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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Mercury/Mariner Outboard 150 HP (EFI) (1998 - 2009)

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    Fault Finder - Diagnose 400+ problems
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    Wiring diagrams for key vehicle systems
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    Suitable for novice and pro mechanics
  • Online edition only!
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    Includes ALL content of a printed manual
    Fault Finder - Diagnose 400+ problems
    Take on bigger jobs with Haynes’ help
    Wiring diagrams for key vehicle systems
    Extra videos in online manual
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    700+ pictures & diagrams of your vehicle

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This Mercury/Mariner manual is 640 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Torque specification / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Basic service methods

CHAPTER THREE / TROUBLESHOOTING
Safety precautions / Operating requirements / Terminology and test equipment / Starting system / Battery charging system / Electrical accessories / Ignition system / Capacitor discharge module (CDM) ignition (65 jet and 75-125 hp, except 105 jet and 115 Optimax) / Alternator driven ignition (1998 and 1999 105 jet and 135-200 hp models [except Optimax models]) / Capacitor discharge module (CDM) ignition (2000-on 105 jet and 135-200 hp [except Optimax models]) / Capacitor discharge module (CDM) ignition (225 and 250 hp) / Digital inductive (DI [Optimax models]) / Fuel system / Fuel primer and enrichment system / EFI fuel system troubleshooting / Optimax 115-225 hp air/fuel system troubleshooting / Engine temperature and overheating / Engine / Starting system troubleshooting / Ignition system troubleshooting / Fuel system troubleshooting / Starter motor current draw specifications / Charging system troubleshooting / Charging system amperage / Battery charging coil (stator) resistance specifications (except belt-driven) system / Ignition system voltage output specifications / Ignition stator resistance specification / Capacitor discharge module (CDM) resistance specifications / Ignition coil resistance specifications / Fuel pump pressure specifications / Engine coolant temperature (ECT) and compressor temperature sensor specifications / Air temperature (IAT) sensor specifications / Cooling system specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrication / Fuel selection / Recommended fuel/oil mixture ratio / Filling the oil tank reservoir / Power head break-in procedure / Fuel mixing procedure / Changing gfear case lubricant / Jet pump maintenance / Propeller shaft maintenance / Corrosion of the propeller shaft bearing carrier / Off-season storage / Anticorrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Remove carbon from combustion chamber / Compression test / Spark plug plugs / Lower gearcase and jet pump unit water pump / Fuel and oil injection systems / Fuel pump / Ignition system service / Sharging system service / Alternator belt (225 and 250 hp models except Optimax models) / Alternator belt (Optimax models) / Battery and starter system / On-water performance testing / Maintenance torque specifications / Maintenance schedule / Spark plug recommendations / Lubricant capacities

CHAPTER FIVE / SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
65 jet, 75 hp and 90 hp models / 80 jet and 100-125 hp models (except 115 Optimax) / 105 jet, 140 jet and 135-200 hp carbureted models / 150-200 hp electronic fuel injection (EFI) models / 115-225 hp Optimax (direct fuel injection) models / 225 hp carbureted models / 225 and 250 hp EFI models

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / Fuel primer valve (65 jet and 75-200 hp [remote control models]) / Thermal air valve (105 jet and 135-200 hp carbureted models) / Fuel enrichment valve (225 hp carbureted models) / Accelerator pump circuit (100-125 hp and 80 jet models) / Antisiphon devices / Fuel filters / Fuel tanks / Fuel hose and primer bulb / Electronic fuel injection (EFI) and direction fuel injection (DFI) / Reed valve service / Fuel bleed (recirculation) system

CHAPTER SEVEN / ELECTRICAL SYSTEM
Battery / Charging system / Fuses / Starting systems / Ignition systems / Capacitor discharge module (CDM) ignition / Digital inductive ignition (115-225 hp Optimax models)

CHAPTER EIGHT / POWER HEAD
Power head break-in, disassembly, cleaning, inspection and assembly / Lubricants, sealants and adhesives / Sealing surfaces / Fasteners and torque

CHAPTER NINE / GEARCASE
Gear case operation, disassembly, assembly, pressure testing, shimming / Corrosion control / Gearcase lubrication / Propeller / Trim tab adjustment / Gear housing / Water pump / Gear ratio and tooth counts

CHAPTER TEN / JET DRIVE
Jet pump unit maintenance / Jet pump unit repair / Specifications

CHAPTER ELEVEN / TRIM AND TILT SYSTEMS
Power trim and tilt system service / Specifications

CHAPTER TWELVE / MIDSECTION AND TILLER CONTROL
Specifications

CHAPTER THIRTEEN / OIL INJECTION SYSTEM
Variable ratio oil injection / Variable ratio electronically controlled oil injection / Specifications

CHAPTER FOURTEEN / REMOTE CONTROL
Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 65 Jet
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 75 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 80 Jet
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 90 Jet
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 100 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 105 Jet
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 115 HP (4 Cyl.)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 115 HP Optimax (V-6)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 125 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 135 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 135 HP Optimax
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 140 Jet
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 150 HP (Carburetor Equipped)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 150 HP (EFI)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 150 XR6
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 150 HP Optimax
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 150 Mag III
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 175 HP (Carburetor Equipped)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 175 HP (EFI)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 175 HP Optimax
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 200 HP (Carburetor Equipped)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 200 HP (EFI)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 200 HP Optimax
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 225 HP (Carburetor Equipped)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 225 HP (EFI)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 225 HP Optimax
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Mercury/Mariner 250 HP (EFI)

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Mercury/Mariner 65 Jet (1998-2009)
Mercury/Mariner 75 HP (1998-2009)
Mercury/Mariner 80 Jet (1998-2009)
Mercury/Mariner 90 Jet (1998-2009)
Mercury/Mariner 100 HP (1998-2009)
Mercury/Mariner 105 Jet (1998-2009)
Mercury/Mariner 115 HP (4 Cyl.) (1998-2009)
Mercury/Mariner 115 HP Optimax (V-6) (1998-2009)
Mercury/Mariner 125 HP (1998-2009)
Mercury/Mariner 135 HP (1998-2009)
Mercury/Mariner 135 HP Optimax (1998-2009)
Mercury/Mariner 140 Jet (1998-2009)
Mercury/Mariner 150 HP (Carburetor Equipped) (1998-2009)
Mercury/Mariner 150 HP (EFI) (1998-2009)
Mercury/Mariner 150 XR6 (1998-2009)
Mercury/Mariner 150 HP Optimax (1998-2009)
Mercury/Mariner 150 Mag III (1998-2009)
Mercury/Mariner 175 HP (Carburetor Equipped) (1998-2009)
Mercury/Mariner 175 HP (EFI) (1998-2009)
Mercury/Mariner 175 HP Optimax (1998-2009)
Mercury/Mariner 200 HP (Carburetor Equipped) (1998-2009)
Mercury/Mariner 200 HP (EFI) (1998-2009)
Mercury/Mariner 200 HP Optimax (1998-2009)
Mercury/Mariner 225 HP (Carburetor Equipped) (1998-2009)
Mercury/Mariner 225 HP (EFI) (1998-2009)
Mercury/Mariner 225 HP Optimax (1998-2009)
Mercury/Mariner 250 HP (EFI) (1998-2009)

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