Mercury 200 OptiMax DTS Installation manual

Outboard OptiMax I
Technician’s Guide
1
Table of Contents
Section 1 – General Information
Section 2 – Powerheads
Section 3 – Air Systems
Section 4 – Fuel Systems
Section 5 – Oil Injection Systems
Section 6 – Electrical Systems
Section 7 – Warning System and Diagnostics
Section 8 – Tools for OptiMax
Section 9 – Service Bulletins
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2
Section 1 - General Information
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Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
Installation .....................................................................................................5
14 Pin Adapter and Control Harnesses .........................................................5
Adapter Harnesses (Key/Choke)...................................................................5
Adapter Harness ...........................................................................................6
Adapter Harness ...........................................................................................6
Analog Instrument Harness ...........................................................................7
New Test Key Switch 14 pin15000A12 ........................................................7
8 pin Service Key Switch 15000A7 ...............................................................7
Data Harness Pulling Procedure ...................................................................7
Dielectric Grease ...........................................................................................8
Battery Cable Size For Outboard Models......................................................8
Battery Information All OptiMax...................................................................10
DTS Battery Installation...............................................................................10
Connecting Battery Cables and DTS Power Harness .................................11
System Wiring Reference Points DTS.........................................................11
Single Engine - Battery At Stern..................................................................12
Single Engine - Battery At Helm ..................................................................13
Dual Engine - Battery At Stern ....................................................................14
Dual Engine - Battery At Helm ....................................................................15
Connecting 04 DTS 10 Pin Data Harness Single Engine............................16
Connecting 14 Pin Data Harness - Single Engine.......................................16
Command Module Installation.....................................................................17
Single Helm Command Module Harness Installation ..................................18
DTS Command Module History...................................................................18
Panel Mount Control Wiring Connections....................................................19
DTS Wiring Guidelines ................................................................................19
Wiring Guidelines for Electrical Boat Accessories.......................................20
Key Switch Wiring Connections ..................................................................20
Key Switch Options .....................................................................................21
Wiring Instructions for Non-Mercury Marine Ignition Key Switch.................22
DTS Configuration and Adaptation Methods ...............................................22
Typical SmartCraft Installation Configurations Non DTS OptiMax 2000-2005
....................................................................................................................23
Analog Gauge Connections for Digital Optimax Models Bulletin 2000-11 .28
Installing Standard Speedometer Gauge to Digital Optimax Engines .........32
SmartCraft Boat Sensor Harness 84-865891T03........................................33
Switched 12V Accessory Connection..........................................................34
System Wiring Installation Checklist............................................................35
Remote Control Cables ...............................................................................36
Measuring Throttle and Shift Cables ...........................................................36
SHIFT EFFORT TOOL ................................................................................38
Tool Installation ...........................................................................................38
Priming the Fuel and Oil System .................................................................41
Oil Injection Set-Up .....................................................................................42
Priming the Oil Injection Pump ....................................................................43
Purging Air From the Engine Oil Tank.........................................................44
Propeller Installation....................................................................................45
Emissions Information.....................................................................................48
Models Affected...........................................................................................48
Exhaust Emissions Standards ........................................................................49
What Are Emissions? ..................................................................................49
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Hydrocarbons – HC..................................................................................... 50
Carbon Monoxide – CO .............................................................................. 50
Oxides of Nitrogen - NOx ............................................................................ 50
Controlling Emissions.................................................................................. 50
Stoichiometric (14.7:1) Air/Fuel Ratio ......................................................... 50
Outboard Hydrocarbon Emissions Reductions............................................... 51
8 1/3% _ PER YEAR OVER 9 MODEL YEARS.......................................... 51
Engine Emission Certification Label ............................................................... 52
Engine Emission Certification Label ............................................................... 53
Speed / Density Theory and Operation .......................................................... 54
Speed/Density Theory................................................................................. 54
Speed/Density Operation ............................................................................ 55
Mass Air Flow Systems............................................................................... 55
Stratified VS Homogenized Charge................................................................ 56
Stratified Charge ......................................................................................... 56
Homogenized Charge ................................................................................. 57
Theory of Operation - V6 Models.................................................................... 58
Air Induction Through Crankcase................................................................ 58
Air Compressor System .............................................................................. 59
Fuel ............................................................................................................. 60
Oil................................................................................................................ 61
Electrical...................................................................................................... 61
Operation .................................................................................................... 61
Theory of Operation - 3 Cylinder Models........................................................ 63
Air Induction Through Crankcase................................................................ 63
Air Compressor System .............................................................................. 63
Fuel ............................................................................................................. 64
Oil................................................................................................................ 64
Electrical...................................................................................................... 65
Operation .................................................................................................... 65
3 Cylinder/1.5 Liter.......................................................................................... 67
75/90/115 HP.................................................................................................. 67
Cowls (Upper & Lower) ............................................................................... 67
Emissions & Noise Levels........................................................................... 68
Powerhead .................................................................................................. 68
Cooling System ........................................................................................... 69
Mid-Section ................................................................................................. 70
Accessories................................................................................................. 71
Power Trim.................................................................................................. 72
Lower Unit ................................................................................................... 72
Performance Gear Lube.............................................................................. 72
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Installation
Notes
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14 Pin Adapter and Control Harnesses
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Models Affected
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4-stroke models 9.9 thru 225 HP V-6 EFI (Excluding Verado)
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2-stroke V-6 Outboards 135 thru 250 HP (Excluding Jet Drive)
The 2006 models listed above will be changing to a 14 pin connector for the
main engine to boat control harness connection. A number of harness
adapters have been developed to allow the use of older controls on new
engines that use the 14 pin connector. Some of the new adapters will also
allow the 2005 and prior models to use the new style 14 pin controls and
key/choke harnesses.
•
•
New engine harness requires a new 14 pin key/choke harnesses &
controls. CAN # 1 & 3 built into harness with separate terminator
locations. Old will NOT supersede to new.
Reference Current Parts Catalogue for part numbers.
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Adapter Harnesses (Key/Choke)
84-896539T_ Adapts 2005 model year and prior engines that use the round 8
pin harness to the new 14 pin key/choke harness. Use with engines not being
equipped with SmartCraft gauges.
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Notes
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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/choke harness. Use with engines
not being equipped with SmartCraft gauges.
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Adapter Harness
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84-892092T_ Adapts 2005 model year and prior engines that use the round 8
pin harness to the new 14 pin control or key/choke harness. Use with engines
being equipped with SmartCraft gauges. The adapter allows engine and boat
data to be transmitted through the new 14 pin control or key/choke harness.
The new 14 pin control or key/choke harnesses have connections at the helm
for SmartCraft gauges.
Important: A separate blue data harness would longer be required.
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Analog Instrument Harness
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84-892990T01 connects to the 10 pin/J-box connection on new 14 pin
key/choke harness, to operate analog gauges
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New Test Key Switch 14 pin15000A12
Service tool to isolate the boat from the engine.
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8 pin Service Key Switch 15000A7
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Data Harness Pulling Procedure
IMPORTANT: Do not route data harness near engine ignition components
(coils, spark plug leads, and spark plugs), high power VHF coax or radios. An
electrical field generated from these components could cause interference
with data transmission.
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IMPORTANT: Do not route data harness near sharp edges, hot surfaces or
moving parts. Fasten cables away from any sharp edges, fasteners or objects
that could wear into the harness.
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Notes
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IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius
should be 7.6 cm (3 in.) for the final wiring installation.
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1. Inspect the routing path to make sure surfaces are free of any sharp edges
or burrs that could cut the harness.
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2. Install cable pulling tool to data harness.
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3. Secure pulling tool with 2 cable ties.
IMPORTANT: The cables ties must be tight to prevent any slipping during
installation.
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IMPORTANT: Carefully inspect data harness pins to ensure all pins are
securely fastened to data harness connector end following installation.
NOTE: Data harness should be secured with mounting clips or cable ties
along the routing path.
Dielectric Grease
•
Dielectric grease will no longer be used on electrical connection except
the 8 pin cannon plug on 2005 product Improved electrical connection
allows the removal of the grease
Battery Cable Size For Outboard Models
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IMPORTANT: Only use copper battery cables. Do not use aluminum cables
for any outboard marine installations.
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• If longer battery cables are required, the wire gauge size must increase. See
chart following for correct wire gauge size.
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• DTS L models are equipped with 3.7 m (12 ft.) cables. DTS XL and XXL
models are not shipped with battery cables.
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1. Standard (original) cable length and wire gauge size.
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Notes
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Battery Information All OptiMax
• Do not use deep cycle batteries. Engines must use a marine starting battery
with 1000 MCA, 800 CCA or 180 Ah.
• When connecting engine battery, hex nuts must be used to secure battery
leads to battery posts. Torque nuts to specification.
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DTS Battery Installation
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IMPORTANT: Battery cable size and length is critical. Refer to engine
installation manual for size requirements. Decal needs to be placed on or
near battery box for future service reference. One 5/16 in. and one 3/8 in. hex
nut are supplied per battery for wing nut replacement. Metric hex nuts are not
supplied.
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Connecting Battery Cables and DTS Power Harness
Notes
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• Install DTS power harness directly to the starting battery only.
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• Do not extend lead length of harness.
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• See accessory manual for optional lead connection kit.
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System Wiring Reference Points DTS
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• DTS power harness - Provides 12V power to the DTS system. Requires
connection to the starting battery. If starting battery is located at the helm,
DTS power harness accessory kit is required to minimize voltage drop. Use
cable ties to secure power harness leads to battery cables, beginning within
15 cm (6 in.) of battery posts and continuing along the entire length of the
harness.
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• Battery cables - Connect to the starting battery.
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• Vessel sensor harness - This harness connects to the main fuel tank sensor,
auxiliary fuel tank and the paddle wheel speed/temperature sensor, if
equipped.
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Notes
Single Engine - Battery At Stern
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Single Engine - Battery At Helm
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Notes
Dual Engine - Battery At Stern
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Important: Make sure twin applications have the common ground. If
missing can result in open DTS fuse and configuring problems
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Dual Engine - Battery At Helm
Important: Make sure twin applications have the common ground. If
missing can result in open DTS fuse.
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Notes
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Connecting 04 DTS 10 Pin Data Harness Single Engine
Single Helm
•
SC5000 data cable (yellow) with termination resistor at engine end is
required.
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•
Install termination resistor in the junction box.
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•
Fasten cable connections within 25.4 cm (10 in.) of the junction box.
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Connecting 14 Pin Data Harness - Single Engine
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Single Helm
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IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius
should be 7.6 cm 3 inches.
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_
Command Module Installation
1. Plug the command module connector into the command module.
Notes
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2. To minimize vibration, mount the command module with the supplied rubber
grommets/bushings according to the following guidelines:
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• Mount in an area that is accessible
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• Mount in an area where the wiring connections will not be stepped on or
disturbed
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• Mount with the Command Module connector facing down to prevent water
intrusion.
• Fasten the command module harness to prevent flexing at the command
module connection.
IMPORTANT: Avoid sharp bends in the cable. The minimum bend radius
should be7.6 cm (3 in.).
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Notes
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Single Helm Command Module Harness Installation
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1. Connect the 14 pin Deutch connector on the command module harness to
the 14 pin data harness.
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2. Ensure the CAN 1 and CAN 2 connectors have terminator resistors
installed, and the CAN 3 connector is sealed with a weather cap.
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CAN 1
CAN 2
CAN 3
Gauges and back up for DTS
DTS data communication
Vessel Systems (Racing trim tabs)
inputs
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DTS Command Module History
IMPORTANT: DTS Command Modules must not be intermixed with different
model year DTS Command Modues. The model year of the command module
must match the model year of the PCM calibration.
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Panel Mount Control Wiring Connections
Notes
1. Connect the trim harness and lever harness.
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2. Insert the bayonet end of the lever harness into the bracket hole. This will
prevent the connector from pulling out. See illistration below
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3. Connect the lanyard stop switch bullet connectors.
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IMPORTANT: Allow slack in the trim harness. Harness will flex and move
during control handle movement.
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DTS Wiring Guidelines
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• Never attempt to connect, network, tie into, switch, and/or sink source
voltage or current from the DTS wiring harnesses.
• Never attempt to connect any type of communication or navigation
equipment into the DTS wiring harnessing other than at the designated
connection point.
• Boat accessory equipment being installed must be connected to an
appropriate power source such as a fuse panel or junction block.
• Never attempt to tap directly into any of the DTS electrical wiring harnesses
for a source of power.
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Notes
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Wiring Guidelines for Electrical Boat Accessories
!
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IMPORTANT: Do not connect boat accessories to 12 volt or ignition key
switch DTScircuits. Use a separate switched 12 volt source for wiring boat
accessories. The DTS system requires a consistent 12 volt power source.
Splicing or connectingaccessories to the 12 volt or ignition key switch DTS
circuits (purple, purple/white, or red wires) could blow a fuse or overload
circuits, causing intermittent or complete loss of operation.
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Harness Installation Guidelines
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• Locate a routing path for the harness connections so they reach their
installation points.
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• Inspect the routing path to make sure surfaces are free of any sharp edges
or burrs that could cut the harness.
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• Fasten and support the harness with clamps or cable ties along the routing
path. A clamp or cable tie must be used within 25.4 cm (10 in.)of any
connection in a DTS system.
• Ensure all connections are tight and seal all unused connectors with weather
caps.
Key Switch Wiring Connections
1. Install the ignition key switch. Refer to the installation instructions which are
provided with the key switch.
2. Connect the key switch to the harness as shown.
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Notes
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Key Switch Options
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• Key Switch Three Position (Off, Run, and Start) has shorter key and
mounting length 3/4 inch cut out. Without mounting hardware. Can be used on
DTS as well as Non DTS installations. Fits up to 1/2 inch thick dash boards.
• Key Switch Four Position (Off, Accessory, Run and Start). 7/8 cut out.
Without mounting hardware. Can be used on DTS as well as Non DTS
installations.
• Key Switch Kit- Four Position includes key switch, key cover, bezel 2 1/8
diameter mounting housing adaptor and mounting hardware 7/8 cut out.
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Notes
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Wiring Instructions for Non-Mercury Marine Ignition Key
Switch
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• The ignition key switch must comply with Mercury specifications for key
switches and controller input switches (897741-5 or 897791-5). Switches that
do not meet these specifications could leak current.
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DTS Configuration and Adaptation Methods
•
System View version 3.44 or greater for 06 DTS Systems.
•
System View version 3.42 or greater for 05 DTS Systems.
•
System View version 3.33 or greater for 04 DTS Systems Single
engine and helm only.
• For instructions reference SmartCraft DTS Service Manual pertaining to
specific DTS system model year.
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• 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 System
• For step by step instructions reference the Help Icon (purple book with
question mark) on top row of CDS.
Important: CDS requires CAN cable 84-892663
Typical SmartCraft Installation Configurations Non DTS
OptiMax 2000-2005
Question: How do you tell the difference between the current Smart Tach and
Speedo and the new System Tach and Speed?
Answer: The new System Tach and Speed will have a blue back. It also has
the SmartCraft logo on the dial face, the background is one color and it has
what we call “eyebrows”.
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TERMINATION RESISTOR PLACEMENT
Notes
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NOTE: Termination resistors are designed to reduce noise and provide proper
DC voltage levels on the C.A.N. Bus circuit.
1. Each system must include exactly two (2) termination resistors.
2. Termination resistors must be located at the furthest ends of the main
C.A.N. Bus trunk.
3. The main C.A.N. Bus trunk may not exceed 36.6 m (120 ft.) in length
(measured along the cable). Main C.A.N. Bus Trunk is defined as the length of
cable located between termination resistors.
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There are three (3) acceptable methods of adding termination resistors to the
system.
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1. Junction box termination resistors.
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2. Termination resistor inside the harness with a termination resistor at the
junction box.
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3. Termination resistor inside the harness at both ends.
NOTE: Junction box termination resistors are designed to plug directly into
junction box ports.
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Harness Termination Resistor (One End)
Some of the SmartCraft wiring harnesses (84-879981T_) are designed with
the termination resistor at one end. Harness termination resistors are used
primarily for installations which do not require a junction box in the rear of the
boat.
Harness Termination Resistor (Both Ends)
Harness (84-879982A20, 30) include termination resistors at both ends and
may be used to connect System Monitor or System tachometer directly to the
engine without junction boxes.
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Notes
System Tachometer/Speedometer Wiring Configurations
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Notes
Dual Engine
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IMPORTANT: The location of the junction box termination resistors are critical
forproper system function. All unused junction box ports must be sealed with a
weathercap. Disconnect the power harness on the port engine.
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If running a single CAN bus (blue data cable) on dual or more engine
installations, only one engine is used to supply 12 volt power. On the
remaining engines, disconnect the 3 wire CAN power harness under the cowl
as shown below. This connector is about 3 inches from the under cowl
SmartCraft data cable (blue boat cable) connection. Plug the connectors with
caps as shown.
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NOTE: Engine electrical damage may result if more than one engine powers
this system. A failure of this nature is not covered under normal engine
warranty.
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Notes
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IMPORTANT: When using single CAN line make sure to disconect one 8 pin
power connector.
Note: For other SmartCraft configurations reference current Outboard
Rigging Guide.
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Analog Gauge Connections for Digital Optimax Models
Bulletin 2000-11
•
2001 Model Year
•
135 thru 225 Optimax
•
S/N 0T178500 and Above
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The 2001 Optimax engines are no longer built in Analog and Digital versions.
The new models are primarily set up for Digital gauge connections. If analog
gauge connections are required, use the following instructions.
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1-28
29
Notes
Installing Standard Analog Tachometer to Digital Optimax Engines
This procedure allows a standard analog tachometer to be connected to the
tachometer plug that is incorporated into the key switch harness.
_______________________
NOTE: SmartCraft speedometer or tachometer communicate with the engine
through the gray lead and the brown/white lead in the key switch harness.
This procedure uses one of these leads to operate the tachometer and breaks
the connection between the SmartCraft gauges and the engine. SmartCraft
gauges will not function with an analog tachometer connected. The System
Monitor, Speedometer and Tachometer communicate with the engine through
a dedicated 10 pin connection on the engine. Using this procedure to install an
analog tachometer will not effect the operation of the System Monitor,
speedometer or tachometer.
_______________________
1. Locate the diagnostic port plug mounted on the ECM. Remove and discard
the diagnostic harness from the port plug.
2. Install cover P/N 832948A1 on the port plug.
3. Locate the gray (tachometer signal) wire in the engine wiring harness. and
remove the rubber plug. Connect the gray wires together.
4. Connect tachometer to the tachometer plug using tachometer harness P/N
84-86396A8.
_______________________
_______________________
_______________________
_______________________
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_______________________
_______________________
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_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Note: Diagnostic harness (b) is no longer standard on engines.
1-29
_______________________
90-898305
30
Notes
Installing Standard Analog Trim Indicator Gauge to Digital Optimax
Engines
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: SmartCraft speedometer or tachometer communicate with the engine
through the gray lead and the brown/white lead in the key switch harness.
This procedure uses one of these leads to operate the Trim Gauge and
breaks the connection between the SmartCraft Gauges and the engine.
SmartCraft gauges will not function with an analog Trim Gauge connected.
The System Monitor, Speedometer and Tachometer communicate with the
engine through a dedicated 10 pin connection on the engine. Using this
procedure to install an analog trim gauge will not interfere with the operation of
the System Monitor, speedometer or tachometer.
However, the digital trim sender must be removed to install the analog trim
sender. The removal of the digital trim sender will eliminate any trim
information from being displayed on System Monitor, speedometer or
tachometer.
1. Tilt the outboard up and engage the tilt support lever.
2. Remove the digital trim sender assembly. Retain screws for reassembly.
3. Install analog trim sender P/N 821180A6 as shown. Route and fasten the
wiring harness at the same locations as the old harness.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
4. Connect the Brown/White wire from the trim sender to the brown/white wire
extending from the key switch harness.
5. Cap the digital trim sender wires that remain in the engine harness. Use 2
female bullet caps P/N 13540 and 1 male bullet cap P/N 13541.
6. Connect trim indicator gauge to the tachometer plug on the key switch
harness using tachometer harness P/N 84-86396A8.
_______________________
_______________________
_______________________
_______________________
90-898305
1-30
31
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: If none of the digital sensors (oil level, fuel level, paddle wheel,
speedo, and trim) are used, digital harness P/N 84-859244T1 could be
removed from the engine. The 8-pin connection on the engine should then be
capped with P/N 877613A1.
Installing Standard Analog Temperature Gauge to Digital Optimax
Engines
1. Remove the 2 wire temp sender from the air compressor and install 4 wire
temp sender P/N 13536A14.
2. Install wire harness P/N 84-88824A4 between the 4 wire temp sender
(tan/blue) wire and the tan wire extending from the key switch harness.
3. The ground wire (Black) on the 4 wire temp sender should be installed
under the temp sender retainer bolt.
NOTE: Harness P/N 84-88824A4 is the single Tan wire which is normally
supplied with the gauge. The eyelet connector will need to be removed, wire
cut to length and a bullet connector installed at one end. Available later this
year will be harness P/N 84-11149A50 which has a single tan wire with a
bullet connectors at both ends. Using this procedure to install an analog
temperature gauge will not effect the operation of the System Monitor or any
of the SmartCraft speedometer or tachometer functions.
NOTE: Starting with the serial numbers listed below, the 4-wire temp. sender,
and TAN wire have been installed on the outboard at the factory.
Replacement of the temp. sender and addition of the TAN wire are NOT
required, to connect analog temp gauge.
S/N 0T280001 3.0 Liter
S/N 0T275885 2.5 Liter
_______________________
_______________________
_______________________
_______________________
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_______________________
1-31
90-898305
32
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Installing Standard Speedometer Gauge to Digital
Optimax Engines
NOTE: The digital speedometer sensor must be disconnected to connect the
analog speedometer. The removal of the digital speedometer sensor will
eliminate speed information from being displayed on System Monitor and the
SmartCraft speedometer or tachometer gauges.
1. Remove the speedometer pressure hose (black) from the speedometer
sensor.
NOTE: Coupler connection will be inside the cowl on 200/225 Hp models.
2. Install coupler P/N 22-859747 on the end of the speedometer hose, this will
allow a direct connection of later style Mercury speedometer.
NOTE: If older Mercury or after market speedometer is used, barb fitting
adapter P/N 22-859731 must be installed into the coupler.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Rigging kit P/N 881120A1 includes all the parts outlined in this Advisory to
connect analog gauges to the engine, except the 4 wire temperature sensor
P/N 13536A14 and the TAN temperature sensor connector wire P/N 8488824A 4.
90-898305
1-32
33
Installing Standard Water Pressure Gauge to Digital
Optimax Engines
1. Remove the RED plug P/N 22-859732 from the connector at the end of the
water pressure hose (gray color). This will allow a direct connection of later
style Mercury water pressure gauge.
NOTE: If older Mercury or after market water pressure gauge is used, barb
fitting adapter P/N 22-859731 must be installed into the coupler.
Notes
_______________________
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_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
SmartCraft Boat Sensor Harness 84-865891T03
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-33
90-898305
34
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
IMPORTANT: Most vessels have Coast Guard and/or static grounds on their
fuel tank. Do not add additional grounds. This is to prevent ground loop
problems (power feeding back on sensor grounds) which can cause high idle
and potential faults. See bulletin 2000-13.
_______________________
_______________________
_______________________
Switched 12V Accessory Connection
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Important: Needed to provide accessory power to auxiliary loads when
the keyswitch is in the "Run" or "Accessory" positions.
_______________________
_______________________
90-898305
1-34
35
System Wiring Installation Checklist
Notes
Data Cable
•
•
Verify the data harness is not routed near sharp edges, hot surfaces or
moving parts.
Verify data harness is not routed near ignition components (coils,
spark plug leads, and spark plugs), high power VHF coax or radios.
•
•
Verify the data harness is not routed near sharp edges, hot surfaces or
moving parts.
Ensure the harness connections are fastened within 25.4 cm (10 in.) of
the junction box.
Verify that all unused receptacles are covered with a weather cap.
Non-Mercury Marine Supplied Ignition Key Switch
•
If a non-Mercury Marine ignition key is used, verify that it passes the
ingress protection testing per IEC IP66 specification minimum. Ignition
switches must pass this specification.
Ensure Electronic Remote Control (ERC) connections are completed
following ERC installation instructions prior to engine operation.
DTS Command Module Harness
•
•
•
•
Verify that all connectors are properly inserted and locked in their
receptacle (remote control, key switch, command module, lanyard stop
switch and junction box, if equipped). Verify that while moving the
remote control handle (full forward and full reverse) the harness has
unobstructed movement (moves freely).
Verify that the lanyard stop switch is wired into the system correctly.
Verify that the harness is fastened along the routing path.
Verify that all unused connectors have weather caps to prevent
corrosion.
•
•
Verify that wing nuts have been replaced with hex nuts, provided.
Verify that all engine battery cables are connected to the correct
terminals.
Verify that the DTS power harness leads are connected to the starting
battery and secured with locknuts.
Ensure the 5 Amp fuse for the DTS power harness is accessible.
_______________________
_______________________
_______________________
_______________________
_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Lanyard Stop Switch
•
•
_______________________
_______________________
Battery
•
•
_______________________
_______________________
Electronic Remote Control
•
_______________________
_______________________
Junction Box (if equipped)
•
_______________________
Verify that the switch is installed.
Verify that the switch is connected to the DTS command module
harness.
_______________________
_______________________
_______________________
1-35
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Remote Control Cables
Remote control cables are the mechanical connection between the control box
and engine, selection and use of the high quality cables are imperative in
maintaining this connection. Control cables are designed with a hard
composite outer shell (casing) and with a solid inner core (wire). This core
moves back and forth inside the casing each time the control is operated. A
tighter tolerance between the core and casing, results in less lost motion
(sideways travel) over the length of the cable. The greater the length of the
cable, the greater the lost motion. For longer cable runs where “lost
motion” is a problem, try using the MMP 877774A__ (denotes length)
Platinum throttle and shift cables.
_______________________
_______________________
Measuring Throttle and Shift Cables
_______________________
_______________________
Panel Mount Remote Control
_______________________
_______________________
_______________________
_______________________
1. Add boat measurements A-B in inches (mm) and add 18 in. (457 mm) to
the total. Dimension B represents the distance from the remote control
location measured along the gunwale to the transom. In dual engine
installations, dimension A is measured from the gunwale to each engine
center-line.
_______________________
_______________________
_______________________
2. Divide by 12 in. (304 mm).
3. This is the length of the throttle and shift cables in feet.
_______________________
_______________________
4. For left hand (Port) remote control installations follow the same measuring
procedure, only on the opposite side of the boat.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
1-36
Console Mount Remote Controls
Notes
1. When measuring cable length for a console mount remote control, measure
along theactual selected cable routing path and add 18 inches (457 mm) to
the total.
_______________________
_______________________
_______________________
2. Divide by 12 in. (304 mm).
_______________________
_______________________
3. This is the length of the throttle and shift cables in feet.
NOTE: Allow for clearance of cables directly behind panel mount remote
control and under console mount remote control. The Commander 3000
Series Panel Mount Remote Control mounting surface must not exceed 1 in.
(25.4 mm) thickness. Cable radius at any point must not be less than 12 in.
(304.8 mm). On boats with considerable freeboard drop or unusual routing of
cables, it may be necessary to add extra length to cables.
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_______________________
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1-37
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
SHIFT EFFORT TOOL
Part Numbers (current at time of print)
•
MPC 4000 Gen II 91-892535A01
•
MCC 4500 Gen II, 91-892539A01
•
MSC Commander 4000 Side Mount Tool OB, 91-892542A01
•
MPC 4000 Gen II Panel Mount Tool with lock bar 91-892547A01
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Tool Installation
1. With the engine off, push the throttle button and move the remote control
into the FORWARD (F) gear position.
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90-898305
1-38
2. Remove the throttle only button covering the hex nut in the base of the
remote control using a screwdriver or similar tool.
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
3. Move the remote control into the NEUTRAL (N) position.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
4. Install the appropriate shift tool on the hex nut at the base of the remote
control.
a. If the neutral lock button is on the bottom of the handle, push the
neutral lock button in and install the clevis pin.
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1-39
90-898305
Notes
_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
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
pushed in.
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_______________________
_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
5. Install an inch pound torque wrench at the 3/8 in. drive connection on the
back of the Shift Effort Tool.
_______________________
90-898305
1-40
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Torque Specifications
Engine Not Running
_______________________
_______________________
CABLES NOT CONNECTED (OUTBOARD MODELS)
NOTE: The torque specifications do not reflect the force required to move the
handle through the detent.
1. Measure the torque by moving the remote control handle to the detent. If
the torque is not within specifications, inspect the cable routing and ensure
that it is not binding.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Priming the Fuel and Oil System
_______________________
_______________________
NOTE: For initial start of a new engine or for an engine that ran out of fuel, or
was drained of fuel, essentially any time maintenance to the system is
required:
_______________________
_______________________
1. Squeeze the fuel line primer bulb until it feels firm.
_______________________
2. Turn the ignition key switch to the “ON” position for three seconds. This
operates the electric fuel pump.
_______________________
3. Turn the ignition key switch back to the OFF position, and squeeze the
primer bulb again until it feels firm. Turn the ignition key switch to the “ON”
position again for three seconds. Continue this procedure until the fuel line
primer bulb stays firm.
1-41
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_______________________
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
4. There are three methods for activating the priming process.
•
CDS-Oil Pump Prime in ACTIVE TEST will activate the priming
process.
•
DDT-Oil Pump Prime in SPECIAL FUNCTIONS will activate the
priming process.
_______________________
_______________________
_______________________
_______________________
•
Within the first 10 seconds after the key switch has been turned on,
move the remote control handle from neutral into forward gear 3 to 5
times. This will automatically start the priming process.
NOTE: It may take a few minutes for the pump to complete the priming
process.
_______________________
_______________________
Oil Injection Set-Up
_______________________
1. Fill remote oil tank with the recommended oil listed in the Operation and
Maintenance Manual. Tighten fill cap.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
_______________________
_______________________
_______________________
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90-898305
1-42
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Priming the Oil Injection Pump
Before starting engine for the first time, prime the oil injection pump.
Priming will remove any air that may be in the pump, oil supply hose, or
internal passages.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
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1-43
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
PRIMING THE OIL INJECTION PUMP
a. Connect the fuel hose. Fill the fuel system by squeezing the primer bulb.
Squeeze the fuel line primer bulb until it feels firm.
b. Turn the ignition key switch to the “ON” position for three seconds. This
operates the electric fuel pump.
c. Turn the ignition key switch back to the “OFF” position, and squeeze the
primer bulb again until it feels firm. Turn the ignition key switch to the “ON”
position again for three seconds. Continue this procedure until the fuel line
primer bulb stays firm.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2. Turn the ignition key switch to the “ON” position.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
3. Within the first 10 seconds after the key switch has been turned on, move
the remote control handle from neutral into forward gear 3 to 5 times. This will
automatically start the priming process.
NOTE: It may take a few minutes for the pump to complete the priming
process.
Purging Air From the Engine Oil Tank
1. Loosen the fill cap on the engine oil tank.
2. Start the engine. Run the engine until the all the air has been vented out of
the tank and oil starts to flow out of the tank. Re-tighten fill cap.
_______________________
_______________________
90-898305
1-44
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a- Fill Cap
_______________________
Propeller Installation
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Flow Torque III (included on 1.5L OptiMax)
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-45
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
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 shaft. This allows the
two hub pieces to rotate ± 10° relative to each other, and allows the springs to
absorb the impacts from the combustion cycles instead of the clutch dogs.
The plastic drive sleeve assembly has clearance, which allows it to move
forward and aft slightly over the inner brass hub that is supplied with the FloTorq III hub kit. This free movement, along with the spring wires between the
forward and aft section of the plastic hub, act as a shock absorber, reducing
the noise. Do not shorten the inner brass hub of a Flo-Torq III prop hub; the
prop must be allowed to have a slight forward and aft clearance. Aluminum
props do not have the weight and mass (inertia) to remain at a constant
speed. Generally aluminum props tend to remain at crankshaft speed.
Because of this, the clutch dogs do not separate and there is very little or no
prop rattle.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
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_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
1-46
Notes
_______________________
Emissions Information
_______________________
Models Affected
_______________________
MERCURY/MARINER/FORCE/SPORT JET
_______________________
1998 and Later 2.5 thru 250 HP
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
MANUFACTURERS RESPONSIBILITY:
Beginning with 1998 model year engines, manufacturer’s of all marine
propulsion engines, must determine the exhaust emission levels for each
engine horsepower family, and certify these engines with the United States
Environmental Protection Agency (EPA). A certification decal/emissions
control information label, showing emission levels and engine specifications
directly related to emissions, must be placed on each engine at the time of
manufacture.
DEALER RESPONSIBILITY:
When performing service on all 1998 and later outboards, attention must be
given to any adjustments that are made, that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component, must be executed
in a manner that maintains emission levels within the prescribed certification
standards. Dealers are not to modify an engine, in any manner, that would
alter the horsepower or allow emission levels to exceed their predetermined
factory specifications. Exceptions include manufacturers prescribed changes,
such as that for altitude adjustments.
OWNER RESPONSIBILITY:
The owner / operator is required to have engine maintenance performed to
maintain emission levels within prescribed certification standards.
The owner / operator is not to modify the engine, in any manner, that would
alter the horsepower or allow emission levels to exceed their predetermined
factory specifications.
_______________________
Single engine exceptions may be allowed with permission from the EPA for
racing and testing.
_______________________
EPA EMISSION REGULATIONS:
_______________________
All new 1998 and later outboards manufactured by Mercury Marine, are
certified to the United States Environmental Protection Agency, as conforming
to the requirements of the regulations for the control of air pollution from new
outboard motors. This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory procedure for servicing
the product must be strictly followed and, wherever practicable, returned to the
original intent of the design.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
1-48
The responsibilities listed above are general, and are in no way a complete
listing of the rules and regulations pertaining to the EPA laws on exhaust
emissions for marine products. For more detailed information on this subject,
you may contact the EPA at the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
_______________________
Office of Mobile Sources
_______________________
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
_______________________
_______________________
Washington, DC 20001
_______________________
EPA INTERNET WEB SITE:
_______________________
http:/www.epa.gov/omswww
_______________________
Exhaust Emissions Standards
_______________________
Through the Environmental Protection Agency (EPA), the federal government
has established exhaust emissions standards for all new marine engines sold
in the U.S.
_______________________
What Are Emissions?
_______________________
Emissions are what comes out of the exhaust system in the exhaust gas when
the engine is running. They are formed as a result of the process of
combustion or incomplete combustion. To understand exhaust gas emissions,
remember that both air and fuel are made of several elements. Air contains
oxygen and nitrogen among other elements; gasolene contains mainly
hydrogen and carbon. These four elements combine chemically during
combustion. If combustion were complete, the mixture of air and gasoline
would result in these emissions: water, carbon dioxide and nitrogen, which are
not harmful to the environment. But combustion is not usually complete. Also,
potentially harmful gases can be formed during and after combustion.
_______________________
All marine engines must reduce the emission of certain pollutants, or
potentially harmful gases, in the exhaust to conform with levels legislated by
the EPA. Emissions standards become more stringent each year. Standards
are set primarily with regard to three emissions: hydrocarbons (HC), carbon
monoxide (CO) and oxides of nitrogen (NOx).
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-49
90-898305
Notes
_______________________
Hydrocarbons – HC
_______________________
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are
burned during combustion in combination with oxygen. But they are not totally
consumed. Some pass through the combustion chamber and exit the exhaust
system as unburned gases known as hydrocarbons.
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Carbon Monoxide – CO
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Carbon is one of the elements that make up the fuel burned in the engine
along with oxygen during the combustion process. If the carbon in the
gasoline could combine with enough oxygen (one carbon atom with two
oxygen atoms), it would come out of the engine in the form of carbon dioxide
(CO2). CO2 is a harmless gas. But carbon often combines with insufficient
oxygen (one carbon atom with one oxygen atom). This forms carbon
monoxide, CO. Carbon monoxide is the product of incomplete combustion and
is a dangerous, potentially lethal gas.
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Oxides of Nitrogen - NOx
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NOx is a slightly different byproduct of combustion. Nitrogen is one of the
elements that makes up the air going into the engine. Under extremely high
temperatures it combines with oxygen to form oxides of nitrogen (NOx). This
happens in the engine’s combustion chambers when temperatures are too
high. Nox itself is not harmful, but when exposed to sunlight it combines with
unburned hydrocarbons to create the visible air pollutant known as smog.
Smog is a serious problem in California as well as many other heavily
populated areas of the United States.
Controlling Emissions
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There are two principle methods of reducing emissions from a two-strokecycle marine engine. The first method is to control the air/fuel ratio that goes
into the combustion chamber. The second is to control the time when this
air/fuel mixture enters the combustion chamber. Timing is important, to
prevent any unburned mixture from escaping out of the exhaust port.
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Stoichiometric (14.7:1) Air/Fuel Ratio
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In the search to control pollutants and reduce exhaust emissions, engineers
have discovered that they can be reduced effectively if a gasoline engine
operates at an air/fuel ratio of 14.7:1. the technical term for this ideal ratio is
stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three
elements in the exhaust under almost all conditions. The HC and CO content
of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/ fuel
ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than
14.7:1 they rise rapidly. It would seem that controlling HC and CO by
themselves might not be such a difficult task; the air/fuel ratio only needs to be
kept leaner than 14.7:1. However, there is also NOx to consider.
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As the air/fuel ratio becomes leaner, combustion temperatures increase.
Higher combustion temperatures raise the NOx content of the exhaust. But,
enrichening the air/fuel ratio to decrease combustion temperatures and reduce
NOx also increases HC and CO, as well as lowering fuel economy. So the
solution to controlling Nox - as well as HC and CO - is to keep the air/fuel ratio
as close to 14.7:1 as possible.
90-898305
1-50
Outboard Hydrocarbon Emissions
Reductions
8 1/3% _ PER YEAR OVER 9 MODEL YEARS
Notes
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1-51
90-898305
Engine Emission Certification Label
Notes
Your outboard has been labeled on the cowl with one of the following star
labels.
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The Star Label means Cleaner Marine Engines.
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The Symbol for Cleaner Marine Engines Means:
Cleaner Air and Water – for a healthier lifestyle and environment.
Better Fuel Economy – burns up to 30-40 percent less gas and oil than
conventional carbureted two-stroke engines, saving money and resources.
Longer Emission Warranty – Protects consumer for worry free operation.
The one-star label identifies
engines that meet the CARB's 2001
exhaust emission standards.
Engines meeting these standards
have 75% lower emissions than
conventional carbureted 2-stroke
engines. These engines are
equivalent to the U.S. EPA's 2006
standards
The two-star label identifies engines
that meet the CARB's 2004 exhaust
emission standards. Engines
meeting these standards have 20%
lower emissions than One Star Low Emission engines.
The three-star label identifies
engines that meet the CARB's 2008
exhaust emission standards.
Engines meeting these standards
have 65% lower emissions than
One Star - Low Emission engines.
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1-53
90-898305
Notes
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Speed / Density Theory and Operation
Speed/Density Theory
Outboard OptiMax engines operate on the fuel injection strategy called
“Speed/Density”. This means that the ECM primarily looks at the engine’s
speed and the intake manifold’s air density in order to calculate the correct
amount of fuel to inject.
The engine requires an air/fuel mixture of approximately 14:7 to 1 in the
combustion chambers.
Since the system doesn’t control air flow, it must determine how much air is
flowing through the engine in order to calculate the correct amount of time to
fire the fuel injectors. The net result is that there must be 1 part of fuel for
every 14.7 parts of air going through the engine.
Since the engine is basically an air pump, we know that an engine is capable
of pumping a certain (maximum) amount of air at any specific rpm. The actual
amount of air it pumps (at a specific rpm) depends on the density of the air in
the intake manifold. The air density (in the intake manifold) will vary depending
on rpm, throttle plate position and barometric pressure.
If the air density in the intake manifold is known, the actual amount of air
flowing through the engine (the “Air Mass” or “Mass Air Flow”) could be
calculated. This calculated (and the actual) air flow is a repeatable function,
meaning that at a specific rpm and a specific manifold absolute pressure
reading, the air flow through the engine will always be the same.
However, in the speed/density system we do not actually calculate the actual
air flow. Instead, the ECM measures the rpm and the air density, then refers to
a programmed “lookup table” in the ECM’s EEPROM. This lookup table will be
programmed with the correct fuel injector information for every rpm and
density reading. The programming engineer has to come up with these
figures, because the ECM is not actually calculating the Mass Air Flow.
The speed-density system depends on the engine being unmodified (from its
original production state). If we change the volumetric efficiency of the engine
in any manner, the amount of air flow for a given rpm and air density will
change, causing the ECM to deliver the incorrect amount of fuel. Any
modification to the following components will influence the air flow through the
engine, throwing the speed-density system out of calibration.
a) Pistons and combustion chambers (anything that changes the
compression ratio).
b) Changes to intake and exhaust port size, as well as “porting and
polishing”.
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90-898305
1-54
Speed/Density Operation
Notes
To determine the density of the air in the intake manifold, we need to know the
intake manifold vacuum, which we measure with the MAP (Manifold Absolute
Pressure) sensor. It is important to remember that a MAP sensor measures
the manifold pressure above absolute zero (like a barometer), while a
conventional vacuum gauge measures the manifold pressure below the
current atmospheric pressure. The use of the Manifold Absolute Pressure
Sensor allows us to compensate for variations in atmospheric pressure due to
weather and altitude changes. A conventional vacuum gauge would not
provide us with this needed information.
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NOTE: While the temperature of the air does affect its density, not all engines
use an IAT (intake air temperature) sensor. If no IAT is present, then the ECM
assumes 75 degree Fahrenheit for all density calculations. If an IAT is
present, then the ECM can more accurately determine the air’s density.
However, the amount of correction the IAT adds is a relatively small amount
(approximately 10% maximum change in fuel flow).
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In review, our standard, unmodified production engines flow a repeatable (and
therefore “known”) amount of air at any specific engine rpm and manifold
pressure. With this knowledge, the ECM can be programmed to deliver the
correct amount of fuel from the combination of the speed sensor (distributor
signal) and density information (from the MAP sensor).
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It is often said that the speed-density system runs “in theory alone”, since the
ECM doesn’t really know how much air is flowing through the engine, it is just
assuming it knows how much (based on the repeatability of airflow theory). In
reality, the system is simple, rugged and works extremely well. But, the ECM
cannot compensate for changes in volumetric efficiency of the engine.
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Mass Air Flow Systems
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Mass Air Flow systems actually measure the amount of air (or “Air Mass”)
entering the engine, so they generally can compensate for modifications or
changes to the air flow through the engine. While these systems are generally
considered more accurate, they are generally not as robust (and cost
effective) as the speed-density system. Mass Air Flow systems are typically
used in automotive applications to meet stringent emissions and fuel economy
requirements.
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NOTE: The speed-density system is more than accurate enough for our
marine applications. The additional reduction in emissions and the resulting
increase in fuel economy (with the Mass Air Flow system) are negligible. But
when automotive manufacturers must meet emissions standards, they often
have to take small improvements where they can find them.
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1-55
90-898305
Notes
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Stratified VS Homogenized Charge
OptiMax engines use a stratified charge inside the combustion chamber to aid
in reducing emissions. All other models use a homogenized charge. The
difference between the two is:
Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel
required for combustion is forced into the cylinder through an injector placed in
the top of the cylinder head. The injector sprays a fuel/air mixture in the form
of a bubble into the cylinder. Surrounding this bubble is air supplied by the
transfer system. As the bubble is ignited and burns, the surrounding air
provides almost complete combustion before the exhaust port opens.
A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at
14.7:1 and not easily ignited.
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90-898305
1-56
Homogenized Charge
A homogenized charge has the fuel/air particles mixed evenly throughout the
cylinder. This mixing occurs inside the carburetor venturi, reed blocks and
crankcase. Additional mixing occurs as the fuel is forced through the transfer
system into the cylinder.
The homogenized charge is easy to ignite as the air/fuel ratio is approximately
14.7:1.
Notes
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1-57
90-898305
Notes
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Theory of Operation - V6 Models
Air Induction Through Crankcase
Combustion air enters the cowl through holes located in the top aft end of the
cowl. The cowl liner directs this air to the bottom of the powerhead. This limits
the exposure of salt air to the components inside the engine cowl.
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Once inside the cowl the air enters the plenum through the throttle shutter(s)
which are located in the plenum assembly The air then continues through the
reed valves and into the crankcase The throttle shutter(s) are actuated by the
throttle shaft. Mounted onto a separate shaft are two throttle position sensors
(TPS) These sensors tell the engine control unit (ECM) the position of the
throttle.
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1997/1998/1999 MODELS
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Two TPS’s are installed on the OptiMax engine for safety redundancy. If one
TPS should fail, the dash mounted CHECK ENGINE light will flash and the
warning horn will sound. The 1997 Model engine will continue to perform
normally; the 1998/99 models engine speed will be reduced to 3000 RPM. If
both TPS’s should fail, engine speed will be reduced to idle.
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To reduce emissions, OptiMax engines require large amounts of air into the
cylinders at idle speed. To accomplish this, the throttle shutters are partially
open at low engine speeds. The dual TPS system reads the shaft movement
in both directions, one reads movement up (increasing resistance), while the
other reads the same movement as down (decreasing resistance). The ECM
reads both and calculates the throttle shutter position.
2000 MODELS & NEWER
One TPS is used on these models, if the TPS fails, the ECM will default to the
MAP sensor. If both the TPS and MAP sensors fail, the engine is limited to
idle speed.
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90-898305
1-58
Air Compressor System
Air from inside the engine cowl is drawn into the compressor through the
flywheel cover or air plenum. This cover acts like a muffler to quiet
compressor noise and contains a filter to prevent the ingestion of debris into
the compressor.
A restrictor is located between the filter and compressor. The restrictor design
lowers the compressor intake noise and should be removed at altitudes above
5000 feet (1997 models)
The compressor is driven by a serpentine belt from a pulley mounted on the
crankshaft, and is automatically self adjusted using a single idler pulley. This
air compressor is a single cylinder unit containing a connecting rod, piston,
rings, bearings, reed valves, and a crankshaft. The compressor is water
cooled to lower the temperature of the air charge and is lubricated by oil from
the engine oil pump assembly.
As the compressor piston moves downward inside the cylinder, air is pulled
through the filter, reed valves and into the cylinder. After the compressor
piston changes direction, the intake reeds close and the exhaust reeds open
allowing compressed air into the hose leading to the air/fuel rails. An orifice is
installed in the line between the compressor and air rail to smooth the pulses
transmitted from the compressor to the air rail.
The air/fuel rails contain two passages; one for fuel, the second is the air
passage. The air passage is common between all the cylinders included in the
rail. A hose connects the starboard rail air passage to the air compressor.
Another hose connects the starboard air rail passage to the port air rail
passage.
An air pressure regulator limits the amount of pressure developed inside the
air passages to approximately 80 psi. Air exiting the pressure regulator is
returned into the exhaust adaptor (intake plenum 2000 3.0L) and exits thru the
propeller.
Notes
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1-59
90-898305
Notes
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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. A crankcase mounted pulse driven
diaphragm fuel pump (electric on V-6 M2 Jet Models) draws fuel through the
fuel line, primer bulb, fuel pump assembly and then pushes the fuel thru a
water separating fuel filter. This filter removes any contaminates and water
before the fuel reaches the vapor separator.
Fuel vapors are bled into the air compressor inlet in the front of the flywheel
cover preventing a vapor lock of the electric fuel pump assembly which is
mounted in the vapor separator. The low pressure electric fuel pump was
added in 1998 to eliminate potential vapor locking of the fuel system. This
pump draws fuel from the main chamber of the vapor separator tank (VST)
and pushes the fuel into the chamber where the high pressure electric fuel
pump is located. This creates a pressure of approximately 6 to 7 psi on the
intake side of the high pressure fuel pump.
Excess fuel in the high pressure chamber returns to the main VST chamber
through a 0.030” hole. The high pressure electric fuel pump is different than
the fuel pump that is utilized on the standard EFI engine (non OptiMax), and is
capable of developing fuel pressures in excess of 90 psi. Fuel inside the rail
must remain pressurized at exactly 10 psi over the air rail pressure or the
ECM (map) calibrations will be incorrect. Fuel from the vapor separator is
supplied to the top of one fuel rail. A fuel line connects the bottom of the first
rail to the opposite fuel rail. Fuel is stored inside the rail until an injector opens.
A fuel pressure regulator controls pressure in the fuel rails, and allows excess
fuel to return into the vapor separator. The fuel regulator not only regulates
fuel pressure but also regulates it at approximately 10 p.s.i. higher than
whatever the air rail pressure is. The fuel regulator diaphragm is held closed
with a spring that requires 10 p.s.i. to force the diaphragm off the diaphragm
seat. The back side of the diaphragm is exposed to air rail pressure. As the air
rail pressure increases, the fuel pressure needed to open the regulator will
equally increase. Example: If there is 50 p.s.i. of air pressure on the air rail
side of the diaphragm, 60 p.s.i. of fuel pressure will be required to open the
regulator. The return fuel line to the vapor separator is water cooled. This
design is used to prevent cold fuel from the fuel tank hitting the hot fuel
returning from the fuel rail and flashing off the light ends (boiling over).
To equalize the pulses developed by the pumps (both air and fuel) a tracker
diaphragm is installed in the starboard rail. The tracker diaphragm is
positioned between the fuel and air passages. The tracker diaphragm is a
rubber diaphragm which expands and retracts depending upon which side of
the diaphragm senses the pressure increase (pulse).
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90-898305
1-60
Oil
Notes
Oil in this engine is not mixed with the fuel before entering the combustion
chamber. Oil is stored inside a standard remote oil reservoir. Crankcase
pressure will force oil from the remote oil reservoir into the oil storage tank on
the side of the powerhead. Oil will flow from the oil storage tank into the oil
pump. The oil pump is a solenoid design. It is activated by the ECM and
includes pistons with corresponding discharge ports. The oil pump is mounted
directly onto the powerhead. Each cylinder is lubricated by one of the
discharge ports. The oil is discharged into the crankcase in front of the reed
blocks or crankcase cover. The seventh passage connects to the hose that
leads to the air compressor for lubrication. Excess oil from the compressor
returns into the plenum and is ingested through the crankcase. Later models
have check valves inside the cylinder oil circuits. These check valves prevent
evacuation of the oil hoses under certain operating conditions.
The ECM will change the discharge rate of the oil pump, depending upon
engine demand. The ECM will also pulse the pump on initial start up to fill the
oil passages eliminating the need to bleed the oil system. The ECM provides
additional oil for break in, as determined by its internal clock. The oil ratio
ranges from 300-400:1 at idle to 60:1 at WOT. A OptiMax engine will use less
oil than a non-OptiMax engine.
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Electrical
The electrical system consists of the ECM, crank position sensor (flywheel
speed & crankshaft position), throttle position sensor (TPS), MAP sensor,
engine temperature sensor, ignition coils, water pressure sensor (not used on
all models) and injectors (fuel & direct). The engine requires a battery to start
(i.e. the ignition and injection will not occur if the battery is dead). The system
will run off of the alternator.
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Operation
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The operation of the system happens in milliseconds (ms); exact timing is
critical for engine performance. As the crankshaft rotates, air is drawn into the
crankcase through the throttle shutters, into the plenum, and through the reed
valves. As the piston nears bottom-dead-center, air from the crankcase is
forced through the transfer system into the cylinder. As the crankshaft
continues to rotate the exhaust and intake ports close. With these ports
closed, fuel can be injected into the cylinder. The ECM will receive a signal
from the throttle position sensor (TPS), engine temperature sensor (TS) and
the crank position sensor (flywheel speed and position sensor). With this
information the ECM refers to the fuel calibration (maps) to determine when to
activate (open and close) the injectors and fire the ignition coils. With the
piston in the correct position, the ECM opens the fuel injector, approximately
90 psi fuel is discharged into a machined cavity inside the air chamber of the
air/fuel rail. This mixes the fuel with the air charge. Next the direct injector will
open, discharging the air/fuel mixture into the combustion chamber. The direct
injector directs the mixture at the bowl located in top of the piston. The piston’s
bowl directs the air/fuel mixture into the center of the combustion chamber.
This air fuel mixture is then ignited by the spark plug.
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1-61
90-898305
Notes
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Compressor Notes: To aid in starting when the air rail pressure is low and
before the compressor has time to build pressure, the direct injector is held
open by the ECM. This allows the compression from inside the cylinders to
pressurize the air rail faster (1 or 2 strokes, or 60° of crankshaft rotation).
Idle Notes: Idle quality is controlled by fuel volume and fuel timing. The
throttle shutters will be open at idle speeds. The shift cut-out switch will
interrupt the fuel to 3 of the cylinders to assist in shifting.
The TPS signals the ECM to change the fuel and spark without movement of
the throttle shutters. The throttle cam is manufactured to allow the TPS sensor
shaft to move before opening the throttle shutters.
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90-898305
1-62
Theory of Operation - 3 Cylinder Models
Air Induction Through Crankcase
Combustion air enters the cowl through holes located in the top aft end of the
cowl. The cowl liner directs this air to the bottom of the powerhead. This limits
the exposure of salt air to the components inside the engine cowl. Once inside
the cowl the air enters the plenum through the throttle shutter which is located
in the plenum assembly. The air then continues through the reed valves and
into the crankcase. The throttle shutter is actuated by the throttle shaft.
Mounted on a separate shaft is a throttle position sensor (TPS). This sensor
tells the propulsion control unit (PCM) the position of the throttle.
Notes
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Air Compressor System
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Air from inside the engine cowl is drawn into the compressor through an air
filter in the air attenuator. This attenuator acts like a muffler to quiet
compressor noise and contains a filter to prevent the ingestion of debris into
the compressor. The compressor is driven by a belt from a pulley mounted on
the flywheel and is automatically self-adjusted using a single idler pulley. This
air compressor is a single cylinder unit containing a connecting rod, piston,
rings, bearings, reed valves, and a crankshaft. The compressor is water
cooled to lower the temperature of the air charge and is lubricated by oil from
the engine oil pump assembly. As the compressor piston moves downward
inside the cylinder, air is pulled through the filter, reed valves and into the
cylinder. After the compressor piston changes direction, the intake reeds close
and the exhaust reeds open allowing compressed air into the hose leading to
the air/fuel rails.
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The air/fuel rails contain two passages; one for fuel, the second for air. The air
passage is common between all the cylinders included in the rail. A hose
connects the rail air passage to the air compressor. An air pressure regulator
will limit the amount of pressure developed inside the air passages to
approximately [i.e. 648.1 kPa (94 psi) air vs 744.6 kPa (108 psi) fuel]. Air
exiting the pressure regulator is discharged through a muffler into the lower
cowling.
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1-63
90-898305
Notes
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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 system. A vapor separator
mounted diaphragm fuel pump draws fuel through the fuel line, primer bulb
and fuel pump assembly. The pump then pushes the fuel through a water
separating fuel filter. This filter removes any contaminates and water before
the fuel reaches the vapor separator. Fuel vapors are vented through the
bottom cowling into the atmosphere. The electric fuel pump is capable of
developing fuel pressures in excess of 744.6 kPa (108 psi). Fuel inside the rail
must remain pressurized at exactly 96.5 kPa (14 psi) over the air rail pressure
or the PCM (map) calibrations will be incorrect. Fuel from the vapor separator
is supplied to the top of the fuel rail. Fuel is stored inside the rail until an
injector opens. A fuel pressure regulator controls pressure in the fuel rail, and
allows excess fuel to return into the vapor separator. The fuel regulator not
only regulates fuel pressure but also regulates it at 96.5 kPa (14 psi) higher
than whatever the air rail pressure is. The fuel regulator diaphragm is held
closed with a spring that requires 96.5 kPa (14 psi) to force the diaphragm off
the diaphragm seat. The back side of the diaphragm is exposed to air rail
pressure. As the air rail pressure increases, the fuel pressure needed to open
the regulator will equally increase. Example: If there is 344.7 kPa (50 psi) of
air pressure on the air rail side of the diaphragm, 441.3 kPa (64 psi) of fuel
pressure will be required to open the regulator. The fuel rail is water cooled.
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Oil
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Oil in this engine is not mixed with the fuel before entering the combustion
chamber. Oil is stored inside an engine mounted reservoir.
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
A remote oil tank is available as an option. Crankcase pressure will force oil
from the remote oil tank into the oil reservoir on the front of the powerhead.
Oil will flow from the oil reservoir into the oil pump. The oil pump is a solenoid
design. It is activated by the PCM and includes 7 pistons with corresponding
discharge ports. The oil pump is mounted on the electrical plate. Each cylinder
is lubricated by one of the discharge ports. The oil is discharged into the
crankcase. The seventh passage connects to the hose that leads to the air
compressor for lubrication. Excess oil from the compressor returns into the
cylinder bores.
The PCM will change the discharge rate of the oil pump, depending upon
engine demand. The PCM will also pulse the pump on initial start up to fill the
oil passages eliminating the need to bleed the oil system. The PCM provides
additional oil for break-in, as determined by its internal clock. The oil ratio
varies with engine RPM and load.
_______________________
_______________________
90-898305
1-64
Electrical
Notes
The electrical system consists of the PCM, crank position sensor (flywheel
speed & crankshaft position), throttle position sensor (TPS), MAP sensor,
engine temperature sensor, ignition coils and injectors (fuel & direct). The
engine requires a battery to start (i.e. the ignition and injection will not occur if
the battery is dead). The system will run off of the alternator.
_______________________
_______________________
_______________________
_______________________
_______________________
Operation
The operation of the system happens in milliseconds (ms). Exact timing is
critical for engine performance. As the crankshaft rotates, air is drawn into the
crankcase through the throttle shutter, into the plenum and through the reed
valves. As the piston nears bottom dead center, air from the crankcase is
forced through the transfer system into the cylinder. As the crankshaft
continues to rotate the exhaust and intake ports close. With these ports
closed, fuel can be injected into the cylinder. The PCM will receive a signal
from the throttle position sensor (TPS), engine temperature sensor (TS) and
the crank position sensor (flywheel speed and position sensor). With this
information, the PCM refers to the fuel calibration (maps) to determine when
to activate (open and close) the injectors and fire the ignition coils. With the
piston in the correct position, the PCM opens the fuel injector, 744.6 kPa (108
psi) fuel is discharged into a machined cavity inside the air chamber of the
air/fuel rail. This mixes the fuel with the air charge. Next the direct injector will
open, discharging the air/fuel mixture into the combustion chamber. The direct
injector directs the mixture at the bowl located in top of the piston. The piston’s
bowl directs the air/fuel mixture into the center of the combustion chamber.
This air fuel mixture is then ignited by the spark plug.
Compressor Notes: To aid in starting when the air rail pressure is low and
before the compressor has time to build pressure, some direct injectors are
held open by the PCM. This allows the compression from inside the cylinders
to pressurize the air rail faster (1 or 2 strokes, or 60° of crankshaft rotation).
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Idle Notes: Idle quality is controlled by fuel volume and fuel timing. The
throttle shutter will be open at idle speed. The shift switch is mounted on the
exhaust adaptor plate and is activated by a cam/notch in the upper shift shaft.
The switch has a closed circuit when the engine is in gear (forward or reverse)
and an open circuit when the engine is in neutral. The switch is monitored by
the PCM. The PCM will change fueling, timing and RPM limit according to
whether the engine is in gear or in neutral.
The TPS signals the PCM to change the fuel and spark without movement of
the throttle shutters. The throttle cam is manufactured to allow the TPS sensor
shaft to move before opening the throttle shutter.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-65
90-898305
3 Cylinder/1.5 Liter
Notes
_______________________
75/90/115 HP
_______________________
Cowls (Upper & Lower)
_______________________
•
One piece light weight upper cowl.
_______________________
•
Two piece lower cowls that extend down the drive shaft housing. The
extended lower cowls have sound blankets to reduce engine noise.
_______________________
•
Removable panel on lower Port cowl to allow installation of control cables.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-67
90-898305
Notes
Emissions & Noise Levels
_______________________
•
Three star emission levels
_______________________
•
Operator ear sound pressure level (ICOMIA 39/94: 83.2 dBA
_______________________
Powerhead
_______________________
•
Three Cylinder, 1.5 Liter
_______________________
•
Same cylinder bore (92.1131 mm (3.6265 in.) as 3.0 Liter Outboard
_______________________
•
Lost foam cylinder block with one piece block, head and water jacket
design.
_______________________
•
Cast iron cylinder liners
_______________________
•
Power head is turned 10 ° on drive shaft housing, to improve exhaust flow,
and make clearance for IVST.
•
Change HP by changing cylinder liners/porting
•
Bottom guided connecting rods, using the same bearing as 3.0 Liter. The
1.5 Liter rod is shorter than 3.0 Liter connecting rod.
•
Piston rings are steel with chrome face.
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: The flywheel has a damper to reduce engine vibration.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
1-68
Cooling System
Notes
•
Thermostat/poppet valve controlled.
•
142 degree thermostat
•
Water deflectors (3) to direct water flow around cylinders.
•
Same water pump as currently used on 75 – 125 2-stroke
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a- Water deflectors (3) installed and removed through pipe plug holes at rear
of power head.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-69
90-898305
Notes
Mid-Section
_______________________
•
Larger upper and lower mounts
_______________________
•
Integrated upper mount clamp and cowl seal retainer
_______________________
•
Cast in upper mount pockets
_______________________
•
Improved shift shaft clearance
•
Upper and lower mount limit bumpers
•
Will replace current 75 – 125 HP 2 –stroke midsection
•
Clamp and swivel bracket common with current 75 – 125 2-stroke
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a
b
_______________________
_______________________
a - Limit bumper
_______________________
b - Upper mount clamp and cowl seal retainer
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
1-70
Accessories
Notes
1.5L ACCESSORIES:
_______________________
_______________________
•
Three gallon remote oil tank kit P/N 1257-8742A25
_______________________
•
Tiller handle kit, will not be ready for start of production estimated to be
ready late summer 2003.
_______________________
•
Costal Flush kit P/N 858566A02 is a hose that is run out the front of the
cowling to attach a hose to flush the engine. This will be standard on salt
water version.
_______________________
•
Tilt limit switch kit P/N 87-887979A2. Same switch kit currently used on
the 3.0 Liter, with up-dated instruction sheet.
_______________________
•
Analog power trim position sender kit will be standard on later models.
•
SmartCraft speedo sensor kit.
_______________________
•
Water pressure gauge “TEE” fitting/hose kit will be standard on later
models.
_______________________
•
Tiller handle kits.
_______________________
_______________________
_______________________
_______________________
GAUGES
_______________________
•
Engine will support all analog gauges except block/water temperature.
_______________________
•
Engine is SmartCraft compatible
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1-71
90-898305
Notes
Power Trim
_______________________
•
Common power trim with current 75 -125 2-stroke
_______________________
•
Analog power trim position sender kit will be standard after S/N 0T846415.
_______________________
_______________________
Lower Unit
_______________________
•
- 75/90 2.33:1 Teeth 28/12
_______________________
_______________________
- 115
Internal components common with current 75 – 125 2-stroke, except drive
shaft. Drive shaft is longer to get proper driveshaft to crankshaft
engagement. Lower unit complete is not interchangeable with current 75 –
125 2-stroke. The pinion gear teeth identification decal will have an
LIGHT/GRAY background with BLACK letters, for 1.5 Liter OptiMax
engines.
•
This engine may see prop rattle when using stainless steel and some
aluminum props. Using the Flow Torque III prop hub will eliminate most of
the prop rattle.
_______________________
_______________________
_______________________
2.07:1 Teeth 29/14
•
_______________________
_______________________
Gear Ratios
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Performance Gear Lube
2.5L, 3.0L, Verado L4 SC and Verado L6 (at time of print) will receive the
Hi-Performance gear lubrication. The V-6 product recommendation in the
operations manual will be changed to state the use of the Hi-performance
lub.
_______________________
_______________________
90-898305
1-72
Section 2 - Powerheads
2-1
90-898305
Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
Mechanical Changes to the 2.5L & 3.0L Litre Powerhead ................................4
OptiMax Cylinder Head .....................................................................................4
Head Gasket .................................................................................................5
Model 175 Optimax .......................................................................................7
O–Ring Cylinder Head ..................................................................................8
Pistons...........................................................................................................9
Piston Profile ...............................................................................................10
Temperature Sensor (Location Change) .....................................................10
2-3
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Mechanical Changes to the 2.5L & 3.0L Litre
Powerhead
1) Cylinder Head
a) Direct injector located in the top of the cylinder head.
b) 5/8” hex, long reach spark plug - puts the tip in the direct injector spray
pattern.
c) Head Gasket Change
i) 1998/99 2.5L aluminum gasket with o-ring seals
ii) 1998/99 3.0L & all 2000 models use an o-ring gaskets
2) Pistons
a) Cupped piston dome - directs fuel/air mixture, from the injector back up
towards the spark plug.
b) Outside profile changed and inside shape contoured to pass heat to
skirt and cylinder wall (hotter cylinder temperatures).
c) Pistons are marked “P” for port and “S” for starboard.
3) Cylinder block
a) OpitMax block casting has extra mounting points for OpitMax system
components – different from standard 2.5L or 3.0L block.
OptiMax Cylinder Head
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
The head is modified to support the fuel/air rails and position the spark plug at
the correct location inside the cylinder.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
The OptiMax cylinder head utilizes a unique design to help trap the fuel/air
mixture for efficient and reliable combustion.
_______________________
90-898305
2-4
Head Gasket
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
The 1998/99 2.5L head gasket is aluminum (0.100” thick) with an O-ring type
seal on both sides.
2.5L 2000 MODEL YEAR
_______________________
_______________________
_______________________
Cylinder head will incorporate O–ring style head gasket similar to all 3.0 litre
V–6 models.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2-5
90-898305
Notes
3.0L 2003 MODEL YEAR
_______________________
CYLINDER BORE O-RINGS
_______________________
Cylinder bore sealing O-rings have changed size and material. O-ring seals
separately will NOT back fit to prior model years.
_______________________
_______________________
_______________________
SIZE: Cylinder head seal is .070 (177mm ) smaller in diameter to increase
clearance between the water dam and water passages.
MATERIAL: New material has a higher resistance to heat and oils than the
present material.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
2-6
Model 175 Optimax
Notes
2001 MY
_______________________
This engine is based on the 2.5 Litre OptiMax. Differences between 175 HP
and the 150 HP, 2.5 Litre OptiMax are:
_______________________
•
ECM calibration
•
Head bolts for the 175 heads will be _ inch shorter then the 135 and 150
HP.
•
New open chambered cylinder head for increased power.
•
Cylinder liners (different porting)
•
Added holes in flywheel cover for increased airflow into air plenum to help
increase HP. Same cover will be used on 135 and 150 HP; calibration will
be changed on these models to keep HP within range.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2-7
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
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 much of the O-ring groove as possible. This pre-vents
oil from accumulating around the O-ring and breaking down the O-ring
material.
2.5 Litre
P/N 25-859772
P/N 25-859772-1
SST
3.0 Litre
P/N 25-818573
P/N 25-878453
SST
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: Model Year 2000 – Cylinder head o-rings are oval shaped and are not
directional in their installation. O-rings should not be damaged or twisted.
Replace as required.
Model Year 2001 – Cylinder head o-rings are directional in their installation.
The grooved side faces the cylinder block. The pointed side faces into the
cylinder head. Failure to install the o-rings correctly may result in cylinder
head leakage. O-rings should not be damaged or twisted. Replace as
required. The 2001 style o-rings supercede and backfit to 2000 Model Year
outboards.
Also see “Service Bulletin 2002-13” for more information.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
2-8
Pistons
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
The OpitMax piston contains a bowl inside the dome of the piston. The
position of the bowl will change between the port and starboard piston.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2-9
90-898305
Notes
_______________________
_______________________
Piston Profile
2003 MY
New piston profile and combustion bowl.
_______________________
New profile for improved piston fit, and increased durability.
_______________________
New combustion bowl for improved combustion of fuel charge.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a
b
a) – New combustion bowl
b) – Old combustion bowl
Temperature Sensor (Location Change)
2004 MY
The temperature sensor location was changed to improve water flow around
the sensor for a more accurate reading.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
OLD LOCATION
_______________________
NEW LOCATION
_______________________
_______________________
90-898305
2-10
Section 3 - Air System
3-1
90-898305
Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
Air Compressor Exploded View ........................................................................4
Air Compressor System ................................................................................4
2002 MY and Up- 2.5L Air Compressor Flow Diagram....................................5
2002 MY and Up- 2.5L Air Compressor Flow Diagram....................................6
2002 MY and Up - 3.0L Air Compressor Flow Diagram....................................8
2004 MY 1.5L Air Compressor Flow Diagram.................................................10
Air Pressure Regulator ................................................................................12
Sectional View .............................................................................................12
Air Regulator Tool – P/N 91-889431 ...........................................................13
3-3
90-898305
Notes
_______________________
Air Compressor Exploded View
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Air Compressor System
DESCRIPTION
•
Air from inside the engine cowl is drawn into compressor through the
flywheel cover or plenum.
Flywheel cover contains a filter to prevent ingestion of debris
A restrictor is located between the filter and the compressor
Restrictor lowers intake noise
Restrictor should be removed at altitudes over 5,000 ft
The compressor is driven by a serpentine belt from the crankshaft
The air compressor is a single cylinder unit, containing:
crankshaft
connecting rod
piston
rings
bearings
reed valves
Compressor is water cooled to lower the temperature of the air charge
Compressor is lubricated by the engine oil pump
_______________________
•
•
•
•
•
•
•
•
•
•
•
•
•
•
_______________________
FUNCTION
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
•
Piston moves down, pulling air through the filter & reed valves, into the
cylinder
Piston moves up, intake reeds close & exhaust reeds open, forcing the
compressed air into the hose leading to the fuel rails
_______________________
•
_______________________
FLOW
_______________________
_______________________
•
•
•
•
_______________________
•
_______________________
Air/fuel rails have a fuel passage and an air passage
Air passage is common between all the cylinders on the rail
Hoses connect the rails and the air compressor
The air pressure regulator limits the amount of air pressure in the air
passages to about 10 psi below the fuel in the fuel passages
Air exiting the air pressure regulator is routed to the exhaust adaptor and
exits through the propeller
90-898305
3-4
2002 MY and Up- 2.5L Air Compressor Flow
Diagram
90-898305
3-6
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p) Water Inlet to Fuel Rail
q) Air [79 _ 2 psi (544.0 _ 13.8
kPa)]
r) High Pressure Fuel [89 _ 2 psi
(613.5 _ 13.8)]
s) Air Regulator [79 _ 2 psi (544.0
_ 13.8 kPa)]
t) Fuel Regulator [89 _ 2 psi
(613.5 _ 13.8)]
u) Water Outlet (tell-tale)
v) #1 Fuel Injector
w) Starboard Fuel Rail
x) #3 Fuel Injector
y) #5 Fuel Injector
z) Tracker
aa) Low Pressure (Air)
ab) High Pressure (Air)
Air Inlet
Air Filter
Compressor Oil Inlet
Excess Oil Return
Compressor Air Inlet
Compressor Water Inlet
Fuel System Pressure Test
Valve
#2 Fuel Injector
Port Fuel Rail
Excess Fuel Return to VST
#4 Fuel Injector
40 psi Check Valve
Air Pressure Test Valve
Excess Air Return to Exhaust
Adaptor Plate
#6 Fuel Injector
Tip: The Schrader Valve Test Ports have changed by model year.
1998-1999 MY – Air is Port and Fuel is starboard. For 2000 MY and
Up – See Service Manual for correct locations.
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: Typical example, component location will vary on other models.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
3-7
90-898305
2002 MY and Up - 3.0L Air Compressor Flow
Diagram
90-898305
3-8
Notes
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m) Fuel Regulator [89 ±2 psi
(613.5 ±13.8 kPa)]
n) #4 Fuel Injector
o) Air Regulator [79 ± 2 psi (544.0
± 13.8 kPa)]
p) #2 Fuel Injector
q) Compressor Water Inlet
r) Port Fuel Rail
s) Air Pressure Test Valve
t) Excess Air Return to Air
Plenum
u) Excess Fuel Return to VST
v) 40 psi Check Valve (Not on All
Models)
w) Water Inlet to Fuel Rail
Air Inlet
Air Filter
Compressor Air Inlet
Air [79 ± 2 psi (544.0 ± 13.8
kPa)]
Fuel System Pressure Test
Valve
#1 Fuel Injector
Tracker Valve
#3 Fuel Injector
Starboard Fuel Rail
#5 Fuel Injector
High Pressure Fuel [89 ±2 psi
(613.5 ±13.8 kPa)]
#6 Fuel Injector
Tip: Air Pressure Specification – 2001 updated 3.0L engines and
2002 MY engines have 82 ± 2 psi air pressure.
Tip: Excess air discharge is either into the air plenum or exhaust
adapter plate depending on the model year.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
3-9
90-898305
2004 MY 1.5L Air Compressor Flow Diagram
90-898305
3-10
Notes
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)
_______________________
e - Fuel regulator – 744.6 ± 13.8 kPa (108 ± 2 psi)
_______________________
f - Fuel rail
_______________________
g - Fuel inlet to fuel rail – 744.6 ± 13.8 kPa (108 ± 2 psi)
h - Excess fuel return to VST
_______________________
i - Air pressure test valve (hidden)
_______________________
j - Water inlet hose to air compressor
_______________________
k - High pressure air to fuel rail – 648.1 ± 13.8 kPa (94 ± 2 psi)
_______________________
l - Air compressor
_______________________
m - Compressor air inlet
n - Air filter
_______________________
o - Air inlet
_______________________
p - Oil tank/air attenuator
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
3-11
90-898305
Notes
_______________________
_______________________
Air Pressure Regulator
The air pressure regulator is designed to limit the air pressure inside the rails
to approximately 80 psi (95 psi on 1.5L Models).
_______________________
The air regulator uses a spring (pressure) to control the air pressure. This
spring (80 or 95 psi) holds the diaphragm against the diaphragm seat. The
contact area blocks (closes) the air inlet passage from the excess air, return
passage. As the air pressure rises (below the diaphragm), it must reach a
pressure equal to or greater than the spring pressure holding the diaphragm
closed. Once this pressure is achieved, the spring compresses, allowing the
diaphragm to move. The diaphragm moves away from the diaphragm seat,
allowing air to exit through the diaphragm seat, into the excess air passage
leading to the exhaust adaptor plate.
_______________________
Sectional View
_______________________
AIR REGULATOR VALVE
_______________________
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a - Vent hole
b - 80 lb. spring (95 lb. spring on 1.5L model)
c - Diaphragm
d - Air dump
e - Fuel passage
f - Air passage
g - Air vent opening
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90-898305
3-12
Air Regulator Tool – P/N 91-889431
Notes
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3-13
90-898305
Section 4 - Fuel System
4-1
90-898305
Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
Powerhead Long Term Storage ........................................................................4
Storage Preparation ......................................................................................4
Fuel Starvation..................................................................................................6
Models Affected.............................................................................................6
Inspection/Test ..............................................................................................6
Test Procedure ..............................................................................................8
Test Procedure ..............................................................................................9
Correction:...................................................................................................10
Basic Fuel System Description .......................................................................13
Basic Fuel System Description .......................................................................14
2.5L OptiMax Fuel Schematic .........................................................................15
OptiMax DFI Fuel Schematic w/Fuel Cooler ...................................................16
3.0L OptiMax Fuel Schematic .........................................................................17
3.0L OptiMax Fuel Schematic .........................................................................18
3.0L OptiMax Fuel Schematic (Cont.) .............................................................19
OptiMax 1.5L Fuel Schematic .........................................................................20
OptiMax Fuel and Direct Injector Interface......................................................22
Vapor Separator Fuel Flow .............................................................................23
Integrated Vapor Separator ............................................................................24
2003 MY ......................................................................................................24
2002 & Up 2.5L OptiMax Air/Fuel Schematic..................................................26
2002 & Up 2.5L OptiMax Air/Fuel Schematic..................................................27
Fuel Pressure Regulator .................................................................................28
Sectional View .............................................................................................28
Tracker Valve (V6 Models Only)..................................................................29
Fuel Injector.................................................................................................30
Disconnecting Harness Connectors from Ignition Coils and/or Injectors.....31
Direct Injector ..............................................................................................31
2.5 & 3.0 Liter OptiMax................................................................................32
4-3
90-898305
Notes
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Powerhead Long Term Storage
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it
from rust, corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard
for out of season storage or prolonged storage (two months or longer).
_______________________
_______________________
_______________________
_______________________
CAUTION
Never start or run your outboard (even momentarily) without water
circulating through all the cooling water intake holes in the gear case to
prevent damage to the water pump (running dry) or overheating of the
engine.
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FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can
cause a formation of acid during storage and can damage the fuel
system. If the gasoline being used contains alcohol, it is advisable to
drain as much of the remaining gasoline as possible from the fuel tank,
remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with
treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed
with following instructions.
1) Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline
Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank
back and forth to mix stabilizer with the fuel.
2) Permanently Installed Fuel Tank – Pour the required amount of
Quicksilver Gasoline Stabilizer (follow instructions on container) into a
separate container and mix with approximately one quart (one liter) of
gasoline. Pour this mixture into fuel tank.
3) Place the outboard in water or connect flushing attachment for circulating
cooling water. Run the engine at 2000 rpm for 25 minutes to allow treated
fuel to fill the fuel system.
PROTECTING INTERNAL ENGINE COMPONENTS
NOTE: Make sure the fuel system has been prepared for storage.
1) Remove the spark plugs and add approximately one ounce (30ml) of
engine oil into each spark plug hole. Rotate the flywheel manually several
times to distribute the oil in the cylinders. Reinstall spark plugs.
2) Remove the water separating fuel filter and empty contents into a suitable
container. Refer to Maintenance Section for removal and installation of
filter. Replace fuel filter annually, or every 100 Hours of operation, or if
large amount of fuel contamination is present.
_______________________
90-898305
4-4
FUEL ADDITIVE RECOMMENDATION (QUICKLEEN)
Notes
See Service Bulletin 2001-12
_______________________
Today’s OptiMax engine control systems allow only minute quantities of air
and fuel to reach the combustion chamber in order to produce minimal
emissions. But, these diminutive amounts of air and fuel are easily obstructed
by fuel injector, direct injector and combustion chamber deposits. Due to the
inconsistent fuel quality in some areas, excessive fuel system and combustion
chamber deposits are on the rise. These deposits cause many driveability
problems that range from hesitation, rough idle, spark plug fouling, to
detonation problems. This performance characteristic can be prevented
through fuel system maintenance.
To minimize fuel system, and carbon deposit buildup in the engine, we
recommend adding Mercury or Quicksilver Quickleen P/N 92-802877A1
Engine Treatment additive to your engine’s fuel at each tank fill, throughout
the boating season. Use additive as directed on the container.
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PROTECTING EXTERNAL OUTBOARD COMPONENTS
_______________________
1) Lubricate all outboard components listed in the Inspection and
Maintenance Schedule.
2) Touch up any paint nicks. See your dealer for touch-up paint.
3) Spray Quicksilver Corrosion Guard on external metal surfaces (except
corrosion control anodes).
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GEAR CASE
_______________________
Drain and refill the gear case lubricant (refer to maintenance procedure).
_______________________
POSITIONING OUTBOARD FOR STORAGE
_______________________
Store outboard in an upright (vertical) position to allow water to drain out of
outboard.
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CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling
water or rain water that may have entered the propeller exhaust outlet in
the gear case could freeze and cause damage to the outboard.
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BATTERY STORAGE
_______________________
1) Follow the battery manufacturers instructions for storage and recharging.
2) Remove the battery from the boat and check water level. Recharge if
necessary.
3) Store the battery in a cool, dry place.
4) Periodically check the water level and recharge the battery during storage.
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4-5
90-898305
Notes
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Fuel Starvation
See Service Bulletin 2001-17
Models Affected
MERCURY/MARINER
1987 and Later, 30 Thru 250 HP, (with square fuel pump)
_______________________
FORCE
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1994-1/2 and later 40 Thru 120 HP, 1997 and later 175 Sport Jet
_______________________
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It is important that fuel supply restrictions/vacuum levels do not exceed
specification. High restrictions may result in the engine stalling at low speed,
and /or a lean fuel condition at high RPM, that could cause non-warrantable
engine damage. It is recommended to check fuel system vacuum on all new
boats/engines being prepared for delivery to ensure customer satisfaction and
engine durability.
Inspection/Test
_______________________
The purpose of the following tests is to check the vacuum level required to
draw fuel from the fuel tank to the pulse driven fuel pump, check for air leaks
in the fuel supply system, and the condition of the pulse driven pump. The
following items will be required to perform these tests.
_______________________
•
Short piece of clear hose ¼” .250 [6.35mm] I.D.
_______________________
•
Vacuum gauge, (digital gauge is preferred) obtain locally
•
“TEE” fitting that will fit ¼” .250 [6.35mm] I.D. fuel hose
_______________________
_______________________
_______________________
• Tubing clamp P/N 91-804063
Make vacuum gauge, “TEE” fitting, and hose connection as shown.
_______________________
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NOTE: Prior to performing the following tests, squeeze the primer bulb to
determine if thereis sufficient lift capability. If engine runs, confirm this by
performing the tests on the following page.
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90-898305
4-6
NOTE: Make the “TEE” fitting connection as close to the fuel pump as
possible.
a)
b)
c)
d)
e)
Pulse driven fuel pump
Clear hose connected between pulse pump and “TEE” fitting
Vacuum gauge (digital)
Tubing clamp P/N 91-804063
Fuel supply hose from fuel tank
4-7
90-898305
Test Procedure
Notes
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PUMP CAPABILITY TEST
Before proceeding with the system vacuum test, confirm that the pulse fuel
pump is capable of supplying the required vacuum. To do this, start the engine
and run at idle speed, pinch off/restrict the fuel supply hose between the
vacuum gauge and fuel tank, using tubing clamp.
Normal Reading
2.5 in. of vacuum (mercury) or higher,
proceed to fuel system leak test.
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Reading below 2.5 in. vacuum
(mercury)
•
Pump check valves defective,
replace valves
•
Pump diaphragm defective,
replace diaphragms
_______________________
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_______________________
•
Air leak in pump, rebuild pump
with new gasket,
_______________________
•
check fitting for leaks
_______________________
•
Low crankcase pressure, check
for crankcase
_______________________
•
leaks or plugged pulse pump
pressure/vacuum
•
passageways.
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FUEL SYSTEM LEAK TEST
_______________________
This test is done with the engine running, and the tubing clamp removed. The
clear hose that was installed previously is used to view the fuel flow to the
pulse pump.
_______________________
No air bubbles seen in clear hose
_______________________
No air leaks, perform vacuum test
(following)
_______________________
_______________________
Air bubbles seen in clear hose
Air leak on intake side of fuel system
•
Pick up tube in fuel tank leaking
•
Outlet fitting at fuel tank leaking
•
Fuel inlet hose not properly
clamped at fitting
•
Leaking fuel tank valve
•
Fuel line from kicker engine
connected into fuel line of main
engine.
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4-9
90-898305
Notes
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VACUUM TEST
The system vacuum test is normally performed at an idle speed. As engine
RPM increases, there will be a slight increase in vacuum; this increase should
not exceed normal readings at any RPM.
Normal Reading
Below 2.5 in. of Vacuum (mercury)
Reading above 2.5 in. of vacuum
(mercury)
Restriction within the fuel system
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•
Restricted anti-siphon valve
•
Restricted or malfunctioning
primer bulb
•
Kinked or collapsed fuel hose
•
Plugged water separating fuel
filter (in the boat)
•
Restriction in fuel line thru-hull
fitting
•
Restriction in fuel tank switching
valves
•
Plugged fuel tank pick-up screen
Correction:
_______________________
If the fuel capability test indicated good vacuum level (2.5 in. mercury or
higher) proceed to PRIMER BULB replacement.
_______________________
If the fuel pump capability test indicate low vacuum, proceed with the following
two upgrades to the fuel system to prevent low speed stalling.
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_______________________
PULSE FUEL PUMP:
The new repair kits contain check valves made of a plastic material,
impervious to damage from fuel additives. When repairing the fuel pump
discard old rubber and small plastic check valve disks, and install one new
plastic disk under each retainer. Caution must be taken not to push the check
valve retainer too tightly against the check valve, this may cause the valve to
deform.
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90-898305
4-10
NOTE: Before driving the check valve pin into the retainer, support the pump
housing on the opposite side, directly below the check valve retainer using a
socket or spacer. This will prevent distortion or cracking of the pump housing.
CORRECT
INCORRECT
a) Check Valve Retainer
b) Check Valve
The new plastic check valve started in production at the serial numbers listed
below:
MERCURY/MARINER
200-225 HP, 3.0L Carb/EFI/OptiMax
USA
0G925400
135-200 HP, 2.0/2.5L Carb/EFI/OptiMax
0G912213
75-125 HP, 65 Jet
0G923899
0P054758
40-60 HP
0G919929
0P054357
30-40 HP
0G919618
0P054357
4-11
BELGIUM
90-898305
Notes
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PULSE FUEL PUMP RUNING CHANGE
There is continued improvement planned for the square pulse driven fuel
pump used on most of the larger 2 stroke outboards.
CHECK VALVE CONTACT SURFACE: The outer edge of the check valve
will contact a raised surface that improves sealing of the valve.
RAISED CENTER PORTION: The center portion of the check valve surface
in the pump housing has been raised. This will allow more clearance for debris
to pass through the check valve and pump.
RETAINER HOLE CHAMFER TOP SIDE: Currently the retainer head side of
the retainer hole has a slight chamfer. This sometimes causes the retainer
head to pull the check valve into this chamfer causing the outside edge of the
check valve to raise up which prevents good sealing of the valve.
RETAINER HOLE CHAMFER BOTTOM SIDE: The bottom side of the
retainer hole will have a chamfer added, this allows the split end of the
retainer to spread out without pulling down with excessive force. When there
is too much down pressure on the head of the rivet, the outside edges of the
check valve is raised up preventing good sealing.
RETAINER O-RING: An O-ring will be added under the retainer head, to
prevent leakage past the retainer.
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a
b
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90-898305
4-12
Notes
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Basic Fuel System Description
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 system. A crankcase mounted
pulse driven diaphragm fuel pump draws fuel through the fuel line, primer
bulb, fuel pump assembly and then pushes the fuel thru a water separating
fuel filter. This filter removes any contaminates and water before the fuel
reaches the vapor separator. Fuel vapors are bled into the air compressor
inlet in the front of the flywheel cover preventing a vapor lock of the electric
fuel pump assembly which is mounted in the vapor separator. The electric fuel
pump is different than the fuel pump that is utilized on the standard EFI engine
(non DFI), and is capable of developing fuel pressures in excess of 90 psi.
Fuel inside the rail must remain pressurized at exactly 10 psi over the air rail
pressure or the ECM (map) calibrations will be incorrect. Fuel from the vapor
separator is supplied to the top of one fuel rail. A fuel line connects the bottom
of the first rail to the opposite fuel rail. Fuel is stored inside the rail until an
injector opens. A fuel pressure regulator controls pressure in the fuel rails, and
allows excess fuel to return into the vapor separator. The fuel regulator not
only regulates fuel pressure but also regulates it at approximately 10 p.s.i.
higher than whatever the air rail pressure is. The fuel regulator diaphragm is
held closed with a spring that requires 10 p.s.i. to force the diaphragm off the
diaphragm seat. The back side of the diaphragm is exposed to air rail
pressure. As the air rail pressure increases, the fuel pressure needed to open
the regulator will equally increase. Example: If there is 50 p.s.i. of air pressure
on the air rail side of the diaphragm, 60 p.s.i. of fuel pressure will be required
to open the regulator. The return fuel line to the vapor separator is water
cooled. This design is used to prevent cold fuel from the fuel tank hitting the
hot fuel returning from the fuel rail and flashing off the light ends (boiling over).
To equalize the pulses developed by the pumps (both air and fuel) a tracker
diaphragm is installed in the starboard rail. The tracker diaphragm is
positioned between the fuel and air passages. The tracker diaphragm is a
rubber diaphragm which expands and retracts depending upon which side of
the diaphragm senses the pressure increase (pulse).
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90-898305
4-14
2.5L OptiMax Fuel Schematic
h)
i)
j)
k)
a) Fuel Vapor (to plenum intake
cover)
b) Fuel Return
c) High Pressure Fuel
d) 40 psi (subject to change later
models) Check Valve
e) Water Outlet to Compressor
f) Fuel System Pressure Test
Valve
g) Fuel Regulator
l)
m)
n)
o)
p)
Tracker
Fuel Injector
Water In
Low Pressure Electric Fuel
Pump
Mechanical Fuel Pump
Water Separating Fuel Filter
Fuel Filter
High Pressure Fuel Pump
Vapor Separator Tank (VST)
NOTE: Typical example, component location will vary on other models.
Tip: A stuck 40 psi check valve will result in higher than normal
fuel pressure.
4-15
90-898305
OptiMax DFI Fuel Schematic w/Fuel Cooler
10) Water Out
11) Water In
12) Fuel Cooler
13) Low Pressure Electric Fuel
Pump (10 psi)
14) Vapor Separator
15) Mechanical Fuel Pump (10 psi)
16) Water Separating Fuel Filter
17) Fuel Filter
18) High Pressure Fuel Pump
1)
2)
3)
4)
5)
6)
Air Inlet Compressor
Fuel Vapor
High Pressure Fuel (90 psi)
Fuel Return
40 psi Check Valve
Fuel System Pressure Test
Valve
7) Fuel Regulator
8) Tracker
9) Fuel Injector
90-898305
4-16
3.0L OptiMax Fuel Schematic
VST History
Fuel cooler with VST
Water cooled fuel rail with VST
Water cooled fuel rail with IVST
(shown above)
90-898305
1998/99
2000-2002
2003 and above
4-18
3.0L OptiMax Fuel Schematic (Cont.)
1. Engine Pulse Fuel Pump
2. Fuel/Water Separator Filter
3. Vapor Separator Tank Vent Hose
4. Fuel Outlet from High Pressure Electric Fuel Pump – 620 kPa (90 psi)
5. Bleed Off from Air Pressure Regulator; routed to exhaust adaptor and exits
through the propeller
6. Air Compressor Inlet Coolant Hose
7. Air Compressor
8. Air Compressor Inlet Air Filter
9. High Pressure Air Outlet – 551 kPa (80 psi)
10. Schrader Valve for testing fuel pressure – 620 kPa (90 psi)
11. Fuel Injector is opened by the ECM/PCM, 620 kPa (90 psi) fuel is
discharged into a machined cavity inside the air chamber of the air/fuel rail.
This mixes fuel with the air charge.
12. Tracker Valve has a rubber diaphragm which expands and retracts to
equalize the pulses developed by the pumps [both air and fuel].
13. Cooling water routed from air compressor to tell-tale
14. Direct Injector discharges the air/fuel mixture into the combustion chamber
15. Schrader Valve for testing air pressure – 551 kPa (80 psi)
16. Water Inlet to cool port air/fuel rail and air compressor
17. Fuel Pressure Regulator not only regulates fuel pressure but also
regulates it at approximately 69 kPa (10 psi) higher than whatever the air rail
pressure is. The fuel regulator diaphragm is held closed with a spring that
requires 69 kPa (10 psi) to force the diaphragm off the diaphragm seat. The
backside of the diaphragm is exposed to air rail pressure. As the air rail
pressure increases, the fuel pressure needed to open the regulator will equally
increase.
18. Air Pressure Regulator will limit the amount of pressure developed inside
the air passages to approximately 69 kPa (10 psi) below the pressure of the
fuel inside the fuel passages
19 Bleed off from fuel pressure regulator; routed back to vapor separator tank.
20. Low Pressure Electric Fuel Pump Schrader Valve
21. Fuel Director
22. Vapor Separator Tank Drain Screw
23. Vapor Separator Tank Drain Fitting
24. 172 kPa (25 psi) relief valve
25. Low Pressure Electric Fuel Pump
26. Vapor Separator Tank Float Needle
27. Vapor Separator Tank Float
28. Fuel/Water Drain Fitting
29. Fuel/Water Drain Screw
30. Fuel/Water Sensor
31. Fuel Inlet from primer bulb
4-19
90-898305
OptiMax 1.5L Fuel Schematic
90-898305
4-20
1. Engine pulse fuel pump
2. Fuel/Water separator filter
3. Vapor separator tank vent hose
4. Air compressor inlet coolant hose
5. Fuel outlet from high pressure electric fuel pump – 751.5 kPa (109 psi)
6. High pressure air outlet – 655 kPa (95 psi)
7. Air compressor
8. Air compressor inlet air filter
9. Cooling water routed from air compressor to fuel rail
10. Direct injector discharges the air/fuel mixture into the combustion chamber
11. Schrader valve for testing fuel pressure (design 2 location) – 571.5 kPa
(109 psi)
12. Schrader valve for testing air pressure – 655 kPa (95 psi)
13. Water outlet to tell-tale
14. Schrader valve for testing fuel pressure (design 1 location) – 751.5 kPa
(109 psi)
15. Fuel injector is opened by the PCM, 751.5 kPa (109 psi) fuel is discharged
into a machined cavity inside the air chamber of the air/fuel rail. This mixes
fuel with the air charge.
16. Fuel pressure regulator
17. Air pressure regulator
18. Excess high pressure air muffler
19. Bleed off from air pressure regulator; routed to the outside through bottom
cowl
20. Bleed off from fuel pressure regulator; routed back to vapor separator
tank.
21. Low pressure electric fuel pump Schrader valve
22. High pressure electric fuel pump
23. 172 kPa (25 psi) relief valve
24. Vapor separator tank float needle
25. Vapor separator tank float
26. Low pressure electric fuel pump
27. Fuel Director
28. Vapor separator tank drain screw
29. Vapor separator tank drain fitting
30. Fuel/Water Drain Fitting
31. Fuel/Water Drain Screw
32. Fuel/Water sensor
33. Fuel Inlet from primer bulb
4-21
90-898305
Notes
_______________________
OptiMax Fuel and Direct Injector Interface
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1) Cylinder Head
2) Nylon Seal
3) Bellville Washer
4) Cork Gasket
5) Air Passage
6) Fuel Passage
7) Fuel Injector
8) Area of Detail
9) Air Fuel Rail
10) Fuel Injector
11) 1Direct Injector
_______________________
90-898305
4-22
Vapor Separator Fuel Flow
Notes
_______________________
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_______________________
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_______________________
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_______________________
_______________________
_______________________
_______________________
_______________________
1) High Pressure Fuel (to Air/Fuel
Rail)
2) Return Fuel (from Air/Fuel Rail)
[on 3.0L models this hose
connection point (on VST) is
reversed with low pressure fuel
pump hose connection point.]
3) Vent Tube (to Flywheel Cover)
4) Fuel Inlet (from Pulse Driven
Fuel Pump)
5) Low Pressure Fuel Pump
6) Water Separating Fuel Filter
7) Float
8) Fuel Return Orifice
9) Drain Plug
10) Filter
11) High Pressure Fuel Pump
12) Vapor Separator
The low pressure electric fuel
pump was added, to eliminate
vapor locking of the fuel system.
This pump draws fuel from the
main chamber of the vapor
separator, and pushes the fuel into
the chamber (in the vapor
separator) where the high pressure
electric fuel pump is located. This
creates a pressure of about 6 to 7
psi on the input side of the high
pressure fuel pump. The extra fuel
in this chamber returns to the main
vapor separator chamber through a
0.030 hole. By maintaining this low
pressure on the input side of the
high pressure fuel pump any
potential vapor lock is eliminated.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
4-23
90-898305
Notes
_______________________
Integrated Vapor Separator
_______________________
2003 MY
_______________________
Improved low pressure electric fuel pump for improved durability
_______________________
Low pressure electric pump enclosed in the IVST, simplified fuel hose routing.
_______________________
Pulse pump built onto IVST to simplify hose routing.
_______________________
Easy to remove screw in water separating fuel filter, canister filter no longer
used.
_______________________
High pressure electric fuel pump enclosed inside the IVST.
_______________________
_______________________
Water sensor probe mounted at end of IVST for easy removal.
Water can easily be drained from IVST by rotating drain screws at either end
of IVST.
Low pressure electric fuel pump pressure can be checked directly off schrader
valve mounted on IVST.
90-898305
4-24
1. Engine pulse fuel pump
Notes
2. Fuel/Water separator filter
_______________________
3. Vapor separator tank vent hose
4. Fuel outlet from high pressure electric fuel pump – 751.5 kPa (109 psi)
5. Bleed off from fuel pressure regulator; routed back to vapor separator tank.
_______________________
_______________________
6. Low pressure electric fuel pump Schrader valve
_______________________
7. High pressure electric fuel pump
_______________________
8. 172 kPa (25 psi) relief valve
_______________________
9. Vapor separator tank float needle
_______________________
10. Vapor separator tank float
11. Low pressure electric fuel pump
_______________________
12. Fuel Director
_______________________
13. Vapor separator tank drain screw
_______________________
14. Vapor separator tank drain fitting
_______________________
15. Fuel/Water Drain Fitting
16. Fuel/Water Drain Screw
_______________________
17. Fuel/Water sensor
_______________________
18. Fuel Inlet from primer bulb
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
4-25
90-898305
2002 & Up 2.5L OptiMax Air/Fuel Schematic
j)
k)
l)
m)
a)
b)
c)
d)
e)
f)
g)
Air Intake to Compressor
Air Compressor
Fuel System Test Valve
Starboard Fuel Rail
Tracker
Fuel Injector (6)
Direct Injector (into Combustion
Chamber)
h) Water into Rail
i) Port Fuel Rail
n)
o)
p)
q)
Air Pressure Regulator
Fuel Pressure Regula tor
40 psi Check Valve
Low Pressure Electric Fuel
Pump
Mechanical Fuel Pump
Water Separating Fuel Filter
Fuel Filter
High Pressure Fuel Pump
NOTE: Typical example, component location will vary on other models.
4-27
90-898305
Notes
_______________________
_______________________
Fuel Pressure Regulator
•
Calibrated to raise fuel pressure 10 psi above air pressure
•
Uses both air & internal spring pressure to control fuel pressure
_______________________
♦ Internal spring calibrated at 10 pounds resistance
_______________________
♦ Spring holds the diaphragm against seat
_______________________
♦ Contact between diaphragm and seat closes the passage between
incoming fuel (from the electric fuel pump) and the fuel return passage
_______________________
•
When the engine isn’t running (no air pressure on spring side of
diaphragm) the fuel pressure required to move the diaphragm is 10 psi
•
When the engine is running, air pressure from the air compressor (80 psi)
is routed to the spring side of the diaphragm
•
The air pressure (80 psi) and the spring pressure (10 psi) combine to
regulate the fuel system pressure to 90 psi…or 10 psi than the air
pressure in the DFI system/fuel rails
_______________________
_______________________
_______________________
_______________________
_______________________
Sectional View
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a – 10 lb. spring (15 lb. spring on 1.5L models)
b - Diaphragm
c - Fuel return line to VST
d - Air passage
e - Fuel passage
f - Excess fuel return opening
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
4-28
Tracker Valve (V6 Models Only)
•
Notes
Tracker valve designed to maintain 10 psi differential between the fuel
rails when air or fuel pressure suddenly rises (air compressor pulses or
fuel injectors opening & closing)
_______________________
_______________________
•
Contains a spring (on the ‘air’ side) & a diaphragm
_______________________
•
When engine isn’t running, spring positions diaphragm against seat
_______________________
•
When the engine is running, fuel pressure compresses spring and
diaphragm moves slightly away from seat, to a ‘neutral’ position
_______________________
•
Pressure on both sides of diaphragm is equal
•
Note: to prevent excessive seat wear, the tracker valve is calibrated to
allow the diaphragm to be slightly away from the seat during normal
operation.
_______________________
•
Any air or fuel pressure ‘spikes’ on either side of the diaphragm will
transfer this pressure increase to the other side of the diaphragm
_______________________
•
Both sides (air & fuel) will have a momentary increase in pressure so that
_______________________
the 10 psi difference can be maintained
•
If pressure rises inside fuel passage, the diaphragm will flex into the air
passage, causing a proportionate increase in air pressure
•
If pressure rises in the air passage, the diaphragm flexes into the fuel
passage, increasing the fuel pressure proportionately
_______________________
SECTIONAL VIEW TRACKER VALVE
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a - Spring
b - Air passage
c - Fuel passage
d - Diaphragm
_______________________
_______________________
_______________________
_______________________
_______________________
4-29
90-898305
Notes
_______________________
_______________________
_______________________
Fuel Injector
A fuel injector is an electromagnetic device. The precision mechanical
components are controlled by means of the solenoid in the injector, the
solenoid is energized by an injector driver in the ECM. The driver circuit
controls the “on” time of the solenoid by providing a ground.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
Top Cap
Inner Collar
Sleeve
O-Ring
Solenoid Coil
Tape
O-Ring
Filter
O-Ring
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
4-30
Cap
Needle Valve
Nozzle
Valve Stopper
Core
Bobbin
Spring
Connector
Terminal
Disconnecting Harness Connectors from Ignition Coils
and/or Injectors
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a) Wire Clip (push center down to remove)
_______________________
_______________________
Direct Injector
The Direct injector uses a tapered tip and seat. The tapered tip is ground to
provide a leakproof seal. The tapered tip is controlled by the ECM through the
use of a solenoid inside the injector.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a) Tapered Tip
b) Solenoid Coil
_______________________
_______________________
_______________________
_______________________
_______________________
4-31
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2.5 & 3.0 Liter OptiMax
DIRECT INJECTOR - 2002 MY RUNNING CHANGE
New direct injector with encapsulated coil winding. A hard plastic coating is
placed around the winding prior to the molding process for the plastic housing.
This prevents the outer windings of the coil from being pushed out of place
and shorting to the metal housing as the plastic molding material is injected
into the mold. This product improvement should reduce or eliminate shorted
windings. When this change occurs the blue dot injector housing will be
molded out of blue plastic.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: The color of direct injectors have changed over time as follows:
_______________________
•
All BLACK Injectors supersede to BLUE Injectors.
_______________________
•
The GRAY Injectors are used on 3 Cylinder models and All High
Performance models.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Direct Injector Shorted to Ground
Models: All OptiMax Product, 1998 and Newer
Situation: Current service literature indicates that there should be no
continuity between the direct injector connector pins and engine ground.
Engineering has determined that direct injectors that have an ohms reading
from each connector pin to ground greater then 700 ohms will operate
correctly and does not need to be replaced
NOTE: For best results check the direct injector for continuity to ground
when the injector is near operating temperature (engine warmed up).
To allow for meter and/or temperature variations, a reading of 1000 ohms has
been set as the determining point to replace or not replace the direct injector.
•
Meter reading greater then 1000 ohms, the injector performance will
not be affected and does not need to be replaced
•
Meter reading less then 1000 ohms, the performance could be affected
and the injector should be replaced
_______________________
_______________________
90-898305
4-32
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a – Direct injector ohm test between the two connector pins (1.0 – 1.6 ohms)
_______________________
b – Check between each connector pin and the metal portion of the injector,
ohms reading should be 1000 ohms or greater.
_______________________
NOTE: Making resistance checks on a direct injector while still installed in
the engine can be difficult. An easy and fast way to make resistance (ohms
value) checks on direct injectors is to use service harness 84-858781A2, shown
below. This harness is normally used as a service replacement part for the
direct injector connector if it becomes damaged, but also works well to make
the required resistance and ground test while the injector is in place between
the cylinder head and fuel rail.
Service literature will be updated with this information as manuals are revised
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
4-33
90-898305
Section 5 - Oil Injection System
5-1
90-898305
Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
Oil System Operation ........................................................................................4
1998/1999 2.5L Oil System ...........................................................................4
Check Valve Kit – 1998/1999 135/150 OptiMax............................................5
2.5L - Model Year 2000 Starboard Side Oil Hose Routing............................6
2.5L - Model Year 2000 Port Side Oil Hose Routing .....................................7
2.5L - Model Year 2001 Starboard Side Oil Hose Routing............................8
2.5L - Model Year 2001 Port Side Oil Hose Routing .....................................9
3.0L - Model Year 2000 thru 2002 Starboard Side Oil Hose Routing..........10
3.0L - Model Year 2000 thru 2002 Port Side Oil Hose Routing...................11
3.0L - Model Year 2003 Starboard Side Oil Hose Routing..........................12
3.0L - Model Year 2003 Port Side Oil Hose Routing ...................................13
1.5L – Model Year 2004 Starboard Side Oil Hose Routing .........................14
New 1.5L Models - Oiling System Highlights...............................................15
OptiMax Oil Pump .......................................................................................16
OptiMax Oil Pump Change..........................................................................16
Priming the Oil Pump ..................................................................................17
HIGH OIL CONSUMPTION.........................................................................18
5-3
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Oil System Operation
Oil in this engine is not mixed with the fuel before entering the combustion
chamber. Oil is stored inside the remote oil tank in the boat. Crankcase
pressure forces oil from the remote oil tank into the engine oil tank. The
engine oil tank feeds oil to the oil pump. The oil pump has seven oil discharge
ports. Six of the oil discharge ports inject oil into the crankcase through hoses,
one for each cylinder. The last oil discharge port discharges oil into the air
compressor for lubrication. Unused oil from the air compressor returns to the
plenum and is ingested through the crankcase.
The ECM is programmed to automatically increase the oil supply to the engine
during the initial break-in period. During the initial engine break-in period, the
oil ratio is doubled during the first 120 minutes of operation over 2500 RPM.
Oil ratio below 2500 RPM is at the normal rate. After the engine break–in
period, the oil ratio will return to normal – 300 - 400:1 at idle to maximum of
60:1 at WOT (depending upon engine load).
1998/1999 2.5L Oil System
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
g) Air Compressor
h) Check Valve
i) Oil Return Hose from the Air
Compressor
j) Low Oil Sender Wires (to ECM)
k) Magnetic Float
l) Air Pressure
m) Crankcase Pressure w/One
Way Check Valve
a) Remote Oil Tank
b) Engine Oil Tank
c) Oil Supply Hose to the Oil
Pump
d) Oil Pump
e) Oil Supply Hoses to the
Cylinders
f) Oil Supply Hose to the Air
Compressor
90-898305
5-4
Check Valve Kit – 1998/1999 135/150 OptiMax
Notes
Check valves have been to the crankcase oil delivery hoses to prevent
evacuation of oil from the hoses under certain running conditions and to
improve oil delivery to the engine. This product improvement is being offered
to current owners and on outboards in dealer inventory to provide improved
reliability and durability. The check valves have been installed on production
outboards as a running change beginning with serial number 0G886267.
Check valves used in production will be incorporated into the oil hose fitting
pressed in the cylinder block and not an inline check valve.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Check Valve Location – Port Side (Starboard Side Similar)
a) #2 Cylinder Oil Hose (Trim hose length as required)
b) #4 Check Valve/Hose Assembly
c) #6 Check Valve/Hose Assembly
d) Sta-Straps
_______________________
_______________________
_______________________
Tip: If powerhead is replaced, check valves are in block fittings.
Check valves in oil lines must be removed.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
5-5
90-898305
2.5L - Model Year 2000 Starboard Side Oil Hose Routing
90-898305
5-6
2.5L - Model Year 2000 Port Side Oil Hose Routing
5-7
90-898305
2.5L - Model Year 2001 Starboard Side Oil Hose Routing
90-898305
5-8
2.5L - Model Year 2001 Port Side Oil Hose Routing
5-9
90-898305
3.0L - Model Year 2000 thru 2002 Starboard Side Oil Hose
Routing
a - Oil Pump
b - Bolts (3)
c - Remote oil tank pressure hose
d - SmartCraft speedometer gauge pressure sensor
e - Negative battery cable
90-898305
5-10
3.0L - Model Year 2000 thru 2002 Port Side Oil Hose
Routing
a - Oil pump hoses
a - Oil hoses from oil pump routed under air plenum and secured by sta-strap
5-11
90-898305
3.0L - Model Year 2003 Starboard Side Oil Hose Routing
a - Oil pump
b - Bolts (3)
c - Remote oil tank pressure hose
90-898305
5-12
3.0L - Model Year 2003 Port Side Oil Hose Routing
a - Oil pump hoses
a - Oil hoses and harness from oil pump routed under air plenum and secured
by j-clamps.
5-13
90-898305
1.5L – Model Year 2004 Starboard Side Oil Hose Routing
90-898305
5-14
New 1.5L Models - Oiling System Highlights
Notes
_______________________
•
Engine mounted oil reservoir is standard.
•
Engine reservoir filled without removing top cowl.
_______________________
•
Low oil sensor mounted at bottom of engine reservoir, normally closed
switch.
_______________________
•
Oil level in engine reservoir checked with gauge (chain) connected to fill
cap.
•
Remote 3 gallon oil tank optional P/N 1257-8742A25
•
Oil filter between engine reservoir and oil pump (replace every 100 hours).
•
Same 7 outlet port oil pump as V6 OptiMax, (3 to crankpin area, 3 to
transfer port area, and 1 to air compressor).
_______________________
_______________________
_______________________
•
Oil usage is about 40 % of what the current 3.0 Liter OptiMax uses.
•
Oil ratio is 300-400 : 1 at idle, 50:1 at WOT
•
Return oil from air compressor is directed to cylinder bores.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
5-15
90-898305
Notes
OptiMax Oil Pump
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1)
2)
3)
4)
5)
6)
7)
_______________________
OptiMax Oil Pump Change
_______________________
NOTE: Older pump supersedes to newer pump for service. Refer to Service
Bulletin 2003-8 (New P/N 2.5L is 859372A01 and 3.0L is 859373A01).
_______________________
_______________________
_______________________
_______________________
_______________________
Coil
Piston Assembly
Outlet Check Valve
Return Spring
Oil Discharge Port (4 Shown)
Inlet Check Valve
Plunger
NEWER
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
OLDER
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
5-16
Priming the Oil Pump
Notes
NOTE: If a new powerhead is being installed or oil hoses/oil pump has been
removed, it is recommended all air be purged from oil pump/oil lines. This can
be accomplished by using a gearcase leakage tester(FT-8950). Connect the
leakage tester to the inlet t-fitting on the onboard oil reservoir. While clamping
off the inlet hose, manually pressurize the reservoir to 10 psi. Using the Digital
Diagnostic Terminal 91-823686A2, activate the oil pump prime sequence.
Maintain the 10 psi pressure throughout the auto prime sequence. When the
auto prime is completed, remove the leakage tester and refill the onboard oil
reservoir.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Priming the oil pump (filling pump and hoses) is required on new or rebuilt
engines and any time maintenance is performed on the oiling system.
There are three methods for priming the oil pump:
_______________________
_______________________
_______________________
METHOD 1 - SHIFT SWITCH ACTIVATION PRIME
_______________________
This method does three things:
a) Fills the oil pump, oil supply hose feeding pump and oil hoses going to
the crankcase and air compressor.
b) Activates break-in oil ratio.
c) Initiates a new 120 minute engine break-in cycle.
Refer to priming procedure following.
METHOD 2 - (DDT) DIGITAL DIAGNOSTIC TERMINAL – RESET
BREAK-IN
This method is the same as Method 1, except the run history and fault history
are erased from the ECM.
Refer to procedure in the Technician Reference Manual provided with the
Digital Diagnostic Software Cartridge.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
5-17
90-898305
Notes
_______________________
_______________________
_______________________
METHOD 3 - (DDT) DIGITAL DIAGNOSTIC TERMINAL - OIL PUMP
PRIME
This method fills the oil pump, oil supply hose feeding pump, and oil hoses
going to the crankcase and air compressor.
_______________________
Refer to procedure in the Technician Reference Manual provided with the
Digital Diagnostic Software Cartridge.
Conditions Requiring Priming the Oil Pump
Condition
Priming Procedure
_______________________
New engine
Use Method 1 or 2
Rebuilt Powerhead
Use Method 1 or 2
New Powerhead
Use Method 1 or 2
_______________________
_______________________
_______________________
Oil system ran out of oil
Use Method 3
_______________________
Oil drained from oil supply hose feeding pump
Use Method 3
_______________________
Oil pump removed
Use Method 3
_______________________
Oil injedtion hoses drained
Use Method 3
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
HIGH OIL CONSUMPTION
There have been reports of high oil consumption on both 2.5 & 3.0 Litre
OptiMax. A high fuel to oil ratio may be normal for some light boat
applications. When the engine is run between 4000-5000 RPM, the oil to fuel
ratio can appear very rich on oil, even after the oil break-in has been
completed. The reason for this is because the fuel consumption is lower due
to the Opti-Max design, and the light boat application, but approximately the
same amount of oil is required to lubricate the engine.
Example: An older EFI engine might use 1 gallon of oil and 50 gallons of fuel,
at 5000 RPM traveling to and from an offshore fishing location, resulting in a
50:1 ratio. An OptiMax/DFI may use 1 gallon of oil and 28 gallons of fuel at
5000 RPM, to and from the same location, resulting in a 28:1 ratio. The overall
oil consumption of an OptiMax/DFI product will be about the same as (EFI &
Carb) product, if you compare oil consumption to running time and fuel to oil
ratio. Higher than normal oil consumption can still occur, if you get a complaint
of high oil consumption, use the following steps as a guide line.
•
Use the DDT to confirm that the engine has completed the break-in
procedure. (120 min. 2.5L & 240 min. 3.0L).
•
Confirm how the oil consumption is being measured, and that the above
light boat application does not apply.
_______________________
•
Confirm that the oil tank is NOT retaining pressure on shut down.
_______________________
•
If high oil consumption has been confirmed, it is likely that a check valve in
the oil pump is stuck open. To confirm this, remove the oil pump from the
manifold and remove the oil pump supply hose from the engine oil
reservoir. Using a lower unit pressure checker, apply about 3 psi of
pressure to the oil supply hose. If a continuous flow of oil is exiting an oil
pump, replace the pump.
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
5-18
Section 6 - Electrical System
6-1
90-898305
Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
Ignition System - V6 Models .............................................................................4
Theory of Operation ......................................................................................4
Coil Driver......................................................................................................4
Ignition Coil Driver Operation ........................................................................5
Ignition Coil and Driver Schematic ................................................................6
Ignition Coils ..................................................................................................7
Ignition System - 3 Cylinder 1.5L Models..........................................................8
Theory of Operation ......................................................................................8
3 Cylinder 1.5L Ignition Coil Schematic.........................................................9
Electronic Control Module (ECM) ................................................................10
Flywheel ......................................................................................................11
Crank Position Sensor.................................................................................12
Throttle Position Sensor (TPS)....................................................................12
Charging System Alternator ........................................................................12
Temperature Sensor ...................................................................................13
Manifold Absolute Pressure (MAP) Sensor .................................................13
Air Temperature Sensor ..............................................................................13
6-3
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Ignition System - V6 Models
Theory of Operation
When the ignition key is turned to the RUN position, battery voltage is applied
to the main relay through the PURPLE wire. The main relay is then closed and
D.C. current from the battery or charging system is transferred through the
main relay 20 Amp fuse to the positive terminal of all 6 ignition coil primary
windings. The negative terminal of the coil primary is connected to engine
ground through the Electronic Control Module (ECM). When this circuit is
closed, a magnetic field is allowed to be built up in the ignition coil. The Crank
Position Sensor senses the location of the teeth on the flywheel and supplies
a trigger signal to the ECM. When the ECM receives this signal, the ECM will
then open the ground circuit of the coil primary. The magnetic field in the
ignition coil primary will then collapse cutting across the coil secondary
winding creating a high voltage charge (50,000 volts) that is sent to the spark
plug.
Coil Driver
Model Year 2001 and Up
The ECM sends a 5 VDC pulse to the coil driver mounted on each ignition
coil. Which coil driver receives this pulse is determined by the ECM receiving
a signal from the crank position sensor.
When the coil driver receives its ECM pulse (signal), it closes its circuit which
allows the primary side of the ignition coil to build up energy which it initially
receives from the boat battery.
When the ECM pulse (signal) to the coil driver drops below 1.3 volts, the coil
driver opens its circuit which causes the primary field of the ignition coil to
collapse. This field collapse induces a voltage buildup in the secondary
winding of the ignition coil resulting in a potential voltage of up to 50,000 volts
at the spark plug.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
6-4
Ignition Coil Driver Operation
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
1)
2)
3)
4)
5)
6)
_______________________
12 Volt Power From Fuse
ECM
Ground
Ignition Coil #4
Ignition Coil #1
Coil Driver #1 & #4
_______________________
_______________________
_______________________
_______________________
_______________________
6-5
90-898305
Ignition Coil and Driver Schematic
90-898305
6-6
Notes
Ignition Coils
_______________________
MODEL YEAR 2000
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
MODEL YEAR 2001 AND UP
_______________________
_______________________
_______________________
_______________________
_______________________
1
_______________________
_______________________
2
_______________________
_______________________
1 – Cyl. 1 & 4
2 – Cyl. 2 & 5
3 – Cyl. 3 & 6
3
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
6-7
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Ignition System - 3 Cylinder 1.5L Models
Theory of Operation
When the ignition key is turned to the RUN position, battery voltage is applied
to the electrical system through the main power relay. If the Propulsion Control
Module (PCM) does not sense engine rotation from the starter motor within a
certain time period, the relay is turned off. Engine rotation will again engage
the relay. When the main power relay is closed, system voltage is supplied
through the dedicated 20 ampere ignition fuse to the positive terminal of all 3
ignition coils. Each coil contains an internal driver circuit. The driver circuit
switches the primary current on for a given time period (dwell), and then
switches it off causing the collapse of the coil’s magnetic field which creates a
spark. The Crank Position Sensor reads the encoder tooth pattern on the
flywheel which allows the PCM to monitor the position of the crankshaft while
the engine is running. At the proper time for ignition spark, the PCM sends a
digital signal to the coil driver commanding the driver to dwell and then provide
spark. When the engine is operating at lower RPM, this process is repeated in
quick succession to provide a multi-strike spark for each combustion event.
The number of strikes per event is varied depending on RPM and load
requirements. The spark plug features an extended protrusion into the
combustion chamber and platinum tips on both the center and ground
electrode.
Note: Ignition load test was not operational until PCM part number 885557
047 for 115 HP, 885557046 for 90HP and 885557001 for 75 HP introduced
late 2004.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
6-8
3 Cylinder 1.5L Ignition Coil Schematic
6-9
90-898305
Notes
Electronic Control Module (ECM)
_______________________
ECM/PCM IDENTIFICATION
_______________________
ECM - “Electronic Control Module”
_______________________
PCM - “Propulsion Control Module”. PCM has all functions of ECM, including
the ability to handle Digital Throttle and Shift Functions.
_______________________
_______________________
ECM/PCM DESIGNATIONS
_______________________
Non-555 OptiMax - This is the original ECM used on Optimax engines 19982000 MY. Cannot accept CAN for Smartcraft operation. Smartcraft gauges
utilitized on 2000 MY ran through the 5 pin tach harness.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
555 or Triple Nickel ECM/PCM - Started with 2001MY Optimax engines and
later installed on V-6 EFI (2002MY). This ECM/PCM has CAN capability for
Smartcraft. PCM introduced in 2003 MY for introduction of DTS on 225
Optimax. This ECM/PCM has one 5 volt power source identified as PWR 1 on
scan tool.
PCM 03/038 - Introduced for 2004 MY. Includes all functionality of 555 style
PCM/ECM. Major change is the addition of 5 volt power circuit (as soon as
the engine changes to the 14-pin harness). Now the engine sensors have a
dedicated 5 volt reference circuit while DTS/Smartcraft has a dedicated 5 volt
reference circuit. PWR 1 and PWR 2 now displayed on scan tool.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
6-10
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 monitored and tested
by the Digital Diagnostic Terminal 91-823686A2 using adaptor harness 84822560A5. The ECM performs the following functions:
•
Calculates the precise fuel and ignition timing requirements based on
engine speed, throttle position, manifold pressure and coolant
temperature.
•
Controls fuel injectors for each cylinder, direct injectors for each cylinder
and ignition for each cylinder.
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
•
Controls all alarm horn and warning lamp functions.
•
Maintains correct idle speed in or out of gear.
•
Monitors oil pump solenoid coil.
•
Monitors reserve oil tank level.
•
Monitors air compressor temperature.
_______________________
•
Monitors engine temperature via coolant sensor.
_______________________
•
Monitors atmospheric pressure via MAP sensor
_______________________
•
Monitors shift interrupt via shift switch, above 600 RPM by reducing
engine power.
_______________________
•
Supplies tachometer signal to gauge
_______________________
•
Controls RPM limit function (caused by TPI fault, overheat, overspeed or
power reduction)
_______________________
•
Records engine operating history
•
Records sensor fault history
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Flywheel
The teeth under the flywheel ring gear provide engine rpm and crankshaft
position information to the ECM through the crank position sensor.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
6-11
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
Crank Position Sensor
Senses teeth located on flywheel under ring gear. Supplies the ECM with
crank position information and engine speed. If sensor should fail, the engine
will stop running.
Throttle Position Sensor (TPS)
_______________________
Two (2) Throttle Position Sensors are used in conjunction with one another. If
one sensor should fail, the dash mounted CHECK ENGINE light will light and
the warning horn will sound. RPM will be limited to 3000 rpm. If both TPS’s
should fail, rpm will be reduced to idle by the ECM. TPS settings are not
adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal
through the ECM.
_______________________
NOTE: 2000 & Newer model year engines use only one TPS.
_______________________
Charging System Alternator
_______________________
Battery charging system is contained within the belt driven alternator,
including the regulator. At cranking speeds, electrical power for the engine is
provided by the boat battery – minimum recommended size is 750, or 1,000
MCA, cold cranking amperes. Above 550 RPM, all electrical power is provided
by the alternator. Should engine rpm drop below 550 RPM, the alternator is
not capable of providing sufficient output and the battery becomes the primary
source of electrical power. Once the engine is running and rpm is 650 or
higher, the engine will continue to run should the battery become shorted or
disconnected.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Alternator output (when hot) to the battery @ 2000 RPM is approximately 52 60 amperes.
_______________________
FUSIBLE LINK - 2003 MY AND UP
_______________________
•
A 100 amp fuse (Fusible link) is installed in the alternator power outlet
wire, that runs from the alternator to the starter solenoid.
•
Fuse will prevent damage to alternator and output wire, if battery
connections are reversed by mistake.
•
The fuse is part of the wire so the complete wire must be replaced if the
fuse has an open circuit.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a) 100 Amp Fuse
90-898305
6-12
Temperature Sensor
Notes
Three (3) temperature sensors (2 on 1.5L models) are used to provide
cylinder head temperature information to the ECM. One sensor is mounted in
each cylinder head and one in the air compressor cylinder head. The ECM
uses this information to increase injector pulse width for cold starts and to
retard timing in the event of an over-heat condition.
_______________________
_______________________
_______________________
_______________________
An ohms test of the temperature sensor would be as follows:
Insert digital or analog ohmmeter test leads into both TAN/BLACK sensor
leads. With engine at temperature (Fº) indicated, ohm readings should be as
indicated ±10%.
_______________________
_______________________
_______________________
Manifold Absolute Pressure (MAP) Sensor
_______________________
The ECM regulates fuel flow, in part, based on manifold absolute pressure
(MAP). Drawing a vacuum on the MAP sensor will create a lean fuel condition.
_______________________
_______________________
_______________________
Air Temperature Sensor
The air temperature sensor is mounted on the intake manifold. The ECM
regulates fuel flow, in part, based on manifold air temperature. As air
temperature increases, the ECM decreases fuel flow.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
6-13
90-898305
Table of Contents
Table of Contents..............................................................................................2
Table of Contents..............................................................................................3
1998/99 Warning System..................................................................................4
Warning System Signals ...............................................................................5
Guardian Protection System - All 2000 Models & Newer..................................6
Guardian System Operation with Gauges .....................................................6
Guardian System Activation ..........................................................................7
OptiMax Service Tips ........................................................................................8
Shift Slide: .....................................................................................................8
Main Power Relay .........................................................................................8
Temperature Readings:.................................................................................8
Fuel Supply Hose Restricted: ........................................................................8
Loose Fuse Holder ........................................................................................9
Fuel Injector Test...........................................................................................9
Fuel Pressure (Pressure No Volume)............................................................9
Weak Spark (Ignition Coil).............................................................................9
Alternator:....................................................................................................10
Alternator Belt:.............................................................................................10
Salt In Compressor Inlet..............................................................................10
Direct Injector Stuck: ...................................................................................10
Twin Pressure Gauge:.................................................................................11
Low Pressure Electric Fuel Pump System Failure ......................................11
Incorrect Grommet (Air Handling Assembly) ...............................................11
Hard Starting ...............................................................................................11
Harness Replacement Ends........................................................................12
False Throttle Position Sensor Failures.......................................................13
Incorrect Cam to Roller Setting ...................................................................14
Throttle Position Sensor (TPS) Troubleshooting .........................................14
Engines Stalling On Flushing Attachment ...................................................16
225 Revised Fuel Calibration ......................................................................16
Worksheet Part Numbers................................................................................16
OptiMax DDT Data Worksheet 90-858879...............................................16
SmartCraft Data Worksheet 90-881929--1...............................................16
OptiMax DDT Data Worksheet - P/N 90-858879.........................................17
OptiMax DDT Data Worksheet - P/N 90-858879 ............................................18
Smartcraft Data Worksheet - P/N 90-881929--1 .............................................19
SmartCraft Data Worksheet - P/N 90-881929--1 ............................................20
SmartCraft Data Worksheet Fault ID Description ...........................................21
SmartCraft Data Worksheet Fault ID Description (Cont.) ...............................22
SmartCraft Data Worksheet ............................................................................23
SmartCraft Data Worksheet ............................................................................24
7-3
90-898305
Notes
_______________________
_______________________
_______________________
1998/99 Warning System
The outboard warning system incorporates warning light gauge and warning
horn. The warning horn is located inside the remote control or is part of the
ignition key switch wiring harness.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
When the key switch is turned to the ON position, the warning lights and horn
will turn on for a moment as a test to tell you the system is working.
Tip: The 4 Function Gauge can only be used with 2000 MY and
prior products (Non-555 ECM).
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-4
Warning System Signals
NOTE: The warning system signals which includes audible and visual
indicator involving the horn and lights will identify the potential problems listed
in the chart
Problem
Horn
Power Up/ System
Check
Single Beep
Low Oil
4 Beep… 2
Minutes Off
No Oil Flow
Continuous
Beep
Over Heat
Check
Engine
Light
Yes
Yes
4 Beep… 2
Minutes Off
Over Speed
Continuous
Beep
Yes
Over
Heat
Light
Yes
Water In
Fuel
Light
Yes
Engine Speed
Reduction Activated
(approx. 3000 RPM)
No
Yes
No
Yes
Yes
(Limits to 3000 RPM)
Continuous
Beep
Water In Fuel
Low Oil
Light
Yes
Yes
(Limits to 3000 RPM)
Yes
Yes
(Activated at 5800
RPM)
Coolant Sensor
Failure
No
Yes
MAP Sensor Failure
No
Yes
Air Temperature
Sensor Failure
No
Yes
Ignition Coil Failure
No
Yes
Injector Failure
No
Yes
Horn Failure
N/A
Yes
No
Battery Voltage too
high (16V) or too low
(11V) or very low
(9.5V)
No
Yes
Yes – If battery voltage
is less than 10.4V,
RPM is reduced to
3000.
If voltage is 9.5V or
less, RPM is reduced to
idle.
Over Heat Cyl.
Head/Compressor
Continuous
Beep
Throttle Sensor
Failure
Continuous
Intermittant
Beep
Yes
Yes
Yes
7-5
RPM reduces to 3000 if
1 sensor fails. RPM is
reduced to Idle speed
only if both sensors fail
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Guardian Protection System - All 2000
Models & Newer
The guardian protection system monitors critical engine functions and will
reduce engine power accordingly in an attempt to keep the engine running
within safe operating parameters.
IMPORTANT: The Guardian System cannot guarantee that powerhead
damage will not occur when adverse operating conditions are
encountered. The Guardian System is designed to (1) warn the boat
operator that the engine is operating under adverse conditions and (2)
reduce power by limiting maximum rpm in an attempt to avoid or reduce
the possibility of engine damage. The boat operator is ultimately
responsible for proper engine operation.
_______________________
Guardian System Operation with Gauges
_______________________
4 Function Gauge
System will sound warning horn and
illuminate appropriate light on gauge.
SmartCraft Gauge
System will sound warning horn and
display the warning message.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-6
Guardian System Activation
Condition
Engine Overheat
Result
Engine power level can be reduced to
any percentage down to an idle
speed, if overheat condi-tion persists.
Air Compressor Overheat
2000 Model – engine power level can
be reduced to any percentage down
to an idle speed, if over-heat
condition persists. 2001 Model – no
power reduced.
Block Water Pressure Low
Engine power level can be reduced to
any percentage down to a fast idle, if
condition persists.
Throttle Position Sensor Failure
If the throttle position sensor fails or
becomes disconnected, power will be
limited to a maximum of
approximately 4500 rpm. When the
TPS is in the fail mode, the ECM will
use the MAP sensor for a reference
to determine fuel calibration.
Temperature Sensor (cylinder head
and air compressor) Failure
If a temperature sensor should fail or
become disconnected, power will be
reduced by 25%.
Battery Voltage (too high or too low)
Battery voltage greater than 16.5
volts or less than 10.5 volts will result
in engine output power being
reduced. The higher or lower the
voltage is outside of these
parameters, the greater the
percentage of power reduction. In an
extreme case, power could be
reduced to idle speed.
Oil Pump Failure
If the oil pump fails or an open circuit
occurs between the pump and the
ECM, engine power will be reduced to
idle.
7-7
90-898305
Notes
OptiMax Service Tips
_______________________
1998/99 135/150, 2.5 LITRE
_______________________
1998/99 200/225, 3.0 LITRE
_______________________
_______________________
The following Troubleshooting/Service tips have been accumulated over the
past several months. These are not necessarily the only solution to the
problem.
_______________________
Shift Slide:
_______________________
3.0 LITRE
_______________________
There have been reports of the shift slide P/N 853968--1 being installed
upside down, in the roller guide, this could result in hard shifting. The ribbed
side of the slide should face down.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Main Power Relay
2.5 & 3.0 LITRE
On occasions dealers have diagnosed an electrical problem, to no output from
the main power relay. The relay has been found to be good, there is battery
voltage on both the PURPLE and RED leads, going to the relay, but the ECM
is not allowing it to turn on. The YELLOW/PURPLE wire is a ground circuit in
the ECM that allows the main power relay to close. If there is a fault in the kill
circuit (BLACK/YELLOW) wire the ECM will not allow the main power relay to
turn on. See DDT main power relay load test, page 128 of DDT Reference
Manual.
Temperature Readings:
3.0 LITRE
The 3.0L power head has rubber water deflectors/dams in the water passages
between the cylinders (see cooling system section 4B). If these
deflectors/dams are not installed, the cylinder temperature will read 30 to 40
degrees higher on that bank of cylinders. Remove cylinder head and install
water deflectors P/N 824857--2.
Fuel Supply Hose Restricted:
_______________________
2.5 & 3.0 LITRE
_______________________
Fuel restriction problems have been seen in two locations on Optimax
product.
_______________________
_______________________
_______________________
_______________________
Where the fuel hose passes through the bottom cowl clamp, on both 2.5 and
3.0 Litre.
On the 3.0 Litre product, if excess fuel hose gets pushed into the bottom cowl,
the pulse pump inlet fuel hose may kink at the lower formed 90 degree bend.
This may not occur when the engine is first put into operation, it may occur
some time later when the fuel hose becomes soft from heat and fuel.
_______________________
90-898305
7-8
Loose Fuse Holder
Notes
2.5 & 3.0 LITRE
_______________________
If the DDT shows a fault on all 6 direct injectors, fuel injectors, or ignition coils,
it is not likely that all 6 of these component have failed, make sure the fuse for
that circuit is good and that it is making good contact with the fuse
socket/connector.
_______________________
2.5 & 3.0 LITRE
_______________________
_______________________
_______________________
An engine that surges between 1200 and 2000 RPM may have a missing
tracker valve spring. The fuel and air pressure may not indicate any problem
and normally the engine will run good below and above this RPM range.
_______________________
_______________________
Fuel Injector Test
_______________________
2.5 (1998 MODEL)
_______________________
When doing the fuel injector load test, with the DDT, the sound from the # 4 &
6 fuel injectors may not be as loud or as many pulses as the other injectors.
This is normal and should not be considered a problem or fault in the engines
electrical system. The 1999 ECM software has corrected this condition.
_______________________
Fuel Pressure (Pressure No Volume)
_______________________
_______________________
_______________________
2.5 & 3.0 LITRE
_______________________
There have been reports of a loss of top RPM. No warning lights or horns are
indicated. The engine has symptoms that strongly indicate loss of fuel. Runs
up to full RPM for a short time (seconds) and then drops down in RPM, or may
not get to full RPM at all. The pressure gauge may indicate good fuel & air
pressure 90 & 80 psi. To confirm that the fuel supply is adequate,
restrict/pinch off the fuel return hose between the fuel cooler and the VST.
This test should be performed at WOT. When restricted the fuel pressure
should rise quickly to above 110 psi. If not, there is some type of fuel supply
problem.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Weak Spark (Ignition Coil)
_______________________
2.5 & 3.0 LITRE
The ignition coil used on the Optimax product has a magnet inside. If the
magnet is installed up side down, the engine may run rough or misfire. The
ohm value will be correct and the DDT will likely not detect a fault. Usually the
problem can be detected by performing the cylinder drop test with the DDT at
the RPM that the engine is running rough or misfiring. Then switch the coil to a
different cylinder and test again. NOTE: The faulty ignition coil may also be
hot to the touch.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
7-9
90-898305
Notes
Alternator:
_______________________
3.0 LITRE
_______________________
There have been three reports of burned/melted alternator RED wires. This
can be caused by the wire being routed incorrectly and chaffing through and
shorting to ground, or the battery cables have been reversed. If the cables
have been reversed the RED wire will be burned/melted the full length of the
wire. If wire is shorted, it will be burned/melted between the short and
connection to the starter solenoid.
_______________________
_______________________
_______________________
_______________________
Alternator Belt:
_______________________
2.5 LITRE
_______________________
_______________________
When the rubber mounted alternator bracket is installed as per Service
Bulletin 98-8, the belt tensioner pulley may hit the flywheel. If the belt was at
the short end of the tolerance is when this is likely to occur. Install new
alternator belt P/N 828507--4, which is .400 longer and will provide proper
clearance.
_______________________
Salt In Compressor Inlet
_______________________
_______________________
_______________________
3.0 LITRE
_______________________
In salt-water areas, if the cooling system is not flushed regularly, salt could
build-up in some of the smaller water hose fittings.
_______________________
On the 3.0 Litre the salt builds up in the inlet water fitting on the air
compressor head, due to the extra heat in this area.
_______________________
Direct Injector Stuck:
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2.5 & 3.0 LITRE
When a direct injector sticks the corresponding fuel injector will continue to
function. This will cause excess fuel to accumulate in the air side of that rail,
affecting the fuel calibration of those cylinders. Example: If the number 1 direct
injector stuck closed, the number 3 & 5 cylinder will run rich. This will result in
a loss of engine RPM or power greater than expected with the loss of one
cylinder. If a Direct injector is mechanically stuck closed, it will not show as an
electrical fault on the DDT.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-10
Twin Pressure Gauge:
Notes
2.5 & 3.0 LITRE
_______________________
Part number of the twin pressure gauge used on Optimax product has su
The new gauge has improved schrader valve connections (screw on type).
The clip on style connectors have been removed and screw on connectors
with quick disconnects have replaced them. The new gauge will also have
FUEL & AIR marked on the gauge manifold. The fuel side will include a check
valve at the connector, to retain fuel in the gauge when gauge is disconnected
from engine.
To up-grade the current gauges in use, there will be an adapter kit available.
Two kits are required for the twin pressure gauge.
•
ADAPTER KIT P/N 91-803804A2
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Low Pressure Electric Fuel Pump System Failure
_______________________
2.5 LITRE
_______________________
If the low pressure pump, or the electrical connection to the pump fail, the
engine will start and run well at lower RPM. As the engine RPMs are
increased (somewhere above 3000) the engine may stall out, or not reach full
RPM. Fuel and air pressure will be lower then normal. Another symptom, if the
pump outlet fitting (upper) is very warm (too hot to touch), the pump itself is
failing.
_______________________
_______________________
_______________________
_______________________
Incorrect Grommet (Air Handling Assembly)
_______________________
2.5 LITRE
_______________________
There are two different grommets used on the Air Handling Assembly (AHA).
The grommet used on the 135 HP has a (1 5/8 in.) opening, which restricts air
flow into the air plenum. The 150 HP grommet has no restriction at all, and
only functions as a grommet for correct fit of the flywheel cover. If a 150 HP
grommet is incorrectly installed on a 135 HP, it will result in poor engine
acceleration due to incorrect fuel calibration. Symptoms are normally a surge
and shake over 3000 RPM, if the operator pulls back on the throttle the engine
will smooth out. Note: To reach maximum RPM, the engine can be throttled
slowly through this range. The Digital Diagnostic Terminal (DDT) will not
indicate any type of failure or fault.
Hard Starting
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
2.5
_______________________
We have received some reports of hard starting 135/150 HP Optimax/DFI
engines. To date we have found 3 reasons (Listed below) for this condition.
1) Incorrect battery (low amp rating, or deep cycle battery used as cranking
battery.
2) Incorrect engine set-up, throttle cable, or roller to cam setting.
3) ECM calibration. We have found that the early ECM calibration may be to
lean for some engines. Refer to S/B 98
_______________________
_______________________
_______________________
_______________________
_______________________
7-11
90-898305
Notes
Harness Replacement Ends
_______________________
2.5 & 3.0 LITRE
_______________________
Service replacement harness connectors for the Optimax fuel injector, Direct
injectors, TPS and Crankshaft Sensor are now available. This will allow the
dealer the option to repair the engine harness rather than replacing it
complete. Both of these connectors have been prone to shipping damage.
Connector kit will include required connectors to hook into the main engine
harness.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Connector Direct Injector
P/N 84-858781A2
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Connector Fuel Injector
P/N 84-858780A2
_______________________
Connector TPS
P/N 84-878073A1
_______________________
Connector Crankshaft Sensor
P/N 84-878074A1
_______________________
Note: There are more connectors then listed please reference current parts
catalogue for part numbers.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-12
False Throttle Position Sensor Failures
Notes
2.5 LITRE
_______________________
If the Throttle Position Sensors (TPS’s) are out of the intended operating
range, or change value at the idle position, after the engine is started, the
Electronic Control Module (ECM) will sense that the (TPS/s) has failed. The
warning horn will sound, check engine light will illuminate, DDT will indicate
failed TPS/s, and the engine may go into power reduction. If TPS failures
codes occur check the following.
•
•
•
•
Check throttle cable adjustment, the throttle stop screw on throttle aria
must be against the throttle stop on the cylinder block when the engine is
started. Pre-load the throttle cable barrel one or two turns if necessary.
When starting the engine make sure the operator is not pushing on the
throttle (if foot throttle is used) or advance the throttle only on the control
box.
Check the throttle cam to roller adjustment. If the roller is not down in the
pocket/valley area on the cam, there is a tendency for the roller to ride up
or down on the cam, this in turn causes the TPS link arm to push/pull on
the TPS lever, changing the valve.
Perform heat test on TPI, replace any units which fail test.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Correct Cam to Roller Setting (2.5L)
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
7-13
90-898305
Notes
Incorrect Cam to Roller Setting
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Throttle Position Sensor (TPS) Troubleshooting
If the throttle position sensor(s) are out of the intended operating range when
the engine is started, the Electronic Control Module (ECM) will sense that the
Throttle Position Sensor (TPS) has failed. The warning horn will sound, check
engine light will illuminate DDT will indicate failed TPS and the engine will go
into RPM reduction. When the engine is started, the throttle arm on the engine
must be against the throttle stop screw.
•
Check throttle cable adjustment. The throttle stop screw on the throttle
arm must be against the throttle stop on the cylinder block when the
engine is started. Pre-load the throttle cable barrel 1 or 2 turns if
necessary.
_______________________
•
Verify driver is not pushing on throttle (if foot throttle is used) or activating
the throttle only on the control box.
_______________________
•
Check throttle cam to roller adjustment. If the roller is not down in the
pocket/valley area in the cam, there is a tendency for the roller to ride up
or down on the cam which causes the TPS link arm to push/pull on the
TPS lever resulting changing values.
•
Make sure the roller doesn’t have any flat spots or is egg shaped if so
replace.
•
Make sure the throttle link rod is not loose or have excessive play this
could result in false TPS voltage readings.
•
Heat or pressure test the TPS.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-14
HEAT TEST
Notes
With engine at idle, heat the TPS (with a hot air gun) below the electrical
connection until warm to the touch. Watch for any one or a combination of the
following symptoms:
_______________________
•
RPM change
_______________________
•
Check engine light illumination
•
Momentary warning horn signal
•
TPS voltage value change (1/2 volt) on DDT
_______________________
_______________________
_______________________
_______________________
NOTE: Excessive heat will damage TPS.
_______________________
PRESSURE TEST
_______________________
IMPORTANT: When testing TPS voltage, do not move the drive
mechanism (rotor/wiper).
_______________________
1) Connect DDT and rotate the key to the “ON” position.
2) Set DDT to read TPS voltage; expand the screen to show Now/Min/Max.
_______________________
NOTE: Test accuracy is improved when TPS is at its lowest voltage reading;
this may be idle or WOT depending on model year.
3) Clear the minimum/maximum values on the DDT - press the “0” button.
4) Watch the DDT reading while pressing below the electrical connection
point on the TPS cover.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
a) Press on Cover Below Electrical Connection
_______________________
5) Voltage reading should change:
• Less than a couple of digits (i.e. 1.90 v to 1.92 v)
_______________________
NOTE: Version 5.0 cartridge gives 3 decimal point (millivolts) accuracy if
below 1 volt.
•
Less than 10 millivolts (i.e. 0.293 v to 0.285 v)
•
Replace any TPS that fails either test.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
7-15
90-898305
Notes
Engines Stalling On Flushing Attachment
_______________________
2.5 LITRE
_______________________
_______________________
When running, on a flushing attachment some engines may stall when the
DDT miss-fire test is performed. These same engines have run well when
used under normal boating conditions.
_______________________
225 Revised Fuel Calibration
_______________________
Some early 1999, 225 HP, OptiMax engines may experience hard starting,
rough idle, and stalling when shifted into gear. There is now a revised ECM
calibration to correct this problem. Before replacing the ECM, MAKE SURE all
systems are in good operating condition. To confirm that the fuel calibration is
the problem, disconnect the (three) wire (starboard) head temperature sensor
when the engine is cold. If the engine now starts correctly, it is likely the new
ECM (P/N 857127A8) calibration will resolve the problem. Contact the service
department for a pre-authorization.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Worksheet Part Numbers
_______________________
OptiMax DDT Data Worksheet
90-858879
_______________________
SmartCraft Data Worksheet
90-881929--1
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-16
OptiMax DDT Data Worksheet - P/N 90-858879
Dealer Name:
Engine S/N:
Dealer Number:
Engine Type:
Technician Name:
ECM Part Number:
Date:
DDT Software Version:
Total Run Time
Sensor Err
0000-0999
CTS
1000-1499
CTP
1500-2999
ACT
3000-3999
MAP
4000-4999
TPI 1
5000-5999
TPI 2
6000+
AIR
RPM LIM CNT
TRIG
BREAL LN Min.
BPSI
OVER TMP Sec
Switches Err
Ignition Err
LOW OIL
Cyl 1
H2O
Cyl 2
Misc. Err
Cyl 3
BAT
Cyl 4
PWR 1
Cyl 5
PWR 2
Cyl 6
PRLY
Injector Err
LAMP
Cyl 1
HORN
Cyl 2
Cyl 3
WOT RPM
Cyl 4
Cyl 5
Cyl 6
Pump Err
OIL PMP
Description of Problem:
7-17
90-898305
OptiMax DDT Data Worksheet - P/N 90-858879
Dealer Name:
Technician Name:
Dealer Number:
Engine S/N:
#1 Data Monitor
NOW:
Min:
Max:
Notes
NOW:
Min:
Max:
Notes
ENGINE RPM
TPI 1 VOLTS
TPI 2 VOLTS
BATTERY VOLTS
PWR 1 VOLTS
PWR 2 VOLTS
COOL TMP STB
COOL TMP PRT
MAP PSI
AIR TMP
TRIGGER ERR
TIME TO OIL
OIL INJ CNT
AIR COMP TMP
BLOCK PSI
#2 Data Monitor
ENGINE RPM
TPI 1 VOLTS
TPI 2 VOLTS
BATTERY VOLTS
PWR 1 VOLTS
PWR 2 VOLTS
COOL TMP STB
COOL TMP PRT
MAP PSI
AIR TMP
TRIGGER ERR
TIME TO OIL
OIL INJ CNT
AIR COMP TMP
BLOCK PSI
90-898305
7-18
Smartcraft Data Worksheet - P/N 90-881929--1
Dealer Name:
Engine S/N:
Dealer Number:
Engine Type:
Technician Name:
ECM Part Number:
Date:
DDT Software Version:
Fault Seconds
BATT VOLT HIGH
Engine #1
Engine #2
Run History
RUN TIME HR
BATT VOLT LOW
RPM 0-749
BLOCK PRESS LOW
750-1499
COMP OVERHEAT
1500-2999
ETC MOTOR OPEN
3000-3999
ETC MOTOR SHORT
4000-4499
FUEL P INPUT HI
4500-4999
FUEL P INPUT LO
5000-5499
GUARDIAN
5500-6249
KNOCK SENS1
6250+
KNOCK SENS2
BREAK-IN LEFT
OIL PSI STR
RPM LIMIT Sec
OIL REMOTE SRT
GRD LIMIT Sec
OIL RESERVE STR
ACT TEMP Sec
MAP INPUT HI
BLOCK PSI Sec
MAP INPUT LO
CTS TEMP Sec
MAP IDLE CHECK
CTP TEMP Sec
OIL PUMP
LOW OIL Sec
OVERSPEED
OIL PMP Sec
Engine #1
PORT OVERHEAT
Boat Information
STAR OVERHEAT
WARNING HORN
WOT RPM
H2O IN FUEL
Propeller
Type
#1
#5
Propeller Size
LED INDICATORS
#2
#6
Boat Type
ILLUMINATED
#3
#7
Boat Length
#4
#8
Weather
Condition
7-19
90-898305
Engine #2
SmartCraft Data Worksheet - P/N 90-881929--1
Dealer Name:
Engine S/N:
FREEZE FRAME FAULT BUFFER DATA
FAULT
ID
Fault
Buffer
0
Fault
Buffer
1
Fault
Buffer
2
Fault
Buffer
3
Fault
Buffer
4
Fault
Buffer
5
Fault
Buffer
6
Fault
Buffer
7
Fault
Buffer
8
Fault
Buffer
9
BREAK-IN
BARO PSI
BATT VOLTS
BLOCK PSI
BOAT SPEED
AIR TEMP F
COOL TEMP F
DEMAND %
ENGINE RPM
ENGINE STATE
FPC TOTAL
FREQ COUNTER
FUEL LEVEL %
SHIFT
LAKE/SEA TEMP F
LOAD %
MPRLY
MAP PSI
OIL LEVEL %
PORT TAB POS
AVAILABLE PWR %
RUN TIME
STAR TAB POS
TPS %
TRIM POS
COOL TEMP STB F
COOL TEMP PRT F
What was the engine speed when the failure occurred?
______________________________________________
How was the engine being operated before the failure?
1) Steady RPM
3) Accelerating
2) Decelerating
4) Extended Idle
90-898305
7-20
SmartCraft Data Worksheet Fault ID
Description
Notes
_______________________
_______________________
BREAK IN
•
_______________________
Engine is still within oil break-in clock
BARO PSI
_______________________
•
_______________________
The barometric pressure when the fault occurred
BATT VOLTS
•
_______________________
The battery voltage when the fault occurred
_______________________
BLOCK PSI
•
_______________________
The engine block pressure when the fault occurred
BOAT SPEED
_______________________
•
_______________________
Boat speed when the fault occurred
AIR TEMP 0F
•
_______________________
The engine temperature when the fault occurred
_______________________
COOL TMP F
•
_______________________
The primary (CTS) coolant temperature when the fault occurred
DEMAND %
_______________________
•
_______________________
The demand % (TPI%) when the fault occurred
ENGINE RPM
•
_______________________
The engine RPM when the fault occurred
_______________________
ENGINE STATE
•
_______________________
The engine state when the fault occurred
FPC TOTAL
•
_______________________
The calibrated fueling level when the fault occurred
_______________________
FREQ COUNTER
•
The number of times the fault occurred. 0=1 occurrence, 1=2 occurrences
_______________________
FUEL LEVEL %
_______________________
•
_______________________
The main fuel tank level % when the fault occurred
SHIFT
•
_______________________
The engine was in gear (or neutral) when the fault occurred
_______________________
LAKE/SEA TMP F
•
_______________________
The temperature of the lake/sea water when the fault occurred
_______________________
_______________________
_______________________
7-21
90-898305
_______________________
SmartCraft Data Worksheet Fault ID
Description (Cont.)
_______________________
LOAD %
_______________________
•
Notes
_______________________
_______________________
_______________________
_______________________
The engine load % when the fault occurred
MPRLY
•
A value of zero indicates there was no request made to activate the main
power relay. A value greater than zero indicates that the main power relay
was active.
MAP PSI
•
The MAP pressure when the fault occurred
_______________________
OIL LEVEL %
_______________________
•
_______________________
PORT TAB POS
_______________________
•
The main oil tank level % when the fault occurred
The position of the port trim tab when the fault occurred
AVAILABLE PWR %
_______________________
•
_______________________
RUN TIME
_______________________
•
_______________________
_______________________
Available Engine Power % when the fault occurred
The time at which the fault occurred (ECM run time)
STAR TAB POS
•
The position of the starboard trim tab when the fault occurred
TPS %
_______________________
•
_______________________
TRIM POS
_______________________
•
_______________________
_______________________
_______________________
The TPI % (Demand %) when the fault occurred
The trim position when the fault occurred
COOL TMP STB 0F
•
The starboard coolant temperature sensor reading when the fault occurred
COOL TMP PRT 0F
•
The port coolant temperature sensor reading when the fault occurred
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
7-22
SmartCraft Data Worksheet
Dealer Name:
Engine S/N:
Dealer Number:
Engine Type:
Technician Name:
ECM Part Number:
Date:
DDT Software Version:
Data Monitor - OptiMax
ENGINE #
IDLE
1500 RPM
3000 RPM
ENGINE RPM
TPI 1 VOLTS
BATTERY VOLTS
PWR 1 VOLTS
COOL TMP STB (F)
COOL TMP PRT (F)
MAP PSI
AIR TMP (F)
BLOCK PSI
OIL INJ CNT
TPI %
AIR COM TMP (F)
OIL LEVEL
FUEL LEVEL
AVAILABLE PWR %
SHIFT
TRIM
PITOT
PADDLE WHEEL
LAKE/SEA TMP (F)
SPARK ANG BTDC
FPTC TOTAL oz
7-23
90-898305
NOTES:
SmartCraft Data Worksheet
Dealer Name:
Engine S/N:
Dealer Number
Engine type:
Technician Name:
ECM Part Number:
Date:
DDT Software Version:
ENGINE #
ENGINE RPM
TPI 1 VOLTS
BATTERY VOLTS
PWR 1 VOLTS
COOL TMP STB (F)
COOL TMP PRT (F)
MAP PSI
AIR TMP (F)
BLOCK PSI
OIL INJ CNT
TPI %
AIR COM TMP (F)
OIL LEVEL
FUEL LEVEL
AVAILABLE PWR %
SHIFT
TRIM
PITOT
PADDLE WHEEL
LAKE/SEA TMP (F)
SPARK ANG BTDC
FPTC TOTAL oz
90-898305
7-24
Section 8 - Tools For OptiMax
8-1
90-898305
Table of Contents
Table of Contents ............................................................................................. 2
Tool Supplier Contact Information .................................................................... 3
Tools for OptiMax Repair.................................................................................. 4
Single Fuel/Air Pressure Gauge 160 PSI – 91-16850A7 .............................. 4
Dual Fuel/Air Pressure Gauge 160 PSI - P/N 91-881834A1......................... 4
Adapter Kit - P/N 91-803804A2..................................................................... 4
Schrader Valve Tee - P/N 22-849606 ........................................................... 5
Purge Valve - P/N 91-804706 ....................................................................... 5
O-Ring - P/N 25-803803 ............................................................................... 5
Digital OptiMax Sensor Test Harness - P/N 91-875233A2 ........................... 6
DDT Test Harness (5 Pin Digital Adapter) - P/N 91-875232A1 .................... 6
DDT Extension Harness - P/N 84-822560T11 .............................................. 6
Remote Key Switch - P/N 15000A7 .............................................................. 6
OptiMax Wiring End Seal Kit - P/N 91-881814A1 ......................................... 7
Direct Injection Removal Tool - P/N 91-883521............................................ 7
Pressure Gauge Extensions - P/N 91-881835 .............................................. 7
Oil Syringe - P/N 91-803976T ....................................................................... 8
Screw (5 mm x 25 mm) (2 each) - P/N 10-40073-25 .................................... 8
Flat Washer (2 each)..................................................................................... 8
Seal/Teflon Ring Installation Tool - P/N 91-851980-3................................... 8
Seal/Teflon Ring Sizing Tool - P/N 91-851980-2 .......................................... 8
DDT Carrying Case P/N 804805................................................................... 9
Service Tachometer DMT 2000 - P/N 91-854009A3 .................................... 9
Service Tachometer DMT 2004 - P/N 91-892647A01 .................................. 9
DMT 2000A and 2004 Accessories............................................................... 9
Clamp Tool Kit - P/N 91-803146A2............................................................. 10
Regulator Installation Tool - P/N 91-889431 ............................................... 10
Digital Diagnostic Terminal Order Form ......................................................... 11
CDS - Computer Diagnostic System .............................................................. 12
Dell Latitude ................................................................................................ 12
Panasonic Toughbook ................................................................................ 12
SmartComms Module ................................................................................. 13
Pin Probe Kit & Loaded Volts Lead............................................................. 13
Break-Out Box............................................................................................. 14
Carrying Cases ........................................................................................... 14
Dual Input Pressure Meter – 91-892651A01............................................... 15
4-Pin Diagnostic Connector Harness – 84-822560A13 .............................. 15
DTS CAN Connector Harness – 84-892663 ............................................... 15
90-898305
8-2
Tool Supplier Contact Information
Cole-Parmer
800-323-4340, or 847-549-7600
SPX-OTC
616-792-0088
Blue Point
800-547-5740
Electronic Specialties
815-675-2905
Kent Moore
800-345-2233
Bob Kerr
800-867-4807
Specialty Motors
800-426-8644
Stevens Instruments
847-336-9375
Yardarm Products
800-547-5243
Flaherty Co.
920-921-7680
8-3
90-898305
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
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, order upgrade
91-16850--1.
Dual Fuel/Air Pressure Gauge 160 PSI - P/N 91-881834A1
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
NOTE: To convert older single and dual pressure gauges with quickdisconnect fittings to latest screw on fittings order hose kit 91-803804A2. Kit
contains one replacement hose, dual gauge assembly required two kits.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Adapter Kit - P/N 91-803804A2
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
8-4
Schrader Valve Tee - P/N 22-849606
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Purge Valve - P/N 91-804706
_______________________
Service replacement pressure release valve is now available, for the twin
pressure gauge P/N 91-852087A1/A2/A3 or the single pressure gauge P/N
91-16850, A1/ A2/A3/A5/ & A7 versions.
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
O-Ring - P/N 25-803803
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Replacement O-ring for screw on style schrader valve gauge connections.
Seals off pressure between the schrader valve on engine and gauge
connection.
_______________________
_______________________
_______________________
_______________________
_______________________
8-5
90-898305
Notes
Digital OptiMax Sensor Test Harness - P/N 91-875233A2
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
DDT Test Harness (5 Pin Digital Adapter) - P/N 91875232A1
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Two wire extension harness, OptiMax data cable. Extends DDT adaptor
harness to a length of 15 ft.
DDT Extension Harness - P/N 84-822560T11
_______________________
_______________________
Remote Key Switch - P/N 15000A7
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
8-6
OptiMax Wiring End Seal Kit - P/N 91-881814A1
Notes
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Direct Injection Removal Tool - P/N 91-883521
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Pressure Gauge Extensions - P/N 91-881835
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
8-7
90-898305
Notes
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 Ring Installation Tool - P/N 91-851980-3
_______________________
_______________________
_______________________
_______________________
_______________________
Seal/Teflon Ring Sizing Tool - P/N 91-851980-2
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
8-8
DDT Carrying Case P/N 804805
Notes
_______________________
Service Tachometer DMT 2000 - P/N 91-854009A3
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Service Tachometer DMT 2004 - P/N 91-892647A01
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
DMT 2000A and 2004 Accessories
_______________________
INDUCTIVE PICK-UP - P/N 91-854010-1
_______________________
TEMPERATURE PROBE – P/N 91-854011-1
_______________________
_______________________
REPLACEMENT FERRITE CORE – P/N 91-________
_______________________
INTERFACE MODULE – P/N 91-854013-1
_______________________
HARD CARRYING CASE – P/N 91-854014-1
_______________________
USER’S GUIDE – P/N 90-854015-1
_______________________
TEST LEADS – P/N 91-80265
_______________________
CLAMP-ON CURRENT PROBE – P/N 91-802650-1
_______________________
_______________________
_______________________
8-9
90-898305
Notes
Clamp Tool Kit - P/N 91-803146A2
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
Regulator Installation Tool - P/N 91-889431
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
_______________________
90-898305
8-10