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2001-2006 Mercury 115 Hp EFI 4-Stroke Outboard Service & Repair Manual
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3
C
SERVICE PROCEDURES
90-881980R1 NOVEMBER 2001 Page 3C-1
ELECTRONIC FUEL INJECTION
Section 3C - Service Procedures
Table of Contents
Specifications 3C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Silencer 3C-4 . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake 3C-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Nozzle 3C-8 . . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump 3C-10 . . . . . . . . . . . . . . . . . . . . .
Fuel Pump 3C-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Silencer Assembly 3C-14 . . . . . . . . . . . . . . . . .
Removal 3C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Assembly 3C-16 . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3C-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-19 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body 3C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Control Lever and Linkage 3C-25 . . . . . . . .
Removal 3C-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-26 . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Fuel Line 3C-27 . . . . . . . . . . . . . . . . . .
Releasing Fuel Pressure in the
High-Pressure Fuel Line 3C-27 . . . . . . . . . . . . . . .
Removal 3C-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-29 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cooler 3C-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation 3C-30 . . . . . . . . . . . . . . . . . .
Fuel Hoses 3C-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation 3C-31 . . . . . . . . . . . . . . . . . .
Fuel Injectors 3C-32 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation 3C-32 . . . . . . . . . . . . . . . . . .
Fuel Rail 3C-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly 3C-33 . . . . . . . . . . . . . . . .
Vapor Separator 3C-34 . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3C-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-34 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3C-35 . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 3C-37 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Regulator 3C-39 . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation 3C-39 . . . . . . . . . . . . . . . . . .
Idle Speed Control Assembly 3C-40 . . . . . . . . . . . . .
Removal/Installation 3C-40 . . . . . . . . . . . . . . . . . .
Disassembly/Assembly 3C-41 . . . . . . . . . . . . . . . .
Intake Manifold 3C-42 . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly 3C-42 . . . . . . . . . . . . . . . .
Throttle Position Sensor 3C-43 . . . . . . . . . . . . . . . . . .
Removal/Installation 3C-43 . . . . . . . . . . . . . . . . . .
Low Pressure Fuel Line/Fuel Pump 3C-44 . . . . . . . .
Removal 3C-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3C-45 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly 3C-46 . . . . . . . . . . . . . . . .
Fuel Filter 3C-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly 3C-47 . . . . . . . . . . . . . . . .
Fuel Pump 3C-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3C-48 . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 3C-50 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
Page 3C-2 90-881980R1 NOVEMBER 2001
Specifications
FUEL
SYSTEM
Fuel Pump Type
Fuel Pump:
Discharge (@ 3000 rpm)
Pressure (Maximum)
Plunger Stroke
Fuel Tank Capacity
External (Plunger/Diaphragm)
17 gph (65 L/h)
7 psi (49 kPa)
0.23 - 0.36 in. (5.85 - 9.05 mm)
Accessory
FUEL INJECTION
Fuel Injection System
Idle rpm (In Neutral) Warm
Idle rpm (In Forward Gear) Warm
Fuel Pressure @ Rail
Batch (1 & 4) - (2 & 3)
750 ± 50 rpm
700 ± 50 rpm
43.5 psi (300 kPa)
Special Tools
1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3.
51796
91-16850A7
91-852087A3
2. Tamper proof screw torx bit set p/n 91-881828.
SERVICE PROCEDURES
90-881980R1 NOVEMBER 2001 Page 3C-3
Notes:
SERVICE PROCEDURES
Page 3C-4 90-881980R1 NOVEMBER 2001
INTAKE SILENCER
16
17
13
12
20
20
3
3
19
1
2
9
10
11
21
5
6
18
14
15
16
15
8
7
8
8
7
8
4
SERVICE PROCEDURES
90-881980R1 NOVEMBER 2001 Page 3C-5
INTAKE SILENCER
REF
TORQUE
REF .
NO.
QTY. DESCRIPTION lb. in. lb.ft. Nm
1 1 INTAKE SILENCER
2 1 INTAKE AIR TEMPERATURE SENSOR
3 4 O-RING
4 6 BOLT (M6 X 16 MM) 70 7.9
5 2 BOLT (M8 X 20 MM) 13 18
6 1 BRACKET
7 2 BRACKET
8 8 BOLT (M6 X 20 MM) 70 7.9
9 1 INDUCTION SILENCER
10 1 MOUNTING BRACKET
11 1 SCREW (M6 X 20 MM) 70 7.9
12 2 PIN
13 1 GASKET
14 1 BREATHER PIPE
15 2 CLAMP
16 2 BOLT (M6 X 12 MM) 70 7.9
17 1 CLIP
18 1 CLAMP
19 2 BOLT (M6 X 105 MM) 70 7.9
20 5 BOLT (M8 X 40 MM) 13 18
21 1 SCREEN
SERVICE PROCEDURES
Page 3C-6 90-881980R1 NOVEMBER 2001
INTAKE
23
22
20
21
34
9
9
33
27
26
29
28
35
32
31
25
1
30
2
3
2
4
3
18
19
24
10
12
11
12
13
6
5
9
8
7
9
8
16
17
15
17
SERVICE PROCEDURES
90-881980R1 NOVEMBER 2001 Page 3C-7
INTAKE
REF
TORQUE
REF .
NO.
QTY. DESCRIPTION lb. in. lb.ft. Nm
1 1 MANIFOLD
2 4 O-RING
3 4 DOWEL PIN
4 3 BOLT
5 1 THROTTLE BODY
6 1 SPRING
7 2 SCREW
8 6 BOLT (M8 X 70 MM) 13 18
9 9 WASHER
10 1 THROTTLE BODY
11 1 SCREW
12 2 SPRING
13 1 SCREW
14 2 SCREW
15 1 LINK JOINT
16 1 LINK JOINT
17 1 NUT
18 1 THROTTLE POSITION SENSOR
19 1 O-RING
20 2 SCREW (M5 X 15 MM) 43 5
21 2 WASHER
22 1 BRACKET
23 3 SCREW (TAMPERPROOF) 40 4.5
24 1 HOSE
– 1 CONTROL VALVE ASSEMBLY
25 1 BODY
26 1 CONTROL VALVE
27 1 O-RING
28 3 SCREW (M4 X 12 MM) 18 2
29 3 WASHER
30 1 FILTER
31 1 MAP SENSOR
32 2 SCREW (M5 X 6 MM) 43 5
33 1 BOLT (M6 X 24 MM) 70 7.9
34 2 BOLT (M6 X 60 MM) 70 7.9
35 1 WIRE HARNESS
SERVICE PROCEDURES
Page 3C-8 90-881980R1 NOVEMBER 2001
FUEL INJECTION NOZZLE
1
2
3
4
5
9
8
4
7
21
10
13
22
23
24
18
24 23
26
6
27
25
15
14
7
12
13
20
19
14
11
25
12
13
10
9
8
9
8
10
9
8
4
4
16 17
SERVICE PROCEDURES
90-881980R1 NOVEMBER 2001 Page 3C-9
FUEL INJECTION NOZZLE
REF
TORQUE
REF .
NO.
QTY. DESCRIPTION lb. in. lb.ft. Nm
1 1 PRESSURE REGULATOR
2 2 SCREW (M6 X 12 MM) 70 7.9
3 2 LOCKWASHER
4 4 CLIP
5 1 HOSE
6 2 SCREW (M5 X 16 MM) 43 5
7 2 CLIP
8 4 BOLT
9 4 GASKET
10 3 COLLAR
11 1 COOLER
12 2 BOLT (M6 X 30 MM) 70 7.9
13 3 WASHER
14 2 CLAMP
15 1 HOSE
16 1 HOSE
17 1 CLAMP
18 1 FUEL RAIL
19 4 INJECTOR UNIT
20 1 O-RING
21 1 CAP
22 1 BOLT (M6 X 25 MM) 70 7.9
23 2 BOLT (M8 X 45 MM) 13 18
24 2 WASHER
25 2 COLLAR
26 1 NIPPLE
27 1 O-RING
SERVICE PROCEDURES
Page 3C-10 90-881980R1 NOVEMBER 2001
FUEL INJECTION PUMP
A = To fitting in exhaust plate
30
22
22
23
21
20
11
12
13
14
15
5
6
4
16
17
10
1
19
19
18
31
32
31
20
20
28
29
20
20
27
27
23
27
23
27
23
27
27
26
24
23
25
A
3
2
7
8
9
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
Get the complete service and repair manual for the 2001-2006 Mercury 115 Hp EFI 4-Stroke Outboard. This manual is a comprehensive resource for troubleshooting, maintenance, and replacement procedures, featuring step-by-step instructions, clear images, and exploded-view illustrations.
Whether you're a professional mechanic or a DIY enthusiast, regular maintenance and eventual part replacements are inevitable for your outboard. This manual provides manufacturer-recommended troubleshooting charts and replacement procedures, ensuring you have everything necessary to keep your outboard in top condition and minimize downtime.
Containing all the service and repair procedures, this manual eliminates the need to search through numerous pages for specific information. It's easily accessible and searchable, making it more convenient than traditional bound manuals. Additionally, it's printable, and compatible with various electronic devices including PC, Mac, Android, and Apple devices, requiring only Adobe Reader.
