2002+ Mercury Mariner 40/50/60 HP 4-Stroke EFI Outboard Service & Repair Manual

Page iii Manual Outline 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation 2 - Electrical A - Ignition B - Charging and Starting System C - Timing, Synchronizing, and Adjusting 3 - Electronic Fuel Injection A - Theory of Operation B - Diagnostics and Troubleshooting C - Service Procedures D - Emissions 4 - Powerhead A - Cylinder Head B - Cylinder Block/Crankcase C - Lubrication 5 - Mid-Section A - Clamp/Swivel Brackets and Driveshaft Housing B - Power Trim C - Gas Assist Manual Trim/Tilt 6 - Lower Unit A - Gear Housing - EZ Shift (1.83:1 Gear Ratio) B - Gear Housing - BigFoot EZ Shift (2.33:1 Gear Ratio) 7 - Attachments/Control Linkage A - Throttle/Shift Linkage B - Tiller Handle 8 - Jet Drive Outboard A - Jet Drive Outboard Important Information 1 Electrical 2 Electronic Fuel Injection 3 Powerhead 4 Mid-Section 5 Lower Unit 6 Attachments/Control Linkage 7 Jet Drive Outboard 8

50/60 40/50/60 BigFoot 40 Jet EFI FourStroke 4 Cyl. Serial Number 1C050252 and Above Serial Number 1C050252 and Above 90-899975 JANUARY 2008 50/60 40/50/60 BigFoot 40 Jet EFI FourStroke 4 Cyl.

Page i Notice to Users of This Manual Throughout this publication, dangers, warnings, cautions, and notices (accompanied by the International HAZARD Symbol ! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials. Observe them carefully! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures. ! DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. ! CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. This manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual without prior notification. © 2007, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.

Page ii All information, illustrations, and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent information concerning the products described in this manual. Precautions It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material into the cylinders which could cause extensive internal damage when the engine is started. During any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original. Replacement Parts Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as a result. ! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components. Cleanliness and Care of Product A Mercury Marine Power Product is a combination of many machined, honed, polished, and lapped surfaces with tolerances measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible.

Page iv

Specifications 90-899975 JANUARY 2008 Page 1A-1 1 A Important Information Section 1A - Specifications Table of Contents 40/50/60 FourStroke EFI Master Specifications .........................................................................1A-2 General Specifications..............................1A-2 Fuel System Specifications.......................1A-2 Ignition Specifications...............................1A-2 Charging and Starting Specifications........1A-4 Cylinder Head Specification......................1A-4 Cylinder Block/Crankshaft Specifications ..................................................................1A-6 Piston Specifications.................................1A-6 Lubrication Specifications.........................1A-7 Mid‑Section Specifications........................1A-7 Gear Housing Specifications (1.83:1).......1A-7 Gear Housing Specifications ‑ BigFoot (2.33:1) (S/N 0T625304 and Above)......................1A-8 Power Trim Specifications........................1A-9 Propeller Information Charts............................1A-9 50 EFI FourStroke Non‑BigFoot...............1A-9 60 EFI FourStroke Non‑BigFoot.............1A-10 40 EFI FourStroke BigFoot.....................1A-11 50 EFI FourStroke BigFoot.....................1A-11 60 EFI FourStroke BigFoot.....................1A-12

Specifications Page 1A-2 90-899975 JANUARY 2008 40/50/60 FourStroke EFI Master Specifications General Specifications Model Specifications Horsepower @ 5500 RPM 29.8 kW (40 hp) 37.7 kW (50 hp) 44.7 kW (60 hp) WOT RPM range 5500 ‑ 6000 Idle speed (in gear) 725 ± 25 Engine weight (40/50/60 ELPT) 112.7 kg (248 lb.) Engine weight (40/50/60 ELPT BigFoot) 119.9 kg (264 lb.) Fuel Automotive unleaded ‑ minimum 87 octane Oil type All temperatures NMMA FC‑W certified synthetic blend SAE 25W‑40 outboard oil Alternate viscosity below 4 °C (40 °F) NMMA FC‑W certified SAE 10W‑30 outboard oil Oil capacity ‑ with oil filter replacement 3.0 L (3.0 qt.) Fuel System Specifications Fuel System Specifications Fuel lift pump type Mechanical water‑cooled (plunger/diaphragm) Fuel pump pressure (maximum) 20 ‑ 41 kPa (3 ‑ 6 psi) Plunger stroke 5.9 mm (0.232 in.) Fuel tank capacity Accessory Fuel injection system Batch (1 and 4) ‑ (2 and 3) Fuel injector resistance 10 ‑ 13.5 ohms Electric fuel pump Pressure 290 ‑ 303 kPa (42 ‑ 44 psi) Engine running ‑ After five minutes 295 kPa (43 psi) Vapor separator float height ‑ float needle seated 36.5 ‑ 39.5 mm (1.437 ‑ 1.555 in.) Idle RPM (neutral) warm 725 ± 25 RPM Idle RPM (forward gear) warm 725 ± 25 RPM Ignition Specifications Ignition Specifications @ 20 °C (68 °F) Ignition type Capacitor discharge ignition Spark plug type Champion RA8HC Spark plug gap 1.0 mm (0.040 in.) Spark plug hex size 16 mm (5/8 in.) Spark plug torque 17 Nm (150 lb. in.) Spark plug hole size 12 mm Firing order 1 ‑ 3 ‑ 4 ‑ 2

Specifications 90-899975 JANUARY 2008 Page 1A-3 Ignition Specifications @ 20 °C (68 °F) Ignition timing @ Idle Controlled by ECM @ 1500 ‑ 1800 RPM 14° BTDC @ WOT 28° BTDC Stator resistance 0.2 ‑ 0.3 Ω (yellow ‑ yellow) Crank position sensor resistance 300 ‑ 350 Ω (red ‑ white) Ignition coil resistance (Model year 2002/2003/2004) Internal shielding 0 ‑ 10 kΩ (pin A ‑ mounting bracket) Electronic spark trigger (EST) 8.5 ‑ 12 kΩ (pin B ‑ pin C) Secondary 3.0 ‑ 7.0 Ω (pin A ‑ coil tower) High‑tension lead/boot 0.6 ‑ 1.1 kΩ Ignition coil resistance (Model year 2005 and newer) Refer to Ignition Coil Resistance Test Chart ECM engine speed limiter Fuel/spark cutout on cylinders #2 and #3 6225 RPM Fuel/spark cutout on all cylinders 6350 RPM ECM overheat speed control Guardian System is activated. Power limit will vary with the level of overheat. ECM low oil pressure speed control Guardian System is activated. Engine power is limited to 10% of maximum (approximately 2000 RPM). MAT/ECT temperature sensor Refer to graph in Section 3B - EFI Manifold absolute pressure (MAP) sensor resistance Refer to table in Section 3B - EFI Fuel injector resistance 10.0 ‑ 13.5 Ω Main power relay 81 ‑ 99 Ω (pin 85 ‑ pin 86) Idle air control (IAC) 24 ‑ 30 Ω (between pins) Throttle position sensor (TPS) typical range Output voltage @ Idle 0.39 ‑ 1.00 volts Output voltage @ WOT (6000 RPM) 3.66 ‑ 4.80 volts

Specifications Page 1A-4 90-899975 JANUARY 2008 Charging and Starting Specifications Charging and Starting Specifications @ 20 °C (68 °F) Alternator Type Single phase stator coil (12 pole) Output @ 1000 RPM 12.5 amps Output @ 5000 RPM 17.5 amps Stator coil resistance 0.2 ‑ 0.3 Ω Fuse 20 amp Starter Type Sliding gear Model/manufacturer Bendix Output 1.1 kW Ampere draw under load 174.0 amps Ampere draw under no load 23.7 amps Battery Rating Minimum requirement 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA) For operation below 0 °C (32 °F) 1000 marine cranking amps (MCA) or 775 cold cranking amps (CCA) Ampere hours (Ah) for operation above 0 °C (32 °F) 70 Ampere hours (Ah) for operation below 0 °C (32 °F) 105 Quicksilver tachometer setting 6P or 4 Cylinder Head Specification Cylinder Head Specifications Camshaft dimensions Intake/exhaust "a" 30.83 ‑ 31.03 mm (1.214 ‑ 1.222 in.) Intake/exhaust "b" 25.90 ‑ 26.10 mm (1.020 ‑ 1.028 in.) b a 20474 Intake/exhaust valve lift 4.73 ‑ 5.13 mm (0.186 ‑ 0.202 in.) Runout limit 0.1 mm (0.0039 in.) Camshaft bearing diameter 36.935 ‑ 36.955 mm (1.4541 ‑ 1.4549 in.) Camshaft bearing oil clearance 0.045 ‑ 0.090 mm (0.0018 ‑ 0.0035 in.) Valve spring free length 37.85 ‑ 39.85 mm (1.491 ‑ 1.569 in.) Tilt limit Less than 1.7 mm (0.060 in.) Cylinder head flatness 0.1 mm (0.0039 in.)

Specifications 90-899975 JANUARY 2008 Page 1A-5 Cylinder Head Specifications Camshaft bore diameter 37.000 ‑ 37.025 mm (1.4567 ‑ 1.4577 in.) Valve clearance (cold) Intake 0.15 ‑ 0.25 mm (0.006 ‑ 0.010 in.) Exhaust 0.25 ‑ 0.35 mm (0.010 ‑ 0.014 in.) Valve dimensions Valve seat angles 30°, 45°, 60° Intake valve head diameter "a" 31.90 ‑ 32.1 mm (1.256 ‑ 1.264 in.) Exhaust valve head diameter "a" 25.90 ‑ 26.1 mm (1.020 ‑ 1.028 in.) Intake/exhaust face width "b" 2.00 ‑ 3.14 mm (0.079 ‑ 0.124 in.) Intake/exhaust seat width "c" 0.90 ‑ 1.10 mm (0.035 ‑ 0.043 in.) Intake/exhaust margin thickness "d" 0.50 ‑ 0.90 mm (0.020 ‑ 0.035 in.) 20473 d c b a Intake stem outside diameter 5.475 ‑ 5.490 mm (0.2156 ‑ 0.2161 in.) Exhaust stem outside diameter 5.460 ‑ 5.475 mm (0.2150 ‑ 0.2156 in.) Valve guide inside diameter (intake/exhaust) 5.500 ‑ 5.512 mm (0.2165 ‑ 0.2170 in.) Stem to guide clearance (intake) 0.010 ‑ 0.037 mm (0.0004 ‑ 0.0015 in.) Stem to guide clearance (exhaust) 0.025 ‑ 0.052 mm (0.0010 ‑ 0.0020 in.) Stem runout limit (maximum) 0.016 mm (0.0006 in.) Rocker shaft outside diameter 15.791 ‑ 15.991 mm (0.6288 ‑ 0.6296 in.) Rocker arm inside diameter of bore 16.000 ‑ 16.018 mm (0.6299 ‑ 0.6306 in.)

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2002+ Mercury Mariner 40/50/60 HP 4-Stroke EFI Outboard Service & Repair Manual

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