Mercury 200 OptiMax DTS Manuel d'installation

Outboard OptiMax I Technician’s Guide 1

1-9 90-898305 1. Standard (original) cable length and wire gauge size. 10

90-898305 4-12PULSE FUEL PUMP RUNING CHANGE There is continued improvement planned for the square pulse driven fuel pump used on most of the larger 2

90-898305 4-14Basic Fuel System Description Fuel for the engine is stored in a typical fuel tank. A primer bulb is installed into the fuel line to all

4-1590-898305 2.5L OptiMax Fuel Schematic a) Fuel Vapor (to plenum intake cover) b) Fuel Return c) High Pressu

90-898305 4-16OptiMax DFI Fuel Schematic w/Fuel Cooler 1) Air Inlet Compressor 2) Fuel Vapor 3) High Pressur

90-898305 4-183.0L OptiMax Fuel Schematic VST History Fuel cooler with VST 1998/99 Water cooled fuel rail with VST 20

4-1990-898305 3.0L OptiMax Fuel Schematic (Cont.) 1. Engine Pulse Fuel Pump 2. Fuel/Water Separator Filter 3. Vapor Separator Tank Vent Hose 4. Fuel

90-898305 4-20OptiMax 1.5L Fuel Schematic

4-2190-898305 1. Engine pulse fuel pump 2. Fuel/Water separator filter 3. Vapor separator tank vent hose 4. Air compressor inlet coolant hose 5. Fuel

90-898305 4-22OptiMax Fuel and Direct Injector Interface 1) Cylinder Head 2) Nylon Seal 3) Bellville Washer 4) C

4-2390-898305 Vapor Separator Fuel Flow 1) High Pressure Fuel (to Air/Fuel Rail) 2) Return Fuel (from Air/Fuel Rail) [o

90-898305 1-10 Battery Information All OptiMax • Do not use deep cycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA

90-898305 4-24Integrated Vapor Separator 2003 MY Improved low pressure electric fuel pump for improved durability Low pressure electric pump enclosed

4-2590-898305 1. Engine pulse fuel pump 2. Fuel/Water separator filter 3. Vapor separator tank vent hose 4. Fuel outlet from high pressure electric f

4-2790-898305 2002 & Up 2.5L OptiMax Air/Fuel Schematic a) Air Intake to Compressor b) Air Compressor c)

90-898305 4-28Fuel Pressure Regulator • Calibrated to raise fuel pressure 10 psi above air pressure • Uses both air & internal spring pressure t

4-2990-898305 Tracker Valve (V6 Models Only) • Tracker valve designed to maintain 10 psi differential between the fuel rails when air or fuel pressu

90-898305 4-30Fuel Injector A fuel injector is an electromagnetic device. The precision mechanical components are controlled by means of the solenoid

4-3190-898305 Disconnecting Harness Connectors from Ignition Coils and/or Injectors a) Wire Clip (push center down to remove) Direc

90-898305 4-322.5 & 3.0 Liter OptiMax DIRECT INJECTOR - 2002 MY RUNNING CHANGE New direct injector with encapsulated coil winding. A hard plastic

4-3390-898305 a – Direct injector ohm test between the two connector pins (1.0 – 1.6 ohms) b – Check between each connector pin and the metal p

5-1 90-898305 Section 5 - Oil Injection System

1-1190-898305 Connecting Battery Cables and DTS Power Harness • Install DTS power harness directly to the starting battery only. • Do not extend

5-3 90-898305 Table of Contents Table of Contents...2 Tabl

90-898305 5-4 Oil System Operation Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil is stored inside the remo

5-5 90-898305 Check Valve Kit – 1998/1999 135/150 OptiMax Check valves have been to the crankcase oil delivery hoses to prevent evacuation of oil fro

90-898305 5-6 2.5L - Model Year 2000 Starboard Side Oil Hose Routing

5-7 90-898305 2.5L - Model Year 2000 Port Side Oil Hose Routing

90-898305 5-8 2.5L - Model Year 2001 Starboard Side Oil Hose Routing

5-9 90-898305 2.5L - Model Year 2001 Port Side Oil Hose Routing

90-898305 5-103.0L - Model Year 2000 thru 2002 Starboard Side Oil Hose Routing a - Oil Pump b - Bolts (3) c -

5-1190-898305 3.0L - Model Year 2000 thru 2002 Port Side Oil Hose Routing a - Oil pump hoses a - Oil hose

90-898305 5-123.0L - Model Year 2003 Starboard Side Oil Hose Routing a - Oil pump b - Bolts (3) c - Remote oil ta

90-898305 1-12 Single Engine - Battery At Stern Notes _________________________________________________________________________

5-1390-898305 3.0L - Model Year 2003 Port Side Oil Hose Routing a - Oil pump hoses a - Oil hoses and h

90-898305 5-141.5L – Model Year 2004 Starboard Side Oil Hose Routing

5-1590-898305 New 1.5L Models - Oiling System Highlights • Engine mounted oil reservoir is standard. • Engine reservoir filled without removing top

90-898305 5-16OptiMax Oil Pump 1) Coil 2) Piston Assembly 3) Outlet Check Valve 4) Return Spring 5) Oil Discharge Port (4 Shown) 6) I

5-1790-898305 Priming the Oil Pump NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed, it is recommended all air be p

90-898305 5-18METHOD 3 - (DDT) DIGITAL DIAGNOSTIC TERMINAL - OIL PUMP PRIME This method fills the oil pump, oil supply hose feeding pump, and oil hos

6-1 90-898305 Section 6 - Electrical System

6-3 90-898305 Table of Contents Table of Contents...2 Tabl

90-898305 6-4 Ignition System - V6 Models Theory of Operation When the ignition key is turned to the RUN position, battery voltage is applied to the m

6-5 90-898305 Ignition Coil Driver Operation 1) 12 Volt Power From Fuse 2) ECM 3) Ground 4) Ignition Coil

1-1390-898305 Single Engine - Battery At Helm 14

90-898305 6-6 Ignition Coil and Driver Schematic

6-7 90-898305 Ignition Coils MODEL YEAR 2000 MODEL YEAR 2001 AND UP Notes ____________________________

90-898305 6-8 Ignition System - 3 Cylinder 1.5L Models Theory of Operation When the ignition key is turned to the RUN position, battery voltage is app

6-9 90-898305 3 Cylinder 1.5L Ignition Coil Schematic

90-898305 6-10Electronic Control Module (ECM) ECM/PCM IDENTIFICATION ECM - “Electronic Control Module” PCM - “Propulsion Control Module”. PCM has all

6-11 90-898305 The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can be monitore

90-898305 6-12Crank Position Sensor Senses teeth located on flywheel under ring gear. Supplies the ECM with crank position information and engine spee

6-13 90-898305 Temperature Sensor Three (3) temperature sensors (2 on 1.5L models) are used to provide cylinder head temperature information to the E

7-3 90-898305 Table of Contents Table of Contents...2 Tabl

90-898305 7-4 1998/99 Warning System The outboard warning system incorporates warning light gauge and warning horn. The warning horn is located inside

90-898305 1-14 Dual Engine - Battery At Stern Important: Make sure twin applications have the common ground. If missing can result in open DTS fus

7-5 90-898305 Warning System Signals NOTE: The warning system signals which includes audible and visual indicator involving the horn and lights will

90-898305 7-6 Guardian Protection System - All 2000 Models & Newer The guardian protection system monitors critical engine functions and will redu

7-7 90-898305 Guardian System Activation Condition Result Engine Overheat Engine power level can be reduced to any percentage down to an idle speed

90-898305 7-8 OptiMax Service Tips 1998/99 135/150, 2.5 LITRE 1998/99 200/225, 3.0 LITRE The following Troubleshooting/Service tips have been accumul

7-9 90-898305 Loose Fuse Holder 2.5 & 3.0 LITRE If the DDT shows a fault on all 6 direct injectors, fuel injectors, or ignition coils, it is not

90-898305 7-10 Alternator: 3.0 LITRE There have been three reports of burned/melted alternator RED wires. This can be caused by the wire being routed

7-11 90-898305 Twin Pressure Gauge: 2.5 & 3.0 LITRE Part number of the twin pressure gauge used on Optimax product has su The new gauge has impro

90-898305 7-12 Harness Replacement Ends 2.5 & 3.0 LITRE Service replacement harness connectors for the Optimax fuel injector, Direct injectors, TP

7-13 90-898305 False Throttle Position Sensor Failures 2.5 LITRE If the Throttle Position Sensors (TPS’s) are out of the intended operating range, or

90-898305 7-14 Incorrect Cam to Roller Setting Throttle Position Sensor (TPS) Troubleshooting If the throttle position sensor(s

1-1590-898305 Dual Engine - Battery At Helm Important: Make sure twin applications have the common ground. If missing can result in open DTS fuse.

7-15 90-898305 HEAT TEST With engine at idle, heat the TPS (with a hot air gun) below the electrical connection until warm to the touch. Watch for an

90-898305 7-16 Engines Stalling On Flushing Attachment 2.5 LITRE When running, on a flushing attachment some engines may stall when the DDT miss-fire

7-17 90-898305 OptiMax DDT Data Worksheet - P/N 90-858879 Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: D

90-898305 7-18 OptiMax DDT Data Worksheet - P/N 90-858879 Dealer Name: Technician Name: Dealer Number: Engine S/N: #1 Data Monitor NOW: Min: Max

7-19 90-898305 Smartcraft Data Worksheet - P/N 90-881929--1 Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number:

90-898305 7-20 SmartCraft Data Worksheet - P/N 90-881929--1 Dealer Name: Engine S/N: FREEZE FRAME FAULT BUFFER DATA Fault Buffer 0 Fault Buffer 1 Fau

7-21 90-898305 SmartCraft Data Worksheet Fault ID Description BREAK IN • Engine is still within oil break-in clock BARO PSI • The barometric pressu

90-898305 7-22 SmartCraft Data Worksheet Fault ID Description (Cont.) LOAD % • The engine load % when the fault occurred MPRLY • A value of zero ind

7-23 90-898305 SmartCraft Data Worksheet Dealer Name: Engine S/N: Dealer Number: Engine Type: Technician Name: ECM Part Number: Date: DDT Softwar

90-898305 7-24 SmartCraft Data Worksheet Dealer Name: Engine S/N: Dealer Number Engine type: Technician Name: ECM Part Number: Date: DDT Software

90-898305 1-16 Connecting 04 DTS 10 Pin Data Harness Single Engine Single Helm • SC5000 data cable (yellow) with termination resistor at engine end

8-1 90-898305 Section 8 - Tools For OptiMax

90-898305 8-2 Table of Contents Table of Contents ...2 Tool

8-3 90-898305 Tool Supplier Contact Information Cole-Parmer 800-323-4340, or 847-549-7600 SPX-OTC 616-792-0088 Blue Point 800-547-5740 Elec

90-898305 8-4 Tools for OptiMax Repair Single Fuel/Air Pressure Gauge 160 PSI – 91-16850A7 Note: To convert 100 psi gauge 91-16850A1 to 160 psi gauge

8-5 90-898305 Schrader Valve Tee - P/N 22-849606 Purge Valve - P/N 91-804706 Service replacement pressure release valve is now availabl

90-898305 8-6 Digital OptiMax Sensor Test Harness - P/N 91-875233A2 DDT Test Harness (5 Pin Digital Adapter) - P/N 91-875232A1

8-7 90-898305 OptiMax Wiring End Seal Kit - P/N 91-881814A1 Direct Injection Removal Tool - P/N 91-883521 Pressure Gauge Exte

90-898305 8-8 Oil Syringe - P/N 91-803976T Screw (5 mm x 25 mm) (2 each) - P/N 10-40073-25 Flat Washer (2 each) Seal/Teflon

8-9 90-898305 DDT Carrying Case P/N 804805 Service Tachometer DMT 2000 - P/N 91-854009A3 Service Tachometer DMT 2004 - P/N 91-892647A01

90-898305 8-10Clamp Tool Kit - P/N 91-803146A2 Regulator Installation Tool - P/N 91-889431 Notes __________

1-1790-898305 Command Module Installation 1. Plug the command module connector into the command module. 2. To minimize vibration, mount the command

90-898305 1-18 Single Helm Command Module Harness Installation 1. Connect the 14 pin Deutch connector on the command module harness to the 14 pin dat

3 Table of Contents Section 1 – General Information Section 2 – Powerheads Section 3 – Air Systems Section 4 – Fuel Systems Section 5 – Oil Injecti

1-1990-898305 Panel Mount Control Wiring Connections 1. Connect the trim harness and lever harness. 2. Insert the bayonet end of the lever harness i

90-898305 1-20 Wiring Guidelines for Electrical Boat Accessories ! IMPORTANT: Do not connect boat accessories to 12 volt or ignition key switch DT

1-2190-898305 Key Switch Options • Key Switch Three Position (Off, Run, and Start) has shorter key and mounting length 3/4 inch cut out. Without

90-898305 1-22 Wiring Instructions for Non-Mercury Marine Ignition Key Switch • The ignition key switch must comply with Mercury specifications for

1-2390-898305 • CDS version 5.09 or higher for 06 DTS System • CDS version 3.23 or higher for 05 DTS System • CDS version 3.12 or higher for 04 DTS

90-898305 1-24 TERMINATION RESISTOR PLACEMENT NOTE: Termination resistors are designed to reduce noise and provide proper DC voltage levels on the C.A

1-2590-898305 Harness Termination Resistor (One End) Some of the SmartCraft wiring harnesses (84-879981T_) are designed with the termination resistor

90-898305 1-26 System Tachometer/Speedometer Wiring Configurations Notes _________________________________________________

1-2790-898305 Dual Engine IMPORTANT: The location of the junction box termination resistors are critical forproper system function. All unused junc

90-898305 1-28 IMPORTANT: When using single CAN line make sure to disconect one 8 pin power connector. Note: For other SmartCraft configurations re

1-1 90-898305 Section 1 - General Information 3

1-2990-898305 Installing Standard Analog Tachometer to Digital Optimax Engines This procedure allows a standard analog tachometer to be connected to

90-898305 1-30 Installing Standard Analog Trim Indicator Gauge to Digital Optimax Engines NOTE: SmartCraft speedometer or tachometer communicate wit

1-3190-898305 NOTE: If none of the digital sensors (oil level, fuel level, paddle wheel, speedo, and trim) are used, digital harness P/N 84-859244

90-898305 1-32 Installing Standard Speedometer Gauge to Digital Optimax Engines NOTE: The digital speedometer sensor must be disconnected to connect

1-3390-898305 Installing Standard Water Pressure Gauge to Digital Optimax Engines 1. Remove the RED plug P/N 22-859732 from the connector at the end

90-898305 1-34 IMPORTANT: Most vessels have Coast Guard and/or static grounds on their fuel tank. Do not add additional grounds. This is to prevent

1-3590-898305 System Wiring Installation Checklist Data Cable • Verify the data harness is not routed near sharp edges, hot surfaces or moving parts

90-898305 1-36 Remote Control Cables Remote control cables are the mechanical connection between the control box and engine, selection and use of the

1-3790-898305 Console Mount Remote Controls 1. When measuring cable length for a console mount remote control, measure along theactual selected cabl

90-898305 1-38 SHIFT EFFORT TOOL Part Numbers (current at time of print) • MPC 4000 Gen II 91-892535A01 • MCC 4500 Gen II, 91-892539A01 • MSC C

1-3 90-898305 Table of Contents Table of Contents...2 Tabl

1-3990-898305 2. Remove the throttle only button covering the hex nut in the base of the remote control using a screwdriver or similar tool. 3.

90-898305 1-40 b. If the neutral lock button is on the side of the handle, firmly push the clip down. You may feel some resistance as the button is

1-4190-898305 Torque Specifications Engine Not Running CABLES NOT CONNECTED (OUTBOARD MODELS) NOTE: The torque specifications do not reflect the

90-898305 1-42 4. There are three methods for activating the priming process. • CDS-Oil Pump Prime in ACTIVE TEST will activate the priming process.

1-4390-898305 Priming the Oil Injection Pump Before starting engine for the first time, prime the oil injection pump. Priming will remove any air

90-898305 1-44 PRIMING THE OIL INJECTION PUMP a. Connect the fuel hose. Fill the fuel system by squeezing the primer bulb. Squeeze the fuel line prim

1-4590-898305 a- Fill Cap Propeller Installation Flow Torque III (included on 1.5L OptiMax) Notes _______________________________________

90-898305 1-46 The Flo-Torq III plastic drive sleeve assembly has a small forward/aft clearance so that it or the prop is not locked to the prop shaf

90-898305 1-48 Emissions Information Models Affected MERCURY/MARINER/FORCE/SPORT JET 1998 and Later 2.5 thru 250 HP MANUFACTURERS RESPONSIBILITY: Be

1-4990-898305 The responsibilities listed above are general, and are in no way a complete listing of the rules and regulations pertaining to the EPA

90-898305 1-4 Hydrocarbons – HC...50 Carbon Monoxide – CO ...

90-898305 1-50 Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination w

1-5190-898305 Outboard Hydrocarbon Emissions Reductions 8 1/3% _ PER YEAR OVER 9 MODEL YEARS Notes _______________________________

1-5390-898305 Engine Emission Certification Label Your outboard has been labeled on the cowl with one of the following star labels. The Star Label me

90-898305 1-54 Speed / Density Theory and Operation Speed/Density Theory Outboard OptiMax engines operate on the fuel injection strategy called “Speed

1-5590-898305 Speed/Density Operation To determine the density of the air in the intake manifold, we need to know the intake manifold vacuum, which w

90-898305 1-56 Stratified VS Homogenized Charge OptiMax engines use a stratified charge inside the combustion chamber to aid in reducing emissions. Al

1-5790-898305 Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the

90-898305 1-58 Theory of Operation - V6 Models Air Induction Through Crankcase Combustion air enters the cowl through holes located in the top aft end

1-5990-898305 Air Compressor System Air from inside the engine cowl is drawn into the compressor through the flywheel cover or air plenum. This cover

90-898305 1-60 Fuel Fuel for the engine is stored in a fuel tank. A primer bulb is installed into the fuel line to allow priming of the fuel system.

1-5 90-898305 Installation 14 Pin Adapter and Control Harnesses Models Affected 4-stroke models 9.9 thru 225 HP V-6 EFI (Excluding Verado) 2-stroke

1-6190-898305 Oil Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil is stored inside a standard remote oil re

90-898305 1-62 Compressor Notes: To aid in starting when the air rail pressure is low and before the compressor has time to build pressure, the direct

1-6390-898305 Theory of Operation - 3 Cylinder Models Air Induction Through Crankcase Combustion air enters the cowl through holes located in the top

90-898305 1-64 Fuel Fuel for the engine is stored in a typical fuel tank. A primer bulb is installed into the fuel line to allow priming of the fuel s

1-6590-898305 Electrical The electrical system consists of the PCM, crank position sensor (flywheel speed & crankshaft position), throttle positi

1-6790-898305 3 Cylinder/1.5 Liter 75/90/115 HP Cowls (Upper & Lower) • One piece light weight upper cowl. • Two piece lower cowls that extend

90-898305 1-68 Emissions & Noise Levels • Three star emission levels • Operator ear sound pressure level (ICOMIA 39/94: 83.2 dBA Powerhead • T

1-6990-898305 Cooling System • Thermostat/poppet valve controlled. • 142 degree thermostat • Water deflectors (3) to direct water flow around cyli

90-898305 1-70 Mid-Section • Larger upper and lower mounts • Integrated upper mount clamp and cowl seal retainer • Cast in upper mount pockets • I

1-7190-898305 Accessories 1.5L ACCESSORIES: • Three gallon remote oil tank kit P/N 1257-8742A25 • Tiller handle kit, will not be ready for start o

90-898305 1-6 Adapter Harness 84-896542T_ Adapts 2006 model year and newer engines that use the 14 pin harness to the old round 8 pin control or key

90-898305 1-72 Power Trim • Common power trim with current 75 -125 2-stroke • Analog power trim position sender kit will be standard after S/N 0T846

2-1 90-898305 Section 2 - Powerheads

2-3 90-898305 Table of Contents Table of Contents...2 Tabl

90-898305 2-4 Mechanical Changes to the 2.5L & 3.0L Litre Powerhead 1) Cylinder Head a) Direct injector located in the top of the cylinder head.

2-5 90-898305 Head Gasket The 1998/99 2.5L head gasket is aluminum (0.100” thick) with an O-ring type seal on both sides. 2.5L 20

90-898305 2-6 3.0L 2003 MODEL YEAR CYLINDER BORE O-RINGS Cylinder bore sealing O-rings have changed size and material. O-ring seals separately will N

2-7 90-898305 Model 175 Optimax 2001 MY This engine is based on the 2.5 Litre OptiMax. Differences between 175 HP and the 150 HP, 2.5 Litre OptiMax a

90-898305 2-8 O–Ring Cylinder Head 2001 MY The cylinder head O-ring seals have a new profile/ design. The purpose of this new design is to fill as muc

2-9 90-898305 Pistons The OpitMax piston contains a bowl inside the dome of the piston. The position of the

90-898305 2-10 Piston Profile 2003 MY New piston profile and combustion bowl. New profile for improved piston fit, and increased durability. New combu

1-7 90-898305 Analog Instrument Harness 84-892990T01 connects to the 10 pin/J-box connection on new 14 pin key/choke harness, to operate analog gaug

3-1 90-898305 Section 3 - Air System

3-3 90-898305 Table of Contents Table of Contents...2 Tabl

90-898305 3-4 Air Compressor Exploded View Air Compressor System DESCRIPTION • Air from inside the engine cowl is drawn into compresso

90-898305 3-6 2002 MY and Up- 2.5L Air Compressor Flow Diagram

3-7 90-898305 a) Air Inlet b) Air Filter c) Compressor Oil Inlet d) Excess Oil Return e) Compressor Air Inlet f) Compressor Water Inlet g) Fue

90-898305 3-8 2002 MY and Up - 3.0L Air Compressor Flow Diagram

3-9 90-898305 a) Air Inlet b) Air Filter c) Compressor Air Inlet d) Air [79 ± 2 psi (544.0 ± 13.8 kPa)] e) Fuel System Pressure Test Valve f) #

90-898305 3-102004 MY 1.5L Air Compressor Flow Diagram

3-1190-898305 a - Excess air return to adaptor plate b - Air muffler c - Water outlet from fuel rail d - Air regulator – 648.1 ± 13.8 kPa (94 ± 2 psi

90-898305 3-12Air Pressure Regulator The air pressure regulator is designed to limit the air pressure inside the rails to approximately 80 psi (95 psi

90-898305 1-8 IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be 7.6 cm (3 in.) for the final wiring installation. 1. In

3-1390-898305 Air Regulator Tool – P/N 91-889431 Notes _______________________________________________________

4-1 90-898305 Section 4 - Fuel System

4-3 90-898305 Table of Contents Table of Contents...2 Tabl

90-898305 4-4 Powerhead Long Term Storage Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rus

4-5 90-898305 FUEL ADDITIVE RECOMMENDATION (QUICKLEEN) See Service Bulletin 2001-12 Today’s OptiMax engine control systems allow only minute quantiti

90-898305 4-6 Fuel Starvation See Service Bulletin 2001-17 Models Affected MERCURY/MARINER 1987 and Later, 30 Thru 250 HP, (with square fuel pump) FOR

4-7 90-898305 NOTE: Make the “TEE” fitting connection as close to the fuel pump as possible. a) Pulse driven fuel pump b) Clear h

4-9 90-898305 Test Procedure PUMP CAPABILITY TEST Before proceeding with the system vacuum test, confirm that the pulse fuel pump is capable of suppl

90-898305 4-10VACUUM TEST The system vacuum test is normally performed at an idle speed. As engine RPM increases, there will be a slight increase in v

4-1190-898305 NOTE: Before driving the check valve pin into the retainer, support the pump housing on the opposite side, directly below the check val