinder, 1.5 Liter _______________________ • Same cylinder bore (92.1131 mm (3.6265 in.) as 3.0 Liter Outboard _______________________ • Lost foam cylinder block with one piece block, head and water jacket design.
Cooling System Notes • Thermostat/poppet valve controlled. • 142 degree thermostat • Water deflectors (3) to direct water flow around cylinders.
Notes Mid-Section _______________________ • Larger upper and lower mounts _______________________ • Integrated upper mount clamp and cowl seal retainer _______________________ • Cast in upper mount pockets _______________________ • Improved shift shaft clearance • Upper and lower mount limit bumpers • Will replace current 75 – 125 HP 2 –stroke midsection • Clamp and swivel bracket common with current 75 – 125 2-stroke _______________________ _______________________ ______________________
Accessories Notes 1.5L ACCESSORIES: _______________________ _______________________ • Three gallon remote oil tank kit P/N 1257-8742A25 _______________________ • Tiller handle kit, will not be ready for start of production estimated to be ready late summer 2003. _______________________ • Costal Flush kit P/N 858566A02 is a hose that is run out the front of the cowling to attach a hose to flush the engine. This will be standard on salt water version.
Notes Power Trim _______________________ • Common power trim with current 75 -125 2-stroke _______________________ • Analog power trim position sender kit will be standard after S/N 0T846415. _______________________ _______________________ Lower Unit _______________________ • - 75/90 2.33:1 Teeth 28/12 _______________________ _______________________ - 115 Internal components common with current 75 – 125 2-stroke, except drive shaft.
Section 2 - Powerheads 2-1 90-898305
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 Mechanical Changes to the 2.5L & 3.0L Litre Powerhead ................................4 OptiMax Cylinder Head .....................................................................................4 Head Gasket ...........................................................
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Mechanical Changes to the 2.5L & 3.0L Litre Powerhead 1) Cylinder Head a) Direct injector located in the top of the cylinder head. b) 5/8” hex, long reach spark plug - puts the tip in the direct injector spray pattern.
Head Gasket Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ The 1998/99 2.5L head gasket is aluminum (0.100” thick) with an O-ring type seal on both sides. 2.
Notes 3.0L 2003 MODEL YEAR _______________________ CYLINDER BORE O-RINGS _______________________ Cylinder bore sealing O-rings have changed size and material. O-ring seals separately will NOT back fit to prior model years. _______________________ _______________________ _______________________ SIZE: Cylinder head seal is .070 (177mm ) smaller in diameter to increase clearance between the water dam and water passages.
Model 175 Optimax Notes 2001 MY _______________________ This engine is based on the 2.5 Litre OptiMax. Differences between 175 HP and the 150 HP, 2.5 Litre OptiMax are: _______________________ • ECM calibration • Head bolts for the 175 heads will be _ inch shorter then the 135 and 150 HP. • New open chambered cylinder head for increased power. • Cylinder liners (different porting) • Added holes in flywheel cover for increased airflow into air plenum to help increase HP.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ O–Ring Cylinder Head 2001 MY The cylinder head O-ring seals have a new profile/ design. The purpose of this new design is to fill as much of the O-ring groove as possible. This pre-vents oil from accumulating around the O-ring and breaking down the O-ring material. 2.5 Litre P/N 25-859772 P/N 25-859772-1 SST 3.
Pistons Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _________________
Notes _______________________ _______________________ Piston Profile 2003 MY New piston profile and combustion bowl. _______________________ New profile for improved piston fit, and increased durability. _______________________ New combustion bowl for improved combustion of fuel charge.
Section 3 - Air System 3-1 90-898305
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 Air Compressor Exploded View ........................................................................4 Air Compressor System ................................................................................4 2002 MY and Up- 2.5L Air Compressor Flow Diagram.............
Notes _______________________ Air Compressor Exploded View _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Air Compressor System DESCRIPTION • Air from inside the engine cowl is drawn into compressor through the flywheel cover or plenum.
2002 MY and Up- 2.
a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) Water Inlet to Fuel Rail q) Air [79 _ 2 psi (544.0 _ 13.8 kPa)] r) High Pressure Fuel [89 _ 2 psi (613.5 _ 13.8)] s) Air Regulator [79 _ 2 psi (544.0 _ 13.8 kPa)] t) Fuel Regulator [89 _ 2 psi (613.5 _ 13.
2002 MY and Up - 3.
Notes a) b) c) d) e) f) g) h) i) j) k) l) m) Fuel Regulator [89 ±2 psi (613.5 ±13.8 kPa)] n) #4 Fuel Injector o) Air Regulator [79 ± 2 psi (544.0 ± 13.8 kPa)] p) #2 Fuel Injector q) Compressor Water Inlet r) Port Fuel Rail s) Air Pressure Test Valve t) Excess Air Return to Air Plenum u) Excess Fuel Return to VST v) 40 psi Check Valve (Not on All Models) w) Water Inlet to Fuel Rail Air Inlet Air Filter Compressor Air Inlet Air [79 ± 2 psi (544.0 ± 13.
2004 MY 1.
Notes a - Excess air return to adaptor plate b - Air muffler _______________________ c - Water outlet from fuel rail _______________________ d - Air regulator – 648.1 ± 13.8 kPa (94 ± 2 psi) _______________________ e - Fuel regulator – 744.6 ± 13.8 kPa (108 ± 2 psi) _______________________ f - Fuel rail _______________________ g - Fuel inlet to fuel rail – 744.6 ± 13.
Notes _______________________ _______________________ Air Pressure Regulator The air pressure regulator is designed to limit the air pressure inside the rails to approximately 80 psi (95 psi on 1.5L Models). _______________________ The air regulator uses a spring (pressure) to control the air pressure. This spring (80 or 95 psi) holds the diaphragm against the diaphragm seat. The contact area blocks (closes) the air inlet passage from the excess air, return passage.
Air Regulator Tool – P/N 91-889431 Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ______________
Section 4 - Fuel System 4-1 90-898305
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 Powerhead Long Term Storage ........................................................................4 Storage Preparation ......................................................................................4 Fuel Starvation...........................................
Notes _______________________ _______________________ _______________________ _______________________ _______________________ Powerhead Long Term Storage Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer).
FUEL ADDITIVE RECOMMENDATION (QUICKLEEN) Notes See Service Bulletin 2001-12 _______________________ Today’s OptiMax engine control systems allow only minute quantities of air and fuel to reach the combustion chamber in order to produce minimal emissions. But, these diminutive amounts of air and fuel are easily obstructed by fuel injector, direct injector and combustion chamber deposits.
Notes _______________________ _______________________ _______________________ _______________________ Fuel Starvation See Service Bulletin 2001-17 Models Affected MERCURY/MARINER 1987 and Later, 30 Thru 250 HP, (with square fuel pump) _______________________ FORCE _______________________ 1994-1/2 and later 40 Thru 120 HP, 1997 and later 175 Sport Jet _______________________ _______________________ _______________________ _______________________ _______________________ It is important that fuel suppl
NOTE: Make the “TEE” fitting connection as close to the fuel pump as possible.
Test Procedure Notes _______________________ PUMP CAPABILITY TEST Before proceeding with the system vacuum test, confirm that the pulse fuel pump is capable of supplying the required vacuum. To do this, start the engine and run at idle speed, pinch off/restrict the fuel supply hose between the vacuum gauge and fuel tank, using tubing clamp. Normal Reading 2.5 in. of vacuum (mercury) or higher, proceed to fuel system leak test.
Notes _______________________ _______________________ _______________________ VACUUM TEST The system vacuum test is normally performed at an idle speed. As engine RPM increases, there will be a slight increase in vacuum; this increase should not exceed normal readings at any RPM. Normal Reading Below 2.5 in. of Vacuum (mercury) Reading above 2.5 in.
NOTE: Before driving the check valve pin into the retainer, support the pump housing on the opposite side, directly below the check valve retainer using a socket or spacer. This will prevent distortion or cracking of the pump housing. CORRECT INCORRECT a) Check Valve Retainer b) Check Valve The new plastic check valve started in production at the serial numbers listed below: MERCURY/MARINER 200-225 HP, 3.0L Carb/EFI/OptiMax USA 0G925400 135-200 HP, 2.0/2.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ PULSE FUEL PUMP RUNING CHANGE There is continued improvement planned for the square pulse driven fuel pump used on most of the larger 2 stroke outboards.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Basic Fuel System Description Fuel for the engine
2.
OptiMax DFI Fuel Schematic w/Fuel Cooler 10) Water Out 11) Water In 12) Fuel Cooler 13) Low Pressure Electric Fuel Pump (10 psi) 14) Vapor Separator 15) Mechanical Fuel Pump (10 psi) 16) Water Separating Fuel Filter 17) Fuel Filter 18) High Pressure Fuel Pump 1) 2) 3) 4) 5) 6) Air Inlet Compressor Fuel Vapor High Pressure Fuel (90 psi) Fuel Return 40 psi Check Valve Fuel System Pressure Test Valve 7) Fuel Regulator 8) Tracker 9) Fuel Injector 90-898305 4-16
3.
3.0L OptiMax Fuel Schematic (Cont.) 1. Engine Pulse Fuel Pump 2. Fuel/Water Separator Filter 3. Vapor Separator Tank Vent Hose 4. Fuel Outlet from High Pressure Electric Fuel Pump – 620 kPa (90 psi) 5. Bleed Off from Air Pressure Regulator; routed to exhaust adaptor and exits through the propeller 6. Air Compressor Inlet Coolant Hose 7. Air Compressor 8. Air Compressor Inlet Air Filter 9. High Pressure Air Outlet – 551 kPa (80 psi) 10. Schrader Valve for testing fuel pressure – 620 kPa (90 psi) 11.
OptiMax 1.
1. Engine pulse fuel pump 2. Fuel/Water separator filter 3. Vapor separator tank vent hose 4. Air compressor inlet coolant hose 5. Fuel outlet from high pressure electric fuel pump – 751.5 kPa (109 psi) 6. High pressure air outlet – 655 kPa (95 psi) 7. Air compressor 8. Air compressor inlet air filter 9. Cooling water routed from air compressor to fuel rail 10. Direct injector discharges the air/fuel mixture into the combustion chamber 11. Schrader valve for testing fuel pressure (design 2 location) – 571.
Notes _______________________ OptiMax Fuel and Direct Injector Interface _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _____
Vapor Separator Fuel Flow Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 1) High Pressure Fuel (to Air/Fuel Rail) 2) Return Fuel (from Air/Fuel Rail) [on 3.
Notes _______________________ Integrated Vapor Separator _______________________ 2003 MY _______________________ Improved low pressure electric fuel pump for improved durability _______________________ Low pressure electric pump enclosed in the IVST, simplified fuel hose routing. _______________________ Pulse pump built onto IVST to simplify hose routing. _______________________ Easy to remove screw in water separating fuel filter, canister filter no longer used.
1. Engine pulse fuel pump Notes 2. Fuel/Water separator filter _______________________ 3. Vapor separator tank vent hose 4. Fuel outlet from high pressure electric fuel pump – 751.5 kPa (109 psi) 5. Bleed off from fuel pressure regulator; routed back to vapor separator tank. _______________________ _______________________ 6. Low pressure electric fuel pump Schrader valve _______________________ 7. High pressure electric fuel pump _______________________ 8.
2002 & Up 2.
Notes _______________________ _______________________ Fuel Pressure Regulator • Calibrated to raise fuel pressure 10 psi above air pressure • Uses both air & internal spring pressure to control fuel pressure _______________________ ♦ Internal spring calibrated at 10 pounds resistance _______________________ ♦ Spring holds the diaphragm against seat _______________________ ♦ Contact between diaphragm and seat closes the passage between incoming fuel (from the electric fuel pump) and the fuel return
Tracker Valve (V6 Models Only) • Notes Tracker valve designed to maintain 10 psi differential between the fuel rails when air or fuel pressure suddenly rises (air compressor pulses or fuel injectors opening & closing) _______________________ _______________________ • Contains a spring (on the ‘air’ side) & a diaphragm _______________________ • When engine isn’t running, spring positions diaphragm against seat _______________________ • When the engine is running, fuel pressure compresses spring an
Notes _______________________ _______________________ _______________________ Fuel Injector A fuel injector is an electromagnetic device. The precision mechanical components are controlled by means of the solenoid in the injector, the solenoid is energized by an injector driver in the ECM. The driver circuit controls the “on” time of the solenoid by providing a ground.
Disconnecting Harness Connectors from Ignition Coils and/or Injectors Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ a) Wire Clip (push center down to remove) _______________________ _______________________ Direct Injector The Direct injector uses a tapered tip and seat.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 2.5 & 3.0 Liter OptiMax DIRECT INJECTOR - 2002 MY RUNNING CHANGE New direct injector with encapsulated coil winding. A hard plastic coating is placed around the winding prior to the molding process for the plastic housing.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ a – Direct injector ohm test between the two connector pins (1.0 – 1.6 ohms) _______________________ b – Check between each connector pin and the metal portion of the injector, ohms reading should be 1000 ohms or greater.
Section 5 - Oil Injection System 5-1 90-898305
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 Oil System Operation ........................................................................................4 1998/1999 2.5L Oil System ...........................................................................4 Check Valve Kit – 1998/1999 135/150 OptiMax...........
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Oil System Operation Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil is stored inside the remote oil tank in the boat. Crankcase pressure forces oil from the remote oil tank into the engine oil tank.
Check Valve Kit – 1998/1999 135/150 OptiMax Notes Check valves have been to the crankcase oil delivery hoses to prevent evacuation of oil from the hoses under certain running conditions and to improve oil delivery to the engine. This product improvement is being offered to current owners and on outboards in dealer inventory to provide improved reliability and durability. The check valves have been installed on production outboards as a running change beginning with serial number 0G886267.
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3.0L - Model Year 2003 Port Side Oil Hose Routing a - Oil pump hoses a - Oil hoses and harness from oil pump routed under air plenum and secured by j-clamps.
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New 1.5L Models - Oiling System Highlights Notes _______________________ • Engine mounted oil reservoir is standard. • Engine reservoir filled without removing top cowl. _______________________ • Low oil sensor mounted at bottom of engine reservoir, normally closed switch. _______________________ • Oil level in engine reservoir checked with gauge (chain) connected to fill cap.
Notes OptiMax Oil Pump _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ 1) 2) 3) 4) 5) 6) 7) _______________________ OptiMax Oil Pump Change _______________________ NOTE: Older pump supersedes to newer pump for service. Refer to Service Bulletin 2003-8 (New P/N 2.5L is 859372A01 and 3.0L is 859373A01).
Priming the Oil Pump Notes NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed, it is recommended all air be purged from oil pump/oil lines. This can be accomplished by using a gearcase leakage tester(FT-8950). Connect the leakage tester to the inlet t-fitting on the onboard oil reservoir. While clamping off the inlet hose, manually pressurize the reservoir to 10 psi. Using the Digital Diagnostic Terminal 91-823686A2, activate the oil pump prime sequence.
Notes _______________________ _______________________ _______________________ METHOD 3 - (DDT) DIGITAL DIAGNOSTIC TERMINAL - OIL PUMP PRIME This method fills the oil pump, oil supply hose feeding pump, and oil hoses going to the crankcase and air compressor. _______________________ Refer to procedure in the Technician Reference Manual provided with the Digital Diagnostic Software Cartridge.
Section 6 - Electrical System 6-1 90-898305
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 Ignition System - V6 Models .............................................................................4 Theory of Operation ......................................................................................4 Coil Driver..........................................
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Ignition System - V6 Models Theory of Operation When the ignition key is
Ignition Coil Driver Operation Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ __________________
Ignition Coil and Driver Schematic 90-898305 6-6
Notes Ignition Coils _______________________ MODEL YEAR 2000 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ MODEL YEAR 2001 AND UP _______________________ _______________________ _______________________ _______________________ ______________
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Ignition System - 3 Cylinder 1.
3 Cylinder 1.
Notes Electronic Control Module (ECM) _______________________ ECM/PCM IDENTIFICATION _______________________ ECM - “Electronic Control Module” _______________________ PCM - “Propulsion Control Module”. PCM has all functions of ECM, including the ability to handle Digital Throttle and Shift Functions. _______________________ _______________________ ECM/PCM DESIGNATIONS _______________________ Non-555 OptiMax - This is the original ECM used on Optimax engines 19982000 MY.
The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal 91-823686A2 using adaptor harness 84822560A5. The ECM performs the following functions: • Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold pressure and coolant temperature.
Notes _______________________ _______________________ _______________________ _______________________ Crank Position Sensor Senses teeth located on flywheel under ring gear. Supplies the ECM with crank position information and engine speed. If sensor should fail, the engine will stop running. Throttle Position Sensor (TPS) _______________________ Two (2) Throttle Position Sensors are used in conjunction with one another.
Temperature Sensor Notes Three (3) temperature sensors (2 on 1.5L models) are used to provide cylinder head temperature information to the ECM. One sensor is mounted in each cylinder head and one in the air compressor cylinder head. The ECM uses this information to increase injector pulse width for cold starts and to retard timing in the event of an over-heat condition.
Table of Contents Table of Contents..............................................................................................2 Table of Contents..............................................................................................3 1998/99 Warning System..................................................................................4 Warning System Signals ...............................................................................5 Guardian Protection System - All 2000 Models & Newer......
Notes _______________________ _______________________ _______________________ 1998/99 Warning System The outboard warning system incorporates warning light gauge and warning horn. The warning horn is located inside the remote control or is part of the ignition key switch wiring harness.
Warning System Signals NOTE: The warning system signals which includes audible and visual indicator involving the horn and lights will identify the potential problems listed in the chart Problem Horn Power Up/ System Check Single Beep Low Oil 4 Beep… 2 Minutes Off No Oil Flow Continuous Beep Over Heat Check Engine Light Yes Yes 4 Beep… 2 Minutes Off Over Speed Continuous Beep Yes Over Heat Light Yes Water In Fuel Light Yes Engine Speed Reduction Activated (approx.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Guardian Protection System - All 2000 Models & Newer 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.
Guardian System Activation Condition Engine Overheat Result Engine power level can be reduced to any percentage down to an idle speed, if overheat condi-tion persists. Air Compressor Overheat 2000 Model – engine power level can be reduced to any percentage down to an idle speed, if over-heat condition persists. 2001 Model – no power reduced. Block Water Pressure Low Engine power level can be reduced to any percentage down to a fast idle, if condition persists.
Notes OptiMax Service Tips _______________________ 1998/99 135/150, 2.5 LITRE _______________________ 1998/99 200/225, 3.0 LITRE _______________________ _______________________ The following Troubleshooting/Service tips have been accumulated over the past several months. These are not necessarily the only solution to the problem. _______________________ Shift Slide: _______________________ 3.
Loose Fuse Holder Notes 2.5 & 3.0 LITRE _______________________ If the DDT shows a fault on all 6 direct injectors, fuel injectors, or ignition coils, it is not likely that all 6 of these component have failed, make sure the fuse for that circuit is good and that it is making good contact with the fuse socket/connector. _______________________ 2.5 & 3.
Notes Alternator: _______________________ 3.0 LITRE _______________________ There have been three reports of burned/melted alternator RED wires. This can be caused by the wire being routed incorrectly and chaffing through and shorting to ground, or the battery cables have been reversed. If the cables have been reversed the RED wire will be burned/melted the full length of the wire. If wire is shorted, it will be burned/melted between the short and connection to the starter solenoid.
Twin Pressure Gauge: Notes 2.5 & 3.0 LITRE _______________________ Part number of the twin pressure gauge used on Optimax product has su The new gauge has improved schrader valve connections (screw on type). The clip on style connectors have been removed and screw on connectors with quick disconnects have replaced them. The new gauge will also have FUEL & AIR marked on the gauge manifold.
Notes Harness Replacement Ends _______________________ 2.5 & 3.0 LITRE _______________________ Service replacement harness connectors for the Optimax fuel injector, Direct injectors, TPS and Crankshaft Sensor are now available. This will allow the dealer the option to repair the engine harness rather than replacing it complete. Both of these connectors have been prone to shipping damage. Connector kit will include required connectors to hook into the main engine harness.
False Throttle Position Sensor Failures Notes 2.5 LITRE _______________________ If the Throttle Position Sensors (TPS’s) are out of the intended operating range, or change value at the idle position, after the engine is started, the Electronic Control Module (ECM) will sense that the (TPS/s) has failed. The warning horn will sound, check engine light will illuminate, DDT will indicate failed TPS/s, and the engine may go into power reduction. If TPS failures codes occur check the following.
Notes Incorrect Cam to Roller Setting _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Throttle Position Sensor (TPS) Troubles
HEAT TEST Notes With engine at idle, heat the TPS (with a hot air gun) below the electrical connection until warm to the touch. Watch for any one or a combination of the following symptoms: _______________________ • RPM change _______________________ • Check engine light illumination • Momentary warning horn signal • TPS voltage value change (1/2 volt) on DDT _______________________ _______________________ _______________________ _______________________ NOTE: Excessive heat will damage TPS.
Notes Engines Stalling On Flushing Attachment _______________________ 2.5 LITRE _______________________ _______________________ When running, on a flushing attachment some engines may stall when the DDT miss-fire test is performed. These same engines have run well when used under normal boating conditions.
OptiMax DDT Data Worksheet - P/N 90-858879 Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: Date: DDT Software Version: Total Run Time Sensor Err 0000-0999 CTS 1000-1499 CTP 1500-2999 ACT 3000-3999 MAP 4000-4999 TPI 1 5000-5999 TPI 2 6000+ AIR RPM LIM CNT TRIG BREAL LN Min. BPSI OVER TMP Sec Switches Err Ignition Err LOW OIL Cyl 1 H2O Cyl 2 Misc.
OptiMax DDT Data Worksheet - P/N 90-858879 Dealer Name: Technician Name: Dealer Number: Engine S/N: #1 Data Monitor NOW: Min: Max: Notes NOW: Min: Max: Notes ENGINE RPM TPI 1 VOLTS TPI 2 VOLTS BATTERY VOLTS PWR 1 VOLTS PWR 2 VOLTS COOL TMP STB COOL TMP PRT MAP PSI AIR TMP TRIGGER ERR TIME TO OIL OIL INJ CNT AIR COMP TMP BLOCK PSI #2 Data Monitor ENGINE RPM TPI 1 VOLTS TPI 2 VOLTS BATTERY VOLTS PWR 1 VOLTS PWR 2 VOLTS COOL TMP STB COOL TMP PRT MAP PSI AIR TMP TRIGGER ERR TIME TO OIL OIL INJ CNT
Smartcraft Data Worksheet - P/N 90-881929--1 Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: Date: DDT Software Version: Fault Seconds BATT VOLT HIGH Engine #1 Engine #2 Run History RUN TIME HR BATT VOLT LOW RPM 0-749 BLOCK PRESS LOW 750-1499 COMP OVERHEAT 1500-2999 ETC MOTOR OPEN 3000-3999 ETC MOTOR SHORT 4000-4499 FUEL P INPUT HI 4500-4999 FUEL P INPUT LO 5000-5499 GUARDIAN 5500-6249 KNOCK SENS1 6250+ KNOCK SENS2 BREAK-IN LEFT OIL PSI
SmartCraft Data Worksheet - P/N 90-881929--1 Dealer Name: Engine S/N: FREEZE FRAME FAULT BUFFER DATA FAULT ID Fault Buffer 0 Fault Buffer 1 Fault Buffer 2 Fault Buffer 3 Fault Buffer 4 Fault Buffer 5 Fault Buffer 6 Fault Buffer 7 Fault Buffer 8 Fault Buffer 9 BREAK-IN BARO PSI BATT VOLTS BLOCK PSI BOAT SPEED AIR TEMP F COOL TEMP F DEMAND % ENGINE RPM ENGINE STATE FPC TOTAL FREQ COUNTER FUEL LEVEL % SHIFT LAKE/SEA TEMP F LOAD % MPRLY MAP PSI OIL LEVEL % PORT TAB POS AVAILABLE PWR % RUN TIME STAR
SmartCraft Data Worksheet Fault ID Description Notes _______________________ _______________________ BREAK IN • _______________________ Engine is still within oil break-in clock BARO PSI _______________________ • _______________________ The barometric pressure when the fault occurred BATT VOLTS • _______________________ The battery voltage when the fault occurred _______________________ BLOCK PSI • _______________________ The engine block pressure when the fault occurred BOAT SPEED _______
_______________________ SmartCraft Data Worksheet Fault ID Description (Cont.) _______________________ LOAD % _______________________ • Notes _______________________ _______________________ _______________________ _______________________ The engine load % when the fault occurred MPRLY • A value of zero indicates there was no request made to activate the main power relay. A value greater than zero indicates that the main power relay was active.
SmartCraft Data Worksheet Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: Date: DDT Software Version: Data Monitor - OptiMax ENGINE # IDLE 1500 RPM 3000 RPM ENGINE RPM TPI 1 VOLTS BATTERY VOLTS PWR 1 VOLTS COOL TMP STB (F) COOL TMP PRT (F) MAP PSI AIR TMP (F) BLOCK PSI OIL INJ CNT TPI % AIR COM TMP (F) OIL LEVEL FUEL LEVEL AVAILABLE PWR % SHIFT TRIM PITOT PADDLE WHEEL LAKE/SEA TMP (F) SPARK ANG BTDC FPTC TOTAL oz 7-23 90-898305 NOTES:
SmartCraft Data Worksheet Dealer Name: Engine S/N: Dealer Number Engine type: Technician Name: ECM Part Number: Date: DDT Software Version: ENGINE # ENGINE RPM TPI 1 VOLTS BATTERY VOLTS PWR 1 VOLTS COOL TMP STB (F) COOL TMP PRT (F) MAP PSI AIR TMP (F) BLOCK PSI OIL INJ CNT TPI % AIR COM TMP (F) OIL LEVEL FUEL LEVEL AVAILABLE PWR % SHIFT TRIM PITOT PADDLE WHEEL LAKE/SEA TMP (F) SPARK ANG BTDC FPTC TOTAL oz 90-898305 7-24
Section 8 - Tools For OptiMax 8-1 90-898305
Table of Contents Table of Contents ............................................................................................. 2 Tool Supplier Contact Information .................................................................... 3 Tools for OptiMax Repair.................................................................................. 4 Single Fuel/Air Pressure Gauge 160 PSI – 91-16850A7 .............................. 4 Dual Fuel/Air Pressure Gauge 160 PSI - P/N 91-881834A1.........................
Tool Supplier Contact Information Cole-Parmer 800-323-4340, or 847-549-7600 SPX-OTC 616-792-0088 Blue Point 800-547-5740 Electronic Specialties 815-675-2905 Kent Moore 800-345-2233 Bob Kerr 800-867-4807 Specialty Motors 800-426-8644 Stevens Instruments 847-336-9375 Yardarm Products 800-547-5243 Flaherty Co.
Notes _______________________ _______________________ _______________________ _______________________ _______________________ Tools for OptiMax Repair Single Fuel/Air Pressure Gauge 160 PSI – 91-16850A7 Note: To convert 100 psi gauge 91-16850A1 to 160 psi gauge, order upgrade 91-16850--1.
Schrader Valve Tee - P/N 22-849606 Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Purge Valve - P/N 91-804706 _______________________ Service replacement pressure release valve is now available, for the twin pressure gauge P/N 91-852087A1/A2/A3 or the single pressure gauge P/N 91-16850, A1/ A2/A3/A5/ & A7 versions.
Notes Digital OptiMax Sensor Test Harness - P/N 91-875233A2 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ DDT Test Harness (5 Pin Digital Adapter) - P/N 91875232A1 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ______
OptiMax Wiring End Seal Kit - P/N 91-881814A1 Notes _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Direct Injection Removal Tool - P/N 91-883521 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Pressure Gauge Extensions - P/N 91-881835 _______
Notes Oil Syringe - P/N 91-803976T _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Screw (5 mm x 25 mm) (2 each) - P/N 10-40073-25 _______________________ _______________________ _______________________ _______________________ _______________________ Flat Washer (2 each) _______________________ _______________________ __________________
DDT Carrying Case P/N 804805 Notes _______________________ Service Tachometer DMT 2000 - P/N 91-854009A3 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Service Tachometer DMT 2004 - P/N 91-892647A01 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ___________________
Notes Clamp Tool Kit - P/N 91-803146A2 _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ Regulator Installation Tool - P/N 91-889431 _______________________ _______________________ _______________________ _________________
