User Manuals: Mercury 20 EFI FourStroke Outboard Motor

Manuals and User Guides for Mercury 20 EFI FourStroke Outboard Motor. We have 2 Mercury 20 EFI FourStroke Outboard Motor manuals available for free PDF download: Service Manual, Installation, Operation & Maintenance Manual

Mercury 20 EFI FourStroke Service Manual

Mercury 20 EFI FourStroke Service Manual (406 pages)

Brand: Mercury | Category: Engine | Size: 18 MB

Table of Contents

Important Information 1

6
Important Information 1

12
- Cleaning Care
  13
  - Do Not Use Caustic Cleaning Chemicals
    13
  - Cleaning Care for Top and Bottom Cowls
    13
- Inspection and Maintenance Schedule
  13
- Battery Inspection
  14
- Flushing the Cooling System
  14
- Fuel System
  15
- Fuse Replacement - Electric Start Models
  18
- Spark Plug Inspection and Replacement
  19
- Timing Belt Inspection
  19
- Engine Oil
  20
- Corrosion Control Anodes
  22
- Propeller Replacement
  24
  - Removal
    24
  - Installation
    25
- Gearcase Lubrication
  25
- Lubrication Points
  27
- Storage Preparation
  28
Important Information 1

32
Important Information 1

50
- Installing Outboard
  51
  - Boat Transom Height Requirement
    51
  - Installing Outboard on Transom
    51
- Lifting the Outboard
  51
- Start in Gear Protection
  51
- Steering Cable Installation
  53
- Steering Link Rod Fasteners
  53
- Remote Wiring Harness and Control Cable Installation
  54
- Battery Installation
  56
  - Mounting Battery
    56
- Battery Connections
  57
  - Connecting Outboard Battery Cables
    57
  - Disconnecting Outboard Battery Cables
    57
Important Information 1

58
- Conditions Affecting Performance
  59
  - Bottom of Boat
    59
  - Cavitation
    59
  - Detonation
    60
  - Elevation, Weather, and Climate
    60
  - Propeller Selection
    60
  - Water Absorption
    60
  - Weight Distribution (Passengers and Gear) Inside the Boat
    60
- Compression Check
  61
- Cylinder Leakage Test
  61
  - Analysis
    61
- Guardian Protection System
  62
- Warning System
  62
  - Warning Horn Location
    62
  - Warning Light Location
    62
  - Warning System Operation
    62
  - Engine Overheat
    63
  - Low Oil Pressure
    63
  - Engine Overspeed Limiter
    63
  - Wire Color Code Abbreviations
    64
  - Warning System Wiring Diagram
    64
- Troubleshooting with CDS G3
  64
  - About CDS G3
    64
  - Connecting CDS G3
    65
  - Using CDS G3
    65
- Troubleshooting Without a Computer Diagnostic System (CDS)
  64
- Accessing ECM Information with CDS G3
  65
- CDS G3 Screens (10/15/20 EFI)
  66
  - CDS G3 Live Data Screen
    66
  - CDS G3 Diagnostics Screen
    67
- Engine Control Module Pinout
  68
- Fault Codes
  68
Electrical 2

72
- Engine Control Module (ECM)
  74
  - ECM Systems Control Matrix
    75
  - Troubleshooting
    75
  - Removal
    75
  - Installation
    75
- General Troubleshooting
  74
- Ignition Theory of Operation
  74
- Sensors
  76
  - Crankshaft Position Sensor
    76
- Wire Color Code Abbreviations
  76
- Engine Coolant Temperature (ECT) Sensor
  78
- Oil Pressure Switch
  80
- Temperature and Manifold Absolute Pressure (TMAP) Sensor
  81
- Throttle Position Sensor (TPS)
  83
- Flywheel
  84
- Ignition Components
  84
- Stator
  85
- Timing Belt
  87
- Ignition Coil
  88
Electrical 2

92
- Charging and Starting Specifications
  93
- General Troubleshooting
  93
- Starter Motor Components
  95
- Starter Motor and Solenoid Electrical Components
  97
- Charging System
  99
- Wire Color Code Abbreviations
  99
- Starter Solenoid Test
  102
- Starting System
  102
- Starting System Components
  102
- Starting System Description
  102
- Troubleshooting the Starting Circuit
  102
- Starting System Wiring Diagrams
  103
- Starter Motor
  104
- Starter Motor Current Draw
  104
- Starting System Troubleshooting Chart
  104
- Starter Motor Disassembly
  105
- Starter Motor Removal
  105
- Starter Motor Reassembly
  106
- Starter Motor Installation
  109
Fuel System 3

112
- Theory of Operation
  113
  - Air Induction System
    113
  - Fuel System
    113
  - Fuel Pump
    113
  - Vapor Separator Tank
    113
  - Throttle Body
    114
- Engine Control Module (ECM)
  114
  - Overview
    114
  - ECM and Fuel Injection
    114
  - Troubleshooting
    115
  - Additional Information
    115
- Actuators
  115
  - Function of Actuators
    115
  - Idle Air Control (IAC)
    115
  - Fuel Injector
    116
- Sensors
  115
Fuel System 3

118
- Fuel Pressure Test
  119
- General Troubleshooting
  119
- Testing Fuel System Inlet Vacuum
  119
- Fuel System Wiring Diagram
  120
- Wire Color Code Abbreviations
  120
- Sensor Wiring Diagram
  121
Fuel System 3

122
- Fuel System Specifications
  123
- Fuel System Components
  125
- Vapor Separator Tank Components
  127
- Air Intake Components
  129
- Fuel Lift Pump
  131
  - Fuel Lift Pump Removal
    131
  - Fuel Lift Pump Installation
    131
- Vapor Separator Tank (VST)
  132
  - VST Removal
    132
  - VST Disassembly
    134
  - VST Reassembly
    135
  - Fuel Cooler
    136
  - VST Installation
    137
- Camshaft Gear Cover/Vent Tank
  138
  - Removal
    138
  - Installation
    139
- Throttle Body
  139
  - Throttle Body Removal
    139
  - Throttle Body Installation
    140
- Fuel Rail
  141
  - Fuel Rail Removal
    141
  - Fuel Rail Disassembly
    142
  - Fuel Rail Reassembly
    142
  - Fuel Rail Installation
    143
- Air Box
  144
  - Air Box Removal
    144
  - Air Box Installation
    144
- Idle Air Control (IAC)
  145
  - IAC Removal
    145
  - IAC Test
    145
  - IAC Installation
    146
Powerhead

148
- Cylinder Block/Crankcase Specifications
  149
- Piston Specifications
  150
- Cylinder Block and Crankcase Components
  151
- Crankshaft Components
  153
- Powerhead Removal
  155
- Cylinder Block Disassembly
  157
  - Electrical Component Removal
    157
  - Throttle Body Removal
    159
  - Crankshaft Timing Gear Removal
    159
  - Thermostat and Exhaust Cover Removal
    160
  - Oil Strainer Removal
    161
  - Crankcase and Crankshaft Removal
    161
  - Piston Disassembly
    163
- Powerhead Cleaning, Inspection, and Repair
  163
  - Flywheel
    163
  - Crankshaft Timing Gear
    164
  - Timing Belt
    164
  - Anode
    164
  - Measuring Cylinder Bore
    164
  - Piston Measurements
    164
  - Connecting Rod Measurements
    166
  - Crankshaft
    167
  - Crankcase Main Bearings
    167
  - Connecting Rod Oil Clearance
    170
- Powerhead Assembly
  171
  - Piston Assembly
    171
  - Piston Ring Installation
    171
  - Piston Installation
    172
  - Crankshaft Installation
    173
  - Crankshaft Timing Gear Installation
    175
  - Thermostat, Exhaust Cover, and Anode Installation
    175
  - Oil Strainer Installation
    177
  - Throttle Body Installation
    177
  - Electrical Component Installation
    178
- Powerhead Installation
  180
Powerhead

186
- Cylinder Head Specifications
  187
- Cylinder Head Components
  189
- Intake/Exhaust Valve Components
  191
- Camshaft and Oil Pump Components
  193
- Valve Adjustments
  195
- Cylinder Head Removal
  196
- Cylinder Head Disassembly
  198
- Camshaft
  200
  - Valves
    200
  - Valve Springs
    201
  - Cylinder Head Resurfacing
    201
  - Valve Guides
    202
  - Rocker Arm and Rocker Arm Shaft Inspection
    202
  - Valve Seat Reconditioning
    202
- Cleaning and Inspection
  200
- Cylinder Head Assembly
  204
- Cylinder Head Installation
  206
Midsection

220
- Clamp Bracket Components (Power Tilt)
  223
- Clamp Bracket Components (Manual Tilt)
  225
- Steering Arm and Copilot Components
  229
- Driveshaft Housing Components
  231
- Driveshaft Housing Cover Components
  233
- Driveshaft Housing Covers
  235
  - Removal
    235
  - Installation
    236
- Front Cowl
  236
  - Removal
    236
  - Installation
    237
- Idle Exhaust Port Cover
  238
  - Removal and Inspection
    238
  - Installation
    238
- Powerhead/Midsection Assembly Separation
  239
  - Remote Control Throttle and Shift Cables
    239
  - Removal
    239
  - Installation
    241
- Engine Mount Replacement
  242
  - Upper Mount
    242
  - Lower Mount
    242
- Clamp Brackets, Swivel Bracket - Power Tilt Models
  244
  - Clamp Brackets - Power Tilt
    244
  - Steering Arm Removal
    249
  - Power Tilt Removal
    250
  - Swivel Bracket Removal
    251
  - Swivel Bracket Inspection
    251
  - Swivel Bracket Installation
    252
  - Power Tilt Installation
    253
  - Steering Arm Installation
    254
- Clamp Brackets, Swivel Bracket - Manual Tilt Models
  256
  - Clamp Brackets - Manual Tilt
    256
  - Steering Arm Removal
    259
  - Swivel Bracket Removal
    260
  - Swivel Bracket Inspection
    260
  - Swivel Bracket Installation
    262
  - Steering Arm Installation
    263
- Driveshaft Housing Removal
  265
- Driveshaft Housing Installation
  266
- Kicker Strap (Tiller Handle Model)
  267
  - Removal
    268
  - Installation
    268
- Shift Operation
  267
Midsection

270
- General Troubleshooting
  271
- Power Tilt - General Information
  271
- Power Tilt Specifications
  271
- Power Tilt Components
  273
- Theory of Operation
  275
  - Power Tilt Hydraulic Diagram
    275
  - Operation
    275
- Power Tilt Features and Operation
  276
  - Power Tilt
    276
  - Manual Tilt Release
    276
  - Tilt-In Stop Adjustment
    276
- Check Fluid and Purge the Power Tilt System
  277
  - Check Fluid
    277
  - Purging the Power Tilt System
    278
- Cowl-Mounted Tilt Switch
  278
  - Removal
    278
  - Installation
    278
- Troubleshooting the Power Tilt System
  279
  - Preliminary Troubleshooting Steps
    279
  - Power Tilt Leakage Test Procedure
    279
  - Hydraulic System Troubleshooting
    280
  - Tilt Electrical System - General Troubleshooting
    280
  - Power Tilt Relay Test
    281
  - Wire Color Code Abbreviations
    282
  - Tilt System Wiring Diagrams
    282
  - Tilt System Troubleshooting Charts
    284
- Power Tilt Removal
  287
- Manual Release Valve Removal and Repair
  288
- Power Tilt Motor
  289
- Power Tilt Pump
  293
  - Power Tilt Pump Disassembly
    293
  - Power Tilt Pump Reassembly
    295
- Power Tilt Installation
  298
Lower Unit

302
- Gearcase Specifications
  305
- Gear Housing and Driveshaft
  307
- Propeller Shaft
  309
- Draining and Inspecting Gear Housing Lubricant
  311
- General Service Recommendations
  311
  - Shims
    311
  - Seals
    311
- Gear Housing Removal
  312
- Gear Housing Disassembly
  313
- Driveshaft Pinion Bearing Removal
  325
- Driveshaft Inspection
  326
- Gear Housing Assembly
  327
- Pinion Bearing Installation
  327
- Upper Driveshaft Bearing Inspection
  327
- Forward Gear Bearing Installation
  328
- Bearing Carrier Assembly
  329
- Water Pump Base Assembly
  331
- Propeller Shaft Assembly
  332
- Pinion Gear and Driveshaft Installation
  333
- Forward Gear Backlash
  334
- Shift Shaft and Water Pump Base Installation
  336
- Water Pump Cover Assembly
  338
- Propeller Shaft and Bearing Carrier Installation
  339
- Gear Housing Installation
  340
- Propeller Installation
  342
Attachments

344
- Throttle and Shift Components (Tiller Models)
  347
- Remote Control Components
  349
- Tiller Handle Models
  351
  - Throttle and Shift Linkage Removal
    351
  - Shift Detent
    352
- Throttle and Shift Linkage Installation
  352
- Remote Models
  353
- Throttle and Shift Linkage Removal
  353
- Shift Detent
  355
- Throttle and Shift Linkage Installation
  355
Attachments

358
- Tiller Handle Features
  359
- Tiller Handle Components
  361
- Tiller Handle Yaw
  365
- Tiller Handle Disassembly
  366
- Tiller Handle Removal
  366
- Disassembly/Inspection
  368
- Throttle Cable Case
  368
- Assembly
  369
- Tiller Handle Assembly
  370
- Tiller Handle Installation
  374
- Shift Cable Installation
  375
- Throttle Cable Installation
  378
- Throttle Cable Adjustments
  379

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Mercury 20 EFI FourStroke Installation, Operation & Maintenance Manual

Mercury 20 EFI FourStroke Installation, Operation & Maintenance Manual (140 pages)

Brand: Mercury | Category: Outboard Motor | Size: 7 MB

Table of Contents

Boater's Responsibilities
11
High‑Speed and High‑Performance Boat Operation
12
Remote Steering Notice
13
Protecting People in the Water
15
Passenger Safety Message ‑ Pontoon Boats and Deck Boats
16
Wave and Wake Jumping
17
Impact with Underwater Hazards
18
Exhaust Emissions
20
Selecting Accessories for Your Outboard
22
Recording Serial Number
25
Model Year Production Code
26
Conditions Affecting Performance
28
Carrying, Storing, and Transporting Your Outboard When Removed from Boat
32
Trailering Boat/Outboard
33
Fuel Requirements
35
Low Permeation Fuel Hose Requirement
36
Mercury Marine's Pressurized Portable Fuel Tank
37
Filling Fuel Tank
38
Checking Engine Oil
39
Fuel and Oil
40
Tiller Handle Features
42
Remote Control Features
48
General Features
50
Manual Tilt Features and Operation
51
Power Tilt Features and Operation, if Equipped
56
Warning System
60
Operation
61
Operation
62
Prestarting Check List
63
Operating Outboard as an Auxiliary Engine
64
Engine Break‑In Procedure
66
Starting the Engine ‑ Remote Control Models
69
Gear Shifting
72
Stopping the Engine
74
Emergency Starting Procedure
75
Cleaning Care Recommendations
79
EPA Emissions Regulations
80
Inspection and Maintenance Schedule
81
Flushing the Cooling System
83
Top Cowl Removal and Installation
84
Battery Inspection
85
Fuel System
86
Propeller Replacement
91
Fuse Replacement ‑ Electric Start Models
94
Spark Plug Inspection and Replacement
96
Timing Belt Inspection
97
Corrosion Control Anodes and Continuity Wire
101
Lubrication Points
104
Gearcase Lubricant
106
Checking Power Tilt Fluid if Equipped
108
Submerged Outboard
109
Storage Preparation
110
Protecting Internal Engine Components
111
Battery Storage
112
Starter Motor will Not Crank the Engine (Electric Start Models)
113
Performance Loss
114
Service Assistance
115
Ordering Literature
117
Boat Horsepower Capacity
119
Low Permeation Fuel Hose Requirement
120
Steering Cable Installation
122
Steering Link Rod Fasteners
123
Remote Wiring Harness and Control Cable Installation
124
Changing the Tiller Handle Throttle Grip Rotation
131
Battery Installation ‑ Electric Start Models
137
Battery Connections
138
Maintenance Log
139

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