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Mariner Manuals
Outboard Motor
150 OPTIMAX
Service manual
Mariner 150 OPTIMAX Service Manual
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Table Of Contents
491
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of
491
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491
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
Important Information
Specifications
Master Specifications
Table of Contents
Maintenance
Gear Case Lubricant Capacity
Special Tools
Quicksilver Lubricant/Sealant
Inspection and Maintenance Schedule
Before each Use
After each Use
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
Flushing Engine
Flushing Cooling System - Using Cowl Flush Plug
Flushing Cooling System - Using Flushing Attachment 44357A2
Fuel System
Fuel Line Inspection
Water Separating Fuel Filter
Corrosion Control Anode
Spark Plug Inspection
Battery Inspection
Fuse Replacement
Compressor Air Intake Filter
Lubrication Points
Removal
Installation
Checking Power Trim Fluid
Gear Case Lubrication
Storage Preparation
General Information
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Trim
Engine Compression
Following Complete Submersion
Salt Water Submersion
Submerged While Running
Model 135/150 DFI Powerhead Front View
Model 135/150 DFI Powerhead Starboard View 1C-10
Model 135/150 DFI Powerhead Port View
Model 135/150 DFI Powerhead Top View
Model 135/150 DFI Powerhead Aft View
Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
Decal Application
Decal Removal
Instructions for "Wet" Application
Outboard Motor Installation
Installation Specifications
Lifting Outboard
Installing Outboard to Boat Transom
Determining Recommended Outboard Mounting Height
Installing Outboard
Drilling Outboard Mounting Holes
Steering Cable
Securing Outboard to Boat Transom
Steering Link Rod
Electrical, Hoses and Control Cables
Installation Note
Remote Wiring Harness
Warning Gauge Harness
Battery Cables
Single Outboard
Dual Outboard
Shift Cable
Counter Rotation Outboards
Installation
Throttle Cable
Installation
Front Clamp Reassembly
Filling Fuel System
Oil Injection Set-Up
Priming the Oil Injection Pump
Purging Air from the Engine Oil Tank
Trim "In" Angle Adjustment
Trim Tab Adjustment
Models Without Power Steering
Models with Power Steering
Electrical
Ignition
Special Tools
Electrical Components
Theory of Operation
Ignition Component Description
Electronic Control Module (ECM)
Flywheel
Ignition Coils
Throttle Position Sensor (TPS)
Charging System Alternator
Crank Position Sensor
Temperature Sensor
Manifold Absolute Pressure (MAP) Sensor
Air Temperature Sensor
Direct Injectors
Disconnecting Harness Connectors from Ignition Coils And/Or Injectors
Fuel Injectors
Troubleshooting
Troubleshooting Without Digital Diagnostic Terminal
Troubleshooting with the Digital Diagnostic Terminal
Notes
DDT Functions – Optimax Models Software Version 4.0 and 4.1
DFI Troubleshooting Guide
Ignition Components Removal and Installation
Flywheel Cover Removal and Installation
Electronic Control Module (ECM)
Ignition Module (Coil)
Crank Position Sensor
Throttle Position Sensors (TPS)
Charging & Starting System
Battery Cable Size
Replacement Parts
Recommended Battery
Battery
Precautions
Special Tools
Charging a Discharged Battery
Winter Storage of Batteries
Flywheel Removal and Installation
Installation
Flywheel/Alternator
System Components
Precautions
Alternator Description
Diagnosis of Alternator System on Engine
Alternator Assembly
Alternator System Circuitry Test
Output Circuit
Sensing Circuit
Voltage Output
Current Output
Repair
Removal
Disassembly and Test
Rotor Test
Stator Test
Reassembly
Pulley
Alternator Belt Tension Adjustment
Installation
Starter Motor Amperes Draw
Starter System Components
Description
Starter Motor
Troubleshooting the Starter Circuit
Starter Circuit Troubleshooting Flow Chart
Starter Removal and Installation
Installation
Disassembly
Starter Cleaning, Inspection and Testing
Cleaning and Inspection
Starter Reassembly
Starter Solenoid Test
Commander 2000 Key Switch Test
Timing, Synchronizing & Adjusting
Special Tools
Crank Position Sensor
Throttle Cam Adjustment
Maximum Throttle
Idle Speed
Throttle Position Sensor (TPS) Adjustment
Throttle Plate Screw
Wiring Diagrams
Power Trim Wiring Diagram
Instrument Wiring Connections
Commander 3000 Classic Panel Remote Control 2D-4
Commander 3000 Panel Remote Control
Instrument/Lanyard Stop Switch Wiring Diagram
Oil Level Gauge Wiring Diagram
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
QSI Gauge Wiring Diagrams
Tachometer Wiring Diagram
Water Temperature Gauge
Oil Level Gauge Wiring
Engine Synchronizer Wiring Diagram
Maintenance
Multi-Function Gauge
Dip Switch Setting/Testing
Outboard Multi-Function Gauge Setting
Warning System
Warning System Signals
Warning System Operation
Panel Mount Remote Control Wiring Installation 2D-22
1998 Model 135/150 DFI Wiring Diagram
1999 Model 135/150 DFI Wiring Diagram
Fuel System
Pulse Crankcase Driven Fuel Pump
Fuel Pump
Fuel Pump Description/Operation
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
Testing Fuel Pump
Fuel Pump Removal/Disassembly
Cleaning/Inspection
Reassembly/Lnstallation
Direct Fuel Injection
Specifications
Special Tools
Notes
Air Handler
Air Handler Components
Vapor Separator Components
Fuel Rails/Air Compressor Hose Routing
Fuel Rails
Air Compressor Components
DFI Operation
Air Induction through Crankcase
Air Compressor System
Fuel
Oil
Electrical
Operation
Testing Electric Fuel Pump Pressure Output
Low Pressure Electric Fuel Pump
High Pressure Electric Fuel Pump
Fuel Management Assembly Removal
Reed Block Assembly Removal
Reed Block Assembly Installation
Air Temperature Sensor Removal
Air Temperature Sensor Installation
Throttle Plate Assembly Removal
Throttle Plate Assembly Installation
Vapor Separator Disassembly
Vapor Separator Reassembly
Air Plenum Installation
Low Pressure Electric Fuel Pump Installation
Vapor Separator Installation
Fuel Rail Removal
Fuel Rail Disassembly
Fuel Pressure Regulator
Air Pressure Regulator
Tracker Valve
Fuel Rail Cleaning
Direct Injector Removal
Fuel Rail and Direct Injector Installation
Air Compressor
Air Compressor Disassembly/Reassembly
Air Compressor Flow Diagram
Air Compressor Pressure Test
Fuel Pressure and Air Pressure Troubleshooting Chart
Oil Injection
Oil System Operation
Oil Pump Output
Oil System
Oil Hose Check Valve Installation on 1998 Model 135/150 DFI Outboards SN 0G886266 and below
Oil Injection Hose Installation
Oil Pump Removal and Installation
Engine Oil Reservoir Removal and Installation
Priming the Oil Pump
Priming Procedure - Method 1
Remote Oil Hose Connections
Filling the Oil Tanks
Purging Air from the Engine Oil Reservoir and Remote Oil Hose
Oil Warning Systems
Oil System Troubleshooting
Low Oil Warning System Is Activated
Emissions
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons – HC
Oxides of Nitrogen - Nox
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Outboard Hydrocarbon Emissions Reductions
Stratified Vs Homogenized Charge
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer's Responsibility
Dealer Responsibility
Owner Responsibility
EPA Emission Regulations
Decal Location
Emission Control Information
Replacement of Certification Label
Date Code Identification
Removal
Installation
Powerhead
Powerhead Specifications
Powerhead Repair Stand
Cylinder Block and End Caps
Exhaust Manifold and Exhaust Plate
Cylinder Head
Crankshaft, Pistons and Connecting Rods
Torque Sequence
Powerhead Removal from Driveshaft Housing
General Information
Powerhead Disassembly
Water Pressure Relief Valve Components
Cylinder Block and Crankcase Cover
Special Service Information
Cylinder Bores
Pistons and Piston Rings
Cylinder Heads and Exhaust Divider Plate
Crankshaft
Crankshaft (and End Cap) Bearings
Reed Block Assembly
End Bearing Bleed System
Connecting Rods
Thermostats
Powerhead Reassembly and Installation
Crankshaft Installation
Piston and Connecting Rod Reassembly
Piston and Piston Ring Combinations
Piston Installation
Crankcase Cover Installation
Assembly of Reed Blocks to Intake Manifold
Assembly of Exhaust Divider Plate to Block
Reinstalling Engine Components
Throttle Lever and Shift Shaft
Powerhead Installation on Driveshaft Housing
Break-Ln Procedure
Cooling
Water Pressure
Thermostat
Water Pressure
Special Tools
2.5 Liter Optimax/Dfi Water Flow
Temperature Sensor
Description
1998/1999 Water Flow Diagram
1999 1/2 Water Flow Diagram
Thermostat Test
Troubleshooting
Water Pressure Check
Water Pump Cleaning and Inspection
Problem Diagnosis
MID-Section
Clamp/Swivel Brackets & Drive Shaft Housing
Swivel Bracket and Steering Arm
Transom Brackets
Drive Shaft Housing and Exhaust Tube
Drive Shaft Housing and Dyna-Float Suspension
Removal and Disassembly
Reassembly and Installation
Power Trim
Power Trim Specifications
Special Tools
Power Trim Components
Power Trim Motor
Power Trim - General Information
Trimming Characteristics
Description
Trailering Outboard
Tilting Outboard Manually
Striker Plate Replacement
Trim "In" Angle Adjustment
Anode Plate
Trim Indicator Gauge
Check, Fill and Purge - Power Trim System
Troubleshooting
Power Trim System with Relays and 2 Wire Trim Motor
Electrical System Troubleshooting
Troubleshooting the "Down Circuit
General Checks
Troubleshooting the "Up" Circuit
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim Assembly Removal and Installation
Installation
Testing Power Trim System with Test Gauge Kit (91-52915A6)
"UP" Pressure Check
“DOWN” Pressure Check
Hydraulic Repair
Trim Rod End Cap Seal
Tilt Ram
Disassembly
Scraper Seal Replacement
Motor and Electrical Tests/Repair
Trim Pump Motor Test
Motor Disassembly
Armature Tests
Motor Repair
Reassembly
Reassembly - Motor and Pump
Priming Power Trim System
Trim Sender Test
Trim Indicator Gauge Needle Adjustment
Trim Indicator Wiring Diagrams
Lower Unit
Right Hand Non-Ratcheting
Gear Housing Specifications (Standard Rotation)
Gear Housing (Drive Shaft)(Standard Rotation)
Gear Housing (Prop Shaft)(Standard Rotation)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection – Standard Rotation
Draining and Inspecting Gear Housing Lubricant
Water Pump
Bearing Carrier and Propeller Shaft Removal
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Pinion Gear and Driveshaft
Forward Gear
Gear Housing
Reassembly and Installation Standard Rotation
Driveshaft Needle Bearing
Bearing Carrier
Forward Gear Bearing Race
Driveshaft and Pinion Gear
Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash
Shift Shaft Bushing
Gear Lubricant Filling Instructions
Installing Gear Housing to Driveshaft Housing
Propeller Installation
Left Hand Non-Ratcheting
Gear Housing Specifications (Counter Rotation)
In. (0.635 MM) with Tool 91-12349A2 Using Disc #2 and Flat #7
Flat #7
Mark #1
In. (0.635 MM) with Tool 91-12349A2 Using Disc #2 and Flat #7 #2
0.018 In. to 0.027 in
0.015 In. to 0.022 in
Gear Housing (Drive Shaft)(Counter Rotation)
Gear Housing (Prop Shaft)(Counter Rotation)
Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing
Bearing Carrier and Propeller Shaft
Forward Gear and Bearing Adapter
Reverse Gear
Reassembly and Installation of Counter Rotation Gear Housing
Bearing Carrier, Forward Gear and Bearing Adaptor
Reverse Gear Bearing Adaptor Assembly
Pinion Gear Depth
Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
Attachments / Control Linkage
Ride Guide Steering Cable/Attaching Kit Installation (92876A1)
Maintenance Instructions
Attachments / Control Linkage
Ride Guide Steering Cable/Attaching Kit Installation (92876A3)
Dual Cable - Single Outboard
Super Ride-Guide Steering Kit Installation
Steering Cable Mounting Tube Installation
Installing Steering Cables
Coupler Installation
Installing Link Rod
Maintenance Instructions
Ride Guide Steering Cable/Attaching Kit Installation (92876A6)
Dual Cable - Dual Outboard
Installation Requirements
Parallel Routed Steering Cables and Attaching Kit Installation
Opposite Side Routed Steering Cables and Attaching Kit Installation
Trim Tab Adjustment
Ride Guide Steering Attachment Extension Couplers
Maintenance Instructions
Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
Attaching Kit Installation
Maintenance Instructions
Clevis Attaching Kit Installation (A-70599A2)
Installation Instructions
Maintenance Instructions
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SERVICE
MANUAL
MODELS
135 150 OPTIMAX
Direct Fuel Injection
With Serial Numbers
With Serial Numbers OG590000 and Above
1999, Mercury Marine
90-855347R1 JANUARY 1999
Printed in U.S.A.
Table of
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Table of Contents
Troubleshooting
Manifold Absolute Pressure (MAP) Sensor
63
Troubleshooting Without Digital Diagnostic Terminal
64
Troubleshooting With the Digital Diagnostic Terminal
65
DFI Troubleshooting Guide
68
Troubleshooting the Starter Circuit
99
Starter Circuit Troubleshooting Flow Chart
100
Fuel pressure and air pressure troubleshooting chart
200
Oil System Troubleshooting
216
Thermostat Test
288
Troubleshooting
317
Electrical System Troubleshooting
320
Troubleshooting the "Up" Circuit
321
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
322
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