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Mercury 200 EFI User Manual
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POWERHEAD
90-883728 JUL
Y 2001
Page 4A-3
Special T
ools
1.
Lifting Eye 91-90455
2.
Flywheel Holder 91-52344
91–52344
54964
3.
Protector Cap 91-24161
4.
Flywheel Puller 91-849154T1
551
17
5.
Powerhead Stand 812549T
6.
Piston Ring Expander 91-24697
7.
Lockring Removal T
ool 91-52952A1
319
321
Table of Contents
Important Information 1
10
Table of Contents
10
Gear Case Lubricant Capacity
10
Mercury/Quicksilver Lubricants and Sealants 1B-2
11
Special Tools
11
Inspection and Maintenance Schedule
12
Before each Use
12
After each Use
12
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
12
Flushing Engine
13
Flushing Cooling System - Using Cowl Flush Plug
13
Flushing Cooling System - Using Flushing Attachment 44357A2
13
Fuel System
14
Fuel Line Inspection
14
Water Separating Fuel Filter - EFI Models 1B-5
14
Corrosion Control Anode
15
Spark Plug Inspection and Replacement
15
Battery Inspection
16
Fuse Replacement
16
Lubrication Points
17
Checking Power Trim Fluid
18
Gear Case Lubrication
19
Storage Preparation
20
Important Information 1
22
Conditions Affecting Performance
23
Weather
23
Boat
24
Trim
24
Engine
26
Engine Compression
26
Following Complete Submersion
27
Salt Water Submersion
27
Submerged While Running
27
Model 150 XRI/175 XRI/200 XRI Powerhead Front View
29
Model 150 XRI/175 XRI/200 XRI Powerhead Starboard View
30
Model 150 XRI/175 XRI/200 XRI Powerhead Port View
31
Model 150 XRI/175 XRI/200 XRI Powerhead Top View
32
Model 150 XRI/175 XRI/200 XRI Powerhead Aft View
33
Painting Procedures
34
Color Impregnated Top Cowls
34
Cleaning & Painting Aluminum Propellers & Gear Housings
34
Decal Application
36
Decal Removal
36
Instructions for "Wet" Application
36
Important Information 1
38
Installing Outboard to Boat Transom
39
Determining Recommended Outboard Mounting Height
39
Installing Outboard
40
Drilling Outboard Mounting Holes
40
Securing Outboard to Boat Transom
41
Steering Cable
41
Steering Link Rod
42
Electrical, Hoses and Control Cables
43
Installation Note
43
Remote Wiring Harness
43
Battery Cables
44
Fuel Hose Connection
45
Oil Hose Connections
45
Speedometer Tubing Connection
45
Water Pressure Tubing Connection
45
Shift Cable
46
Installation
47
Throttle Cable
49
Front Clamp Reassembly
50
Oil Injection Set-Up
51
Installing Remote Oil Tank
51
Installing Oil Hoses to Engine
52
Filling
53
Priming the Oil Pump
54
Priming Procedure - Method 1
55
Purging Air from the Engine Oil Reservoir
56
Trim in Stop Adjustment
56
Trim Tab Adjustment
57
Models Without Power Steering
57
Models with Power Steering
57
Electrical 2
58
Specifications
59
Ignition Coil Ohms Test
59
Manifold Absolute Pressure (MAP) Sensor Ohms Test
60
Port and Starboard Temperature Sensors; Air Temperature Sensor
61
Special Tools
62
Coil Plate Assembly
65
Electrical Plate Assembly
67
Theory of Operation
69
Ignition Component Description
70
Fuses
70
Charging System Alternator
71
Ignition Coil
71
Electronic Control Module
72
Flywheel
73
Crank Position Sensor
73
Throttle Position Sensor (TPS)
74
Throttle Position Sensor (TPS) Troubleshooting
74
Cylinder Head Temperature Sensor
75
Air Temperature Sensor
75
Port and Starboard Temperature Sensors; Air Temperature Sensor
76
Manifold Absolute Pressure (MAP) Sensor
77
Ignition Troubleshooting and Fault Chart
78
Ignition Coil Ohms Test
82
Manifold Absolute Pressure (MAP) Sensor Ohms Test
83
Idle Speed Control
83
RPM-Limit Circuit
83
EFI Detonation Control System (200 Model Only)
84
Detonation Circuit Test
84
Troubleshooting
85
Troubleshooting Without Digital Diagnostic Terminal
85
Troubleshooting with the Digital Diagnostic Terminal
86
Notes
87
DDT Functions - EFI Models
88
Ignition Component Removal and Installation 2A-33
89
Flywheel Removal
89
Flywheel Installation
90
Ignition Coil Removal
90
Ignition Coil Installation
91
Electronic Control Module Removal
91
Electronic Control Module Installation
91
Temperature Sensor Removal
92
Engine Head Temperature Sensor Installation
92
Air Temperature Sensor Removal
93
Air Temperature Sensor Installation
93
Manifold Absolute Pressure (MAP) Sensor Removal
93
Manifold Absolute Pressure (MAP) Sensor Installation
93
Crank Position Sensor Removal
94
Crank Position Sensor Installation
94
Electrical 2
95
Specifications
96
Special Tools
97
Battery Cable Size
98
Recommended Battery
98
Replacement Parts
98
Battery
99
Precautions
99
Charging a Discharged Battery
99
Winter Storage of Batteries
100
Flywheel Removal and Installation
101
Removal
101
Installation
102
Notes
103
Flywheel/Alternator
104
System Components
106
Precautions
106
Alternator Description
107
Diagnosis of Alternator System on Engine
107
Alternator System Circuitry Test
108
Output Circuit
108
Sensing Circuit
109
Voltage Output
110
Current Output
111
Current Output Troubleshooting
112
Repair
112
Removal
112
Alternator Belt Tension Adjustment
114
Starter System
115
Starter Motor Amperes Draw
115
Starter System Components
115
Description
115
Starter Motor (Centrifugal Bendix)
116
Troubleshooting the Starter Circuit (Centrifugal Bendix)
118
Starter Circuit Troubleshooting Flow Chart(Centrifugal Bendix)
119
Flow Chart (Continued)
120
Starter Installation (Centrifugal Bendix)
121
Starter Removal (Centrifugal Bendix)
121
Starter Disassembly (Centrifugal Bendix)
122
Starter Cleaning, Inspection and Testing
124
Starter Reassembly
127
Starter Motor (Solenoid Driven Bendix)
132
Troubleshooting the Solenoid Driven Bendix Starter Circuit
134
Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)
135
Starter Removal (Solenoid Driven Bendix)
137
Disassembly (Solenoid Driven Bendix)
139
Cleaning and Inspection
142
Reassembly (Solenoid Driven Bendix)
143
Commander 2000 Key Switch Test
147
Electrical 2
154
Power Trim Wiring Diagram
155
Instrument Wiring Connections
156
Commander 3000 Classic Panel Remote Control
157
Commander 3000 Panel Remote Control
158
4000 Series Mechanical Panel Control
159
Instrument/Lanyard Stop Switch Wiring Diagram
160
Oil Level Gauge Wiring Diagram
161
Notes
162
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
163
QSI Gauge Wiring Diagrams
165
Tachometer Wiring Diagram
165
Water Temperature Gauge
166
Oil Level Gauge Wiring
167
Engine Synchronizer Wiring Diagram
169
Maintenance
170
Warning System Signals
171
Guardian Protection System
172
Guardian System Activation
172
Analog Gauge Panel Mount Remote Control Wiring Installation
174
System Monitor V2.0
175
Basic Operation
175
Standard Information Display Screens
176
Display of Range and Depth Information
178
Warning System
179
Warning Display Screens
180
CAL1 Calibration
183
CAL2 Calibration
185
Master Reset Command
188
System Tach & Speed
189
Basic Operation and Features
189
Speedometer Display Screens
190
Tachometer Display Screens
191
Troll Control
192
Warning System
193
Alarm Messages
194
Auto-Detection Engine Function
198
Master Reset Command
198
Tachometer Calibration
199
Speedometer Calibration
203
Smartcraft Gauge Operation
205
Basic Operation and Features
205
Speedometer Display Screen
206
Tachometer Display Screens
207
Troll Control
208
Warning System
209
Alarm Messages
210
Tachometer Calibration
214
Speedometer Calibration
217
Smartcraft Gauge Test Specifications
219
Test Equipment Required
219
150/175/200 Wiring Diagram
220
Fuel System
221
Special Tools
222
Specifications
222
Fuel Pump Pressure @ W.O.T
222
Fuel Pump Pressure @ Idle
222
Fuel Pump Assembly
224
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
226
Fuel Pump Description/Operation
226
Checking Fuel Pump Lift (Vacuum)
227
Vacuum Test Troubleshooting
227
Testing Fuel Pump
228
Fuel Pump Removal/Disassembly
229
Cleaning/Inspection
230
Reassembly/Lnstallation
230
Fuel System
233
Specifications
234
Special Tools
235
Notes
237
Fuel Management System
238
Vapor Separator Components
240
Electronic Fuel Injection (Efl) System
242
Introduction
242
Using the Test Procedures
242
EFI System Tests
242
Safety Precautions
242
Fuel Injection System Function
243
Preliminary Checks
243
Ignition Spark Check
243
Electronic Fuel Injection Set up
244
Fresh Quality Fuel
244
Low Battery Voltage
244
Fuel Flow Diagram
245
Fuel Flow Component Description
246
Pulse Fuel Pump
246
Water Separating Filter
246
Vapor Separator
246
Final Filter
246
Electric Fuel Pump
246
Fuel Injectors
246
Fuel Pressure Regulator
246
EFI Electrical Components
247
EFI Fuel Management (Low Pressure Fuel Route)
249
EFI Fuel Management (High Pressure Fuel Route)
250
Fuel Rail Electrical/Fuel Determination
251
EFI System Test Procedures
252
Fuel Gauge Connection/Pressure Test
252
Vapor Separator Fuel Delivery Test
253
Pulse Fuel Pump Delivery Test
254
Water Separating Filter Inspection
255
Vapor Separator Float Test
256
Pressure Regulator Test
259
Injector Electrical Harness Test
261
Injector Load Test
262
Fuel Rail Assembly Leakage Test
262
Air Temperature Sensor and Head Temperature Sensor Test
263
Detonation Control System Test (200 Models Only)
264
Throttle Position Sensor Test
265
MAP Sensor Test
266
Problem Diagnosis
267
Fuel Management Assembly Removal
271
Fuel Rail Removal
275
Fuel Rail Installation
277
Reed Block Assembly Removal
279
Reed Block Assembly Installation
279
Air Temperature Sensor Removal
280
Air Temperature Sensor Installation
280
Manifold Absolute Pressure (MAP) Sensor Removal
280
Manifold Absolute Pressure (MAP) Sensor Installation
280
Throttle Plate Assembly Removal
281
Throttle Plate Assembly Installation
281
Vapor Separator Disassembly
281
Vapor Separator Reassembly
282
Air Plenum Installation
284
Vapor Separator (VST) Installation
285
Water Separating Filter Assembly Removal
286
Water Separating Filter Assembly Installation
286
Throttle Position Sensor Removal
287
Throttle Position Sensor Installation
287
Oil Reservoir Removal
288
Oil Reservoir Installation
288
Fuel Pressure Regulator Removal
289
Fuel Pressure Regulator Disassembly
290
Fuel Pressure Regulator Reassembly
290
EFI System Cleaning and Inspection
291
Cleaning
291
Inspection
291
Fuel System
292
Operation of the Oil Injection System
293
Final Checks before Operation of Engine
293
Checking Operation of the Oil Injection
293
Oil Injection Components
295
Oil Lines
297
Oil Injection Components
301
Oil Injection Flow System
302
Oil Pump Removal and Installation
303
Priming the Oil Pump
305
Priming Procedure - Method 1
306
Remote Oil Hose Connections
307
And Remote Oil Hose
308
Filling the Oil Tanks
308
Purging Air from the Engine Oil Reservoir
308
Oil Warning Systems
309
Low Oil Warning System Is Activated
310
Oil System Troubleshooting
310
Fuel System
311
Controlling Emissions
312
Outboard Hydrocarbon Emissions Reductions
312
Oxides of Nitrogen - Nox
312
Stoichiometric (14.7:1) Air/Fuel Ratio
312
Stratified Vs Homogenized Charge
313
Homogenized Charge
313
Stratified Charge
314
Emissions Information
314
Manufacturer's Responsibility
314
Dealer Responsibility
315
EPA Emission Regulations
315
Owner Responsibility
315
Manufacturer's Certification Label
316
Date Code Identification
317
Decal Location
317
Installation
317
Removal
317
Service Replacement Certification Label
317
Section 4A - Powerhead
318
Specifications
319
Block
319
Reed Valve Opening
319
Cylinder Bore
319
Piston
319
Special Tools
320
Powerhead Repair Stand
321
Notes
322
Cylinder Block Assembly
323
Exhaust Manifold and Exhaust Plate
325
Crankshaft, Pistons and Connecting Rods
327
Cylinder Head
329
Bleed System Routing
331
Torque Sequence
333
General Information
334
Powerhead Removal from Driveshaft Housing
335
Removing Engine Components
341
Removing Engine Components Individually
341
Removing Engine Components as an Assembly
342
Starter Motor
345
Electrical Plate Removal
346
Oil Pump
347
Air Plenum
348
Powerhead Disassembly
349
Torque Specifications
358
Cleaning and Inspection
359
Cylinder Block and Crankcase Cover
359
Special Service Information
359
Cylinder Bores
360
Pistons and Piston Rings
361
Crankshaft
363
Crankshaft (and End Cap) Bearings
363
Reed Block Assembly
364
Reed Block Housing
365
Connecting Rods
365
Powerhead Reassembly and Installation
368
General
368
Crankshaft Installation
372
Piston and Piston Ring Combinations
375
Piston Installation
376
Crankcase Cover Installation
379
Reed Block Assembly
381
Assembly of Reed Blocks to Intake Manifold
381
Assembly of Exhaust Divider Plate to Block
381
Cleaning and Inspection
383
Cylinder Block and Crankcase Cover
383
Reinstalling Engine Components
385
Notes
386
Throttle Lever and Shift Shaft
387
Powerhead Installation on Driveshaft Housing
391
Engine Break-In Procedure
398
Gasoline/Oil Break-In Mixture
398
Break-In Procedure
398
Powerhead
399
Specifications
400
Water Pressure
400
Thermostat
400
Digital Port and Sstarboard Temperature Sensor
401
Analog Temperature Sensor
402
Special Tools
403
Water Flow
404
Description
404
Notes
406
Thermostat Test
407
Troubleshooting
407
Water Pressure Check
408
Water Pump Cleaning and Inspection
409
Problem Diagnosis
410
MID-Section
411
Swivel Bracket and Steering Arm
412
Transom Brackets
414
Drive Shaft Housing and Exhaust Tube
416
Drive Shaft Housing and Dyna-Float Suspension
418
Removal and Disassembly
418
Reassembly and Installation
421
MID-Section
425
Special Tools
426
Power Trim Components
428
Power Trim Motor
430
Power Trim - General Information
431
Description
431
Trimming Characteristics
431
Trailering Outboard
432
Tilting Outboard Manually
432
Trim "In" Angle Adjustment
433
Striker Plate Replacement
433
Anode Plate
434
Trim Indicator Gauge
434
Check, Fill and Purge - Power Trim System
434
Troubleshooting
436
Power Trim System with Relays and 2 Wire Trim Motor
438
Electrical System Troubleshooting
439
General Checks
439
Troubleshooting the "Down Circuit
439
Troubleshooting the "Up" Circuit
440
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
441
Power Trim Assembly Removal and Installation
442
Removal
442
Installation
445
Testing Power Trim System with Test Gauge Kit (91-52915A6)
447
UP" Pressure Check
447
DOWN" Pressure Check
450
Hydraulic Repair
452
Trim Rod End Cap Seal
453
Tilt Ram
454
Disassembly
455
Scraper Seal Replacement
458
Motor and Electrical Tests/Repair
462
Trim Pump Motor Test
462
Motor Disassembly
462
Armature Tests
463
Motor Repair
464
Reassembly
468
Reassembly - Motor and Pump
470
Priming Power Trim System
471
Trim Sender Test
471
Trim Indicator Gauge Needle Adjustment
472
Trim Indicator Wiring Diagrams
473
Lower Unit
474
Special Tools
475
Table of Contents
475
Notes
478
Gear Housing (Drive Shaft)(Standard Rotation)
479
Gear Housing (Prop Shaft)(Standard Rotation)
481
General Service Recommendations
483
Removal, Disassembly, Cleaning and Inspection
484
Removal
484
Draining and Inspecting Gear Housing Lubricant
485
Water Pump
486
Bearing Carrier and Propeller Shaft Removal 6A-16
489
Shift Shaft
491
Propeller Shaft
493
Clutch Actuator Rod
495
Pinion Gear and Driveshaft
495
Forward Gear
498
Lower Unit
522
In. (0.635 MM)With Tool 91-12349A2 Using Disc #2 and Flat #7
522
(0.762 MM to 1.27 MM)
522
Gear Housing (Drive Shaft)(Counter Rotation)
522
Gear Housing Specifications (Counter Rotation)
522
General Service Recommendations
532
Removal, Disassembly, Cleaning and Inspection of
533
Bearing Carrier and Propeller Shaft
538
Shift Shaft
540
Forward Gear and Bearing Adapter
545
Pinion Gear and Driveshaft
547
Left Hand Non-Ratcheting
549
Reverse Gear
549
Driveshaft Needle Bearing
552
Reassembly and Installation of Counter Rotation
552
Reverse Gear Bearing Adaptor Assembly
556
Driveshaft and Pinion Gear
558
Pinion Gear Depth
560
Reverse Gear
562
Forward Gear
563
Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
566
Water Pump
573
Gear Lubricant Filling Instructions
576
Propeller Installation
578
0.015 In. to 0.022 in
522
0.030 In. to 0.050 in
522
Backlash
522
Clutch Actuator Rod
522
Propeller Shaft
522
Water Pump
522
Gear Housing Specifications (Standard Rotation)
522
Attachments / Control Linkage
580
Ride Guide Steering Cable/Attaching Kit Installation (92876A10)
580
Maintenance Instructions
581
(92876A8)
582
Dual Cable - Single Outboard
582
Super Ride-Guide Steering Kit Installation
583
Steering Cable Mounting Tube Installation
584
Installing Steering Cables
585
Coupler Installation
586
Installing Link Rod
586
Maintenance Instructions
588
Ride Guide Steering Cable/Attaching Kit Installation
582
(92876A9)
589
Installation Requirements
589
Parallel Routed Steering Cables and Attaching Kit Installation
590
Opposite Side Routed Steering Cables and Attaching Kit Installation
597
Trim Tab Adjustment
604
Ride Guide Steering Attachment Extension Couplers
604
Maintenance Instructions
605
Ride Guide Steering Cable/Attaching Kit Installation
589
Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
607
Attaching Kit Installation
607
Maintenance Instructions
610
Clevis Attaching Kit Installation (A-70599A5)
611
Installation Instructions
611
Maintenance Instructions
611
150/175/200 EFI 2002 Model Year
614
Wiring Diagram
614
Typical Smartcraft System Monitor/Tachometer
620
Installation with System Link Gauges
620
Typical Smartcraft Dual Outboard Installation 2002 Model Year
623
150/175/200 EFI 2002 Model Year
626
Oil & Fuel Flow Diagram
626
Water Flow Diagram
629
4
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Mercury 200 EFI Specifications
General
Brand
Mercury
Model
200 EFI
Category
Engine
Language
English
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