1990 Mercury Mariner 75HP-275HP Service Repair Manual

Index

A Acceleratorpump circuit l0O-125hp and80jet, tuelsystem ......332-335 Altemator drivencapacitordischarge ignition 6O-275hpand65-140jet, ignition andelectrical systems.

424_439 Alternator drivenignition 135-200hp, 275hp,i05 and140jetV6, troubleshooting .....l.5-g} Alternatordrivenignition, mechanical advance,75-125hp and65-80jet, troubleshooting...... . 64_j5 Anticorrosionmaintenance,lubrication m a i n t e n a n c e a n d t u n.e. .-.u. .p. 2 2 6 Antisiphondevices, fuel system . 3f.S_337

B Battery chargingsystem,ignition and electricalsystems ...4OT-415 Battery chargingsystem, troubleshooting...... . 51_62 Battery ignition andelectrical

systems ....399_407 Bearing housing, lower gearcase andjet driveunits . . . . . . . . . . 670_6jI

c Capacitor discharge module (CDM) ignition 225 and25ohp, troubleshooting . . . . . .... 97_Ll0 75-125 hp and 65-80 jet, serial No. 0G438000-on. houbleshooting.. . .. .... 90_97 ignition and electrical systems.

439_441 Carburetors,fuel system. . . . . . . 30l.-30g CDM ignition 225 and25ohp, ignition and electrical systems.

444_449 75-125 hp and 65-80 jet, serial No. 0G43 8000-on, ignition and electrical systems 441-444 CDM module resistance tests (optional), troubleshooting. . . 1l0_lll Cooling system flushing, lubrication maintenanceandtune-up . . . . 229_23I

Corrosioncontrol,lowergearcase and jetdriveunits... ... 579-591

D DFI airlfuel system t r o u b l e s h o o t i n g . . ...... . . .

166-177 DI digiral inductive, 200 DFI t r o u b l e s h o o t i n g . . ...... . . . lll_l2} Digital inductive ignition, 200 DFI, ignition and elecaical systems M9_452

E EFI fuel system, t r o u b l e s h o o t i n g . . ...... . . .

129_166 Electrical accessories, troubleshooting..... .... 62 Electronic fuel injection (EFI) and direct tuel injection (DFI), fuelsysrem ..... 339-369 Engine submersion, lubrication maintenance andtune-up . . . 226-229 Engine temperature and overheating, troubleshooting .... lj7_Lg2 Engine,troubleshooting..... . lg2-lg7

774

Ii\DEX F

Fastenersandtorque, powerhead .463-465 Fuel primer andenrichmentsystems, ffoubleshooting. . . . . . . . . . . . 123-129 Fuelsystem. ..302-307 acceleratorpump circuit, 100-125hp and80jet. . . . .332-335 antisiphondevices ..335-33i carburetors .307-309 electronicfuel injection (EFI) and direct fuel injection (DFr) . .339_368 fuel bleed (recirculation) system. . .381-392 fuel enrichmentvalve,225hp c a r b u r e t e d m o d e .l s. ....... 3 3 2 fuelfilters .....33j fuel hoseandprimerbulb. . . . 338-339 fuel primer valve,75 -2OOhp, 275hp and35-140jer, remote controlmodels ..329-331 tuelpump . .302-307 fuel tanks,integralandportable, remote. . . 337-338 reedvalveservice. . . 368-381 thermalair valve,135-200hp carburetedmodels . . . . . .. 331-332 troubleshooting.. . . . . . . . . . . l2O-123 WME seriescarburetor,75-L25hp, 65and80jet. ....309-316 WMH andWMV seriescarburetors, 135-225hp and 105-140jet models .316-325 WO series(Mercarb)carburetor, 275hp. . .325-329 Fuelsandlubrication.lubrication maintenance andtune-up. . . . 201-Z2O Fuses,ignition andelecfical systems ....415-416

G Gear housing, lower gearcase and jetdriveunits.. ....... 583 Gear ratio, lower gearcase andjet drive units. . 577-579 Gearcase cleaning and inspection, lower gearcaseand jet driv units.. .....651 Gearcase disassembly/assembly, lower gearcaseandjet drive u n i t s. . ..... 603 Gearcaselubrication, lower gearcase a n d j e t d r i v e u n i t s . . . . . . . . . . . .5. 8 1 Gearcase operation, lower gearcase andjetdriveunits...

5i6-5'77 Gearcasepressure testing, lower gearcaseandjetdriveunits . . . .. 652

Gearcaseshimming,lower gearcase andjetdriveunits.. .... 653 Generalinformation,synchronization andlinkageadjustments . . . . . 249-251

H High-altitudeoperation,lower gearcase andjet driveunits. . . . . . 578 Hour meter,lubricationmaintenance andtune-up .200-201 I

jetdrivemodels. ....... 661 jetpump unitmaintenance. .... ... 661-667 unitservice ..... 667-670 lowergearcase ......... 576 propeller .. 581-583 s e r v i c e p r e c a u t i. o. n . .s. . . . 5 7 8 - 5 7 9 trimtabadjustment ..... 583 waterintakehousingliner. . . . . . . 67I waterpump 593-603 Lubricants,sealantsandadhesives, powerhead 462-463 Lubrication maintenanceand tune-up ....... 200 anticorrosionmaintenance . .. . 226 coolingsystemflushing . . 228-231 enginesubmersion ... ... 226-228 fuelsandlubrication.. ... 201-220 hourmeter. ..... 2OO-1OL off-seasonstorage 220-226 tune-up . 231-244

Ignitionandelectrical systems . .... 399 alternatordrivencapacitordischarge ignition, 60-275hpafi 65-140jet. .....424-438 battery. ....399-407 batterychargingsystem. . . .. 407-415 capacitordischargemodule (CDM)ignition. . .438-441 CDMignition M 2 2 5a n d 2 5h0p . . . . . . . . . 4 4 4 - 4 4 9 75-125hpand65-80jet,serial Mercury/I\4arinermodel No.0G438000-on ... ... 441-444 identification, powerhead. .. .... 460 digital inductiveignition 200DFI. .449-452 tuses.. ....415-416 startingsystems. ....416-424 Off-seasonstorage,lubrication Ignition system, maintenance andtune-up. . . 220-226 troubleshooting. . . . .. . . .. . . . . 62-64 Oil injectionsystem. . 732-733 Ignition systems,ignition and variable-ratioelectronically electricalsystems ...... 424 controlledoil injection,200DFI models 758-763 variable-ratio oil injection J 135-20},275hpand Jetdrive models,lower gearcaseand 105-l40jetmodels. ... . 739-750 j e t d r i v e u n i t. s. ....... 661 225 and250hp models. . . 750-758 Jetpump unit maintenance,lower 75-125hpand65-80jet gearcase andjet driveunits. . . 661-667 models 733-739 Jetpump unit service,lower gearcase Operathg requirements, andjerdriveunits. . .667-670 troubleshooting..... . 35-37

o

L

P

Lowergearcase andjet driveunits. . 576 bearinghousing ....670-671 corrosioncontrol.. . . . . . . . . . 579-581

Powerhead ...... 458 assembly . . 524-570 break-in ....... 461 cleaning andinspection. . . . . 508-524 disassembly. ...... 480-508 fastenersandtorque 463-465 lubricants, sealantsand adhesives 462-463 Mercury/I4ariner model identification ........

460 removaVinstallation. . . . . . . . 465-480 sealingsurfaces...... .... . 463 service considerations. . . . . . 459-460 servicerecommendations.. . 461-462

geil

housing ..583-593 ratio... ..577-578 gearcase cleaningandinspection .. . 651-652 disassembly/assembly. . . . . 603-651 lubrication. ......... 581 operation.

576-577 pressuretesting. . . . . ..... 652-653 shimming 653-661 h i g h - a l t i h r d e o p e r a t i o n . . . . . .5. .2. 8

-

!

;

775

II\[DEX Power trim and tilt systems and power steering system power trim and tilt system service. power steeringsystem . ... power trim and tilt systems.

Propeller, lower gearcaseandjet driveunits ..

702-723 723-729 678-702

T

581-583

Test and repair equipment, troubleshooting.. . . . . . . . . . .37-42 Thermal air valve, 135-200hp carburetedmodels, fuelsystem. ....331.332 Trim and tilt systems, power trim and tilt systems and power steeringsystem. .... 678 Trim tab adjustment, lower gearcase a n d j e t d r i v e u n i t s . . . . . . . . . . .5 8 3 T r o u b l e s h o o t i.n. .g. . ..... 33 alternator driven ignition, 135-200hp, 275 hp, 105 and 140 iet, V6. . . . . .75-90 alternator driven ignition, mechanical advance, 75-125hp and 65-80jet .......64-75 battery charging system. ....51-62 capacitordischargemodule (CDM) ignition, 75-I25 hp and 65-80 jet, serial No. 0G438000-on ...90-97 capacitor discharge module (CDM): ignition, 225 and 250 hp. . . . 97 -110 CDM module resistance tests, optional. . 110-111 DFI airituel system. . 166-177 DI, digital inductive, 200DFr llt-r2O EFItuelsystem. ....129-166 electricalaccessories. .... 62

R Reed valve service, fuel system Remotecontrol.

275hpmodels ......292-297 75, 90 hp and65jet models. ..251-256 generalinformation .249-251 safetyprecautions. . . . .... .. 248-249

. 368-381 ......765-771

S Safety precautions, synchronization and linkage adjustments. .....248-'249 troubleshooting...... .34-35 Sealingsurfaces,powerhead. . .. .. 463 Service considerations, powerhead .459-460 Service precautions,lower gearcase andjet drive units. . .

578-579 Service recommendations, powerhead .46I-462 Starting system, troubleshooting... ... . 42-51 Starting systems,ignition and electricalsystems ...416-424 Synchronization and linkage adjustments. ...248 100-125hp and 80jet models . .256-261 135-200 hp carbureted models . .261-270 150-200 hp EFI (electronic fuel injection) models . 270-276 200 DFI (direct tuel injection) models . .276-279 225 and 250 hp EFI models . .287-292 225 hp carbveted models . . . 279-287

engine temperature and overheating .....

177-182 engine . ... 182-187 fuel primer and enrichment systems . 123-129 tuel system l2O-I23 ignitionsystem. ..... 62-64 operatingrequirements ... .... 35-37 s a f e t y p r e c a u t i o n s ........ . . .

34-35 startingsystem . ..... 42-5I test and repair equipment ........37 Tune-up, lubrication maintenance andtune-up 231-244

V Variable-ratio electronically controlled oil injection, 200 DFI models, oil injection system.

758-763 Variable-ratio oil injection, 135-200,275hp and 105-140jet models, oilinjection system. . . . . .'739-750 225 and250 hp models, oil injection system .

750-758 75-125 hp and 65-80 jet models, oilinjectionsystem...... 733-739

w Water intake housing liner, lower gearcaseandjet drive units. . . . . . 671 Water pump, lower gearcaseand jetdriveunits. ..... 593-603 W i r i n g d i a g r a m. .s. . . . . . . . . . 7 7 6 - 8 0 7s"fi@ WME seriescarburetor,75-l25hp, ?g$@ffi!S 65 and 80 jet, tuel system. . . 309-316 WMH and WMV series carburetor 135-225hp and 105-140jet models,fuelsystem. ..... 316-325 WO series (Mercarb) carburetor, 275 hp, tuel system.

325-329

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