Mercury 3 Liter Work 250 EFI Manuals

Manuals and User Guides for Mercury 3 Liter Work 250 EFI. We have 1 Mercury 3 Liter Work 250 EFI manual available for free PDF download: Service Manual

Mercury 3 Liter Work 250 EFI Service Manual

Mercury 3 Liter Work 250 EFI Service Manual (719 pages)

3.0 Litre Work, Electronic Fuel Injection

Brand: Mercury | Category: Engine | Size: 19.6 MB

Table of Contents

Important Information 1

10
- Table of Contents
  10
- 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
    14
- Corrosion Control Anode
  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
  - Counter Rotation Outboards
    46
  - Installation
    47
- Throttle Cable
  49
  - Installation
    49
  - Front Clamp Reassembly
    50
- Oil Injection Set-Up
  51
  - Installing Remote Oil Tank
    51
  - Filling
    52
  - Priming the Oil Pump
    53
  - Priming Procedure - Method 1
    54
  - Purging Air from the Engine Oil Reservoir
    55
- Trim in Stop Adjustment
  55
- Trim Tab Adjustment
  56
  - Models Without Power Steering
    56
  - Models with Power Steering
    56
Electrical 2

57
Electrical 2

92
- Specifications
  93
- Special Tools
  94
- Battery Cable Size
  95
- Recommended Battery
  95
- Replacement Parts
  95
- Battery
  96
  - Precautions
    96
- Charging a Discharged Battery
  96
- Winter Storage of Batteries
  97
- Flywheel Removal and Installation
  98
  - Removal
    98
  - Installation
    99
- Notes
  100
- Flywheel/Alternator
  101
- System Components
  102
  - Precautions
    103
- Alternator Description
  103
- Diagnosis of Alternator System on Engine
  104
- Alternator System Circuitry Test
  105
  - Output Circuit
    105
  - Sensing Circuit
    106
  - Voltage Output
    107
  - Current Output
    108
  - Current Output Troubleshooting
    109
- Repair
  109
  - Removal
    109
- Alternator Belt Tension Adjustment
  111
- Starter System
  112
  - Starter Motor Amperes Draw
    112
  - Starter System Components
    112
  - Description
    112
- Starter Motor (Centrifugal Bendix)
  113
- Troubleshooting the Starter Circuit (Centrifugal Bendix)
  115
  - Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix)
    116
  - Flow Chart (Continued)
    117
- Starter Installation (Centrifugal Bendix)
  118
- Starter Removal (Centrifugal Bendix)
  118
- Starter Disassembly (Centrifugal Bendix)
  119
  - Starter Cleaning, Inspection and Testing
    121
  - Starter Reassembly
    124
- Starter Motor (Solenoid Driven Bendix)
  129
- Troubleshooting the Solenoid Driven Bendix Starter Circuit
  131
  - Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)
    132
- Starter Installation (Solenoid Driven Bendix) 2B-43
  134
- Starter Removal (Solenoid Driven Bendix)
  134
- Disassembly (Solenoid Driven Bendix Starter) 2B-45
  136
- Cleaning and Inspection
  139
- Reassembly (Solenoid Driven Bendix Starter) 2B-49
  140
- Commander 2000 Key Switch Test
  144
Electrical 2

151
- Power Trim Wiring Diagram
  152
- Instrument Wiring Connections
  153
- Commander 3000 Classic Panel Remote Control
  154
- Commander 3000 Panel Remote Control
  155
- 4000 Series Mechanical Panel Control
  156
- Instrument/Lanyard Stop Switch Wiring Diagram
  157
- Oil Level Gauge Wiring Diagram
  158
- Notes
  159
- Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
  160
- QSI Gauge Wiring Diagrams
  162
  - Tachometer Wiring Diagram
    162
  - Water Temperature Gauge
    163
  - Oil Level Gauge Wiring
    164
  - Engine Synchronizer Wiring Diagram
    166
- Maintenance
  167
- Warning System Signals
  168
- Guardian Protection System
  169
  - Guardian System Operation with Gauges 2D-19
    169
  - Guardian System Activation
    169
- Analog Gauge Panel Mount Remote Control Wiring Installation
  171
- System Monitor V2.0
  172
  - Basic Operation
    172
  - Initial Power up (or after Master Reset) . 2D-22
    172
  - Standard Information Display Screens
    173
  - Display of Range and Depth Information
    175
  - Warning System
    176
  - Warning Display Screens
    177
  - CAL1 Calibration
    180
  - CAL2 Calibration
    182
  - Master Reset Command
    185
- System Tach & Speed
  186
  - Basic Operation and Features
    186
  - Speedometer Display Screens
    187
  - Tachometer Display Screens
    188
  - Troll Control
    189
  - Warning System
    190
  - Alarm Messages
    191
  - Auto-Detection Engine Function
    195
  - Master Reset Command
    195
  - Tachometer Calibration
    196
  - Speedometer Calibration
    200
- Smartcraft Gauge Operation
  202
  - Basic Operation and Features
    202
  - Speedometer Display Screen
    203
  - Tachometer Display Screens
    204
  - Troll Control
    205
  - Warning System
    206
  - Alarm Messages
    207
  - Tachometer Calibration
    211
  - Speedometer Calibration
    214
- Smartcraft Gauge Test Specifications
  216
  - Test Equipment Required
    216
- Liter Work/225 EFI/250 EFI Wiring Diagram
  217
Fuel System

218
- Special Tools
  219
- Specifications
  219
  - Fuel Pump Pressure @ W.O.T
    219
  - Fuel Pump Pressure @ Idle
    219
- Notes
  220
- Fuel Pump Assembly
  221
- Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
  223
- Fuel Pump Description/Operation
  223
- Checking Fuel Pump Lift (Vacuum)
  224
- Fuel Pump Capability Test
  225
- Fuel System Leak Test
  225
- Vacuum Test
  225
- Fuel Pump Removal/Disassembly
  226
- Cleaning/Inspection
  227
- Reassembly/Lnstallation
  227
Fuel System

230
- Specifications
  231
- Special Tools
  232
- Notes
  234
- Fuel Management System
  235
- Vapor Separator Components
  239
- Electronic Fuel Injection (Efl) System
  241
  - Introduction
    241
  - Using the Test Procedures
    241
  - EFI System Tests
    241
  - Safety Precautions
    241
  - Fuel Injection System Function
    242
- Preliminary Checks
  242
  - Ignition Spark Check
    242
  - Electronic Fuel Injection Set up
    243
  - Fresh Quality Fuel
    243
  - Low Battery Voltage
    243
- Fuel Flow Diagram
  244
- Fuel Flow Component Description
  245
  - EFI Electrical Components
    246
- EFI Fuel Management (Low Pressure Fuel Route)
  248
- EFI Fuel Management (High Pressure Fuel Route)
  249
- Fuel Rail Electrical/Fuel Determination
  250
- EFI System Test Procedures
  251
  - Fuel Gauge Connection/Pressure Test
    251
  - Vapor Separator Fuel Delivery Test
    252
  - Pulse Fuel Pump Delivery Test
    253
  - Water Separating Filter Inspection
    254
  - Vapor Separator Float Test
    255
  - Pressure Regulator Test
    258
  - Injector Electrical Harness Test
    260
  - Injector Load Test
    261
  - Fuel Rail Assembly Leakage Test
    261
  - Air Temperature Sensor and Head Temperature Sensor Test
    262
  - Detonation Control System Test (200 Work Models Only)
    263
  - Throttle Position Sensor Test
    264
  - MAP Sensor Test
    265
  - Problem Diagnosis
    266
- Engine Head Temperature Sensor Installation
  269
- Fuel Management Assembly Removal
  270
  - Fuel Rail Removal
    274
  - Fuel Rail Installation
    276
  - Reed Block Assembly Removal
    278
  - Reed Block Assembly Installation
    278
  - Air Temperature Sensor Removal
    279
  - Air Temperature Sensor Installation
    279
  - Manifold Absolute Pressure (MAP) Sensor Removal
    279
  - Manifold Absolute Pressure (MAP) Sensor Installation
    279
  - Throttle Plate Assembly Removal
    280
  - Throttle Plate Assembly Installation
    280
  - Vapor Separator Disassembly
    280
  - Vapor Separator Reassembly
    282
  - Air Plenum Installation
    283
  - Vapor Separator (VST) Installation
    284
  - Water Separating Filter Assembly Removal
    285
  - Water Separating Filter Assembly Installation
    285
  - Throttle Position Sensor Removal
    286
  - Throttle Position Sensor Installation
    286
  - Oil Reservoir Removal
    287
  - Oil Reservoir Installation
    287
  - Fuel Pressure Regulator Removal
    288
  - Fuel Pressure Regulator Disassembly
    289
  - Fuel Pressure Regulator Reassembly
    289
- EFI System Cleaning and Inspection
  290
  - Cleaning
    290
  - Inspection
    290
Fuel System

291
- Operation of the Oil Injection System
  292
  - Final Checks before Operation of Engine
    292
  - Checking Operation of the Oil Injection
    292
- Specifications
  
  298
  - Oil Injection Components
    294
    
    Oil Pump Removal and Installation
    298
    
    Oil Injection
    298
- Table of Contents
  
  300
  - Priming the Oil Pump
    300
  - Priming Procedure - Method 1
    301
  - Remote Oil Hose Connections
    302
  - Filling the Oil Tanks
    303
  - And Remote Oil Hose
    303
  - Oil Warning Systems
    304
  - Oil System Troubleshooting
    305
  - Low Oil Warning System Is Activated
    305
Fuel System

306
- Controlling Emissions
  307
- Outboard Hydrocarbon Emissions Reductions
  307
- Oxides of Nitrogen - Nox
  307
- Stoichiometric (14.7:1) Air/Fuel Ratio
  307
- Stratified Vs Homogenized Charge
  308
  - Homogenized Charge
    308
  - Stratified Charge
    309
- Emissions Information
  309
  - Manufacturer's Responsibility
    309
  - Dealer Responsibility
    310
  - Owner Responsibility
    310
  - EPA Emission Regulations
    310
- Manufacturer's Certification Label
  311
- Service Replacement Certification Label
  312
  - Removal
    312
  - Date Code Identification
    312
  - Installation
    312
  - Decal Location
    312
Section 4A - Powerhead

313
- Specifications
  314
  - Block
    314
  - Reed Valve Opening
    314
  - Cylinder Bore
    314
  - Piston
    314
- Special Tools
  315
  - Powerhead Repair Stand
    316
- Notes
  317
- Cylinder Block Assembly
  318
- Exhaust Adaptor Plate
  322
- Crankshaft, Pistons and Connecting Rods
  324
- Starboard Bleed System Routing
  326
- Port Bleed System Routing
  328
- Torque Sequence
  330
- General Information
  332
- Powerhead Removal from Driveshaft Housing
  333
- Removing Engine Components
  339
  - Removing Engine Components Individually
    339
  - Vapor Separator Tank (VST) Removal
    340
  - Air Plenum Removal
    342
  - Starter Motor
    345
  - Electrical Plate Removal
    346
  - Alternator Removal
    347
- Powerhead Disassembly
  348
- Cleaning and Inspection
  359
  - Cylinder Block and Crankcase Cover
    359
  - Special Service Information
    359
  - Cylinder Bores
    360
  - Pistons and Piston Rings
    361
  - Cylinder Heads
    363
  - Crankshaft
    363
  - Crankshaft (and End Cap) Bearings
    364
  - Reed Block Assembly
    365
  - End Bearing Bleed System
    365
  - Connecting Rods
    365
  - Thermostats (120 F) (49 C)
    367
- Powerhead Reassembly and Installation
  368
  - General
    368
  - Crankshaft Installation
    371
  - Piston and Piston Ring Combinations
    374
  - Piston Installation
    375
  - Crankcase Cover Installation
    379
  - Assembly of Reed Blocks to Reed Block Adaptor Plate
    381
- Notes
  385
- Powerhead Installation on Driveshaft Housing
  388
- Shift Cable
  394
  - Counter Rotation Outboards
    394
  - Installation
    395
- Throttle Cable
  397
  - Installation
    397
  - Front Clamp Reassembly
    398
- Engine Break-In Procedure
  399
  - Gasoline/Oil Break-In Mixture
    399
  - Break-In Procedure
    399
Powerhead

400
- Specifications
  401
  - Water Pressure
    401
  - Thermostat
    401
  - Digital Port and Starboard Temperature Sensor
    402
  - Analog Temperature Sensor
    403
- Special Tools
  404
- Water Flow
  405
  - Description
    405
- Water Flow Diagram
  406
- Notes
  407
- Thermostat Test
  408
- Troubleshooting
  408
- Water Pressure Check
  409
- Water Pump Cleaning and Inspection
  410
- Problem Diagnosis
  411
MID-Section

412
- Swivel Bracket and Steering Arm
  413
- Transom Brackets
  415
- Drive Shaft Housing and Exhaust Tube
  417
- Drive Shaft Housing and Dyna-Float Suspension
  419
  - Removal and Disassembly
    419
  - Reassembly and Installation
    423
MID-Section

427
- Special Tools
  428
- Power Trim Components (Oildyne)
  430
- Power Trim Motor (Oildyne)
  432
- Power Trim - General Information
  433
  - Description
    433
  - Trimming Characteristics
    433
  - Trailering Outboard
    434
  - Tilting Outboard Manually
    434
  - Trim "In" Angle Adjustment
    435
  - Striker Plate Replacement
    435
  - Anode Plate
    436
  - Trim Indicator Gauge
    436
  - Check, Fill and Purge - Power Trim System
    436
  - Trim Circuit
    438
  - Tilt Circuit
    440
  - Down Circuit
    442
  - Trail over and Shock Absorber
    445
  - Manual Tilt
    447
  - Troubleshooting
    448
  - Power Trim System with Relays and 2 Wire Trim Motor
    450
- Electrical System Troubleshooting
  451
  - General Checks
    451
- Troubleshooting the "Down Circuit
  451
- Troubleshooting the "Up" Circuit
  452
- Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
  453
- Power Trim Assembly Removal and Installation
  454
  - Removal
    454
  - Installation
    457
  - Testing Power Trim System with Test Gauge Kit (91-52915A6)
    459
  - UP" Pressure Check
    459
  - DOWN" Pressure Check
    462
  - Hydraulic Repair
    464
  - Trim Rod End Cap Seal
    465
  - Tilt Ram
    467
  - Disassembly
    468
  - Memory Piston Removal
    470
- Cleaning/Inspection/Repair
  471
  - Scraper Seal Replacement
    471
- Power Trim Disassembly
  475
  - Trim Motor Removal
    476
  - Pump and Component Removal
    477
- Motor and Electrical Tests/Repair
  479
  - Trim Pump Motor Test
    479
  - Motor Disassembly
    479
  - Armature Tests
    480
  - Motor Repair
    481
  - Reassembly
    484
  - Reassembly - Motor and Pump
    486
  - Priming Power Trim System
    488
  - Analog Trim Sender Test
    488
  - Digital Trim Sender
    489
  - Troubleshooting Digital Trim Sender
    490
- Trim Indicator Wiring Diagrams
  491
Lower Unit

492
- Special Tools
  493
- Gear Housing (Drive Shaft)(Standard Rotation)
  497
- Gear Housing (Prop Shaft)(Standard Rotation)
  499
- General Service Recommendations
  501
- Removal, Disassembly, Cleaning and Inspection - Standard Rotation
  502
  - Removal
    502
  - Draining and Inspecting Gear Housing Lubricant
    504
  - Water Pump
    505
  - Oil Seal Carrier Assembly
    507
  - Drive Shaft Assembly
    518
  - Propeller Shaft Assembly and Forward Gear Bearing Cup
    523
  - Forward Gear Assembly
    526
  - Shift Spool Assembly
    529
  - Propeller Shaft Assembly
    531
  - Shift Shaft Assembly
    532
  - Pinion Bearing
    535
- Gear Housing Reassembly
  536
  - Gear Housing Inspection
    536
  - Pinion Bearing
    537
  - Forward Gear Bearing Cup
    538
  - Shift Shaft Assembly
    539
  - Propeller Shaft Assembly
    541
  - Drive Shaft and Pinion Gear
    542
- Gear Location/Backlashes/Checking and Adjustment
  545
  - Drive Shaft - Bearing Preload Tool
    545
  - Pinion Gear Location
    546
  - Bearing Carrier Assembly
    549
  - Forward Gear Backlash
    551
  - Reverse Gear Backlash
    552
  - Drive Shaft - Bearing Preload Tool
    554
- Bearing Carrier Assembly
  555
  - Final Installation
    555
- Oil Seal Carrier Assembly
  558
- Water Pump Assembly
  558
  - Gear Lubricant Filling Instructions
    561
  - Propeller Installation
    562
  - Speedometer Tube Installation
    564
Lower Unit

565
- Special Tools
  566
- Gear Housing (Drive Shaft)(Counter Rotation)
  572
- Gear Housing (Prop Shaft)(Counter Rotation)
  574
- General Service Recommendations
  576
- Removal, Disassembly, Cleaning and Inspection of
  577
- Pre-Disassembly Inspection
  580
  - Propeller Shaft
    580
  - Water Pump
    581
  - Oil Seal Carrier Assembly
    583
  - Forward Gear Bearing Adaptor Assembly
    597
  - Drive Shaft Assembly
    599
  - Propeller Shaft Assembly
    604
  - Reverse Gear Assembly
    608
  - Shift Spool Assembly
    611
  - Reverse Gear Bearing Adaptor Assembly
    614
  - Shift Shaft Assembly
    616
  - Pinion Bearing
    619
- Gear Housing Reassembly
  620
  - Gear Housing Inspection
    620
  - Pinion Bearing
    621
  - Reverse Gear Bearing Adaptor Assembly
    622
  - Shift Shaft Assembly
    624
- Gear Location/Backlashes Checking and Adjustment
  625
  - Reverse Gear
    625
  - Drive Shaft and Pinion Gear
    626
- Gear Location/Backlashes/Checking and Adjustment
  629
  - Pinion Gear Location
    630
  - Reverse Gear Backlash
    634
  - Forward Gear/Bearing Carrier Assembly
    636
  - Forward Gear Backlash
    642
  - Propeller Shaft Assembly
    644
    
    Component Reassembly
    644
- Propeller Shaft Assembly
  646
  - Installation
    646
  - Drive Shaft and Pinion Gear
    649
    
    Final Installation
    649
  - Bearing Carrier Assembly
    651
    
    Final Installation
    651
  - Oil Seal Carrier Assembly
    660
- Water Pump Assembly
  661
  - Gear Lubricant Filling Instructions
    664
  - Propeller Installation
    666
  - Speedometer Tube Installation
    667
Attachments / Control Linkage

668

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