Mercury 0T409000 Manuals

Manuals and User Guides for Mercury 0T409000. We have 1 Mercury 0T409000 manual available for free PDF download: Service Manual

Mercury 0T409000 Service Manual

Mercury 0T409000 Service Manual (631 pages)

Electronic Fuel Injection,

Brand: Mercury | Category: Engine | Size: 17 MB

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
- 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
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
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

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