Mariner Mercury 135 JET User Manual

3C-0 - FUEL SYSTEMS 90-824052R3 JUNE 2002
Table of Contents
Page
Specifications 3C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Control Module (ECM) Assembly 3C-2.
Fuel Management System3C-4. . . . . . . . . . . . . . . .
Fuel Pump and Fuel Filter 3C-8. . . . . . . . . . . . . . . . .
Outboard Powerhead View 3C-10. . . . . . . . . . . . . . .
Electronic Fuel Injection (EFl) System 3C-10. . . . . .
Introduction 3C-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Test Procedures 3C-10. . . . . . . . . . . . .
EFI System Tests 3C-11. . . . . . . . . . . . . . . . . . . . .
Safety Precautions 3C-11. . . . . . . . . . . . . . . . . . . .
Fuel Injection System Function 3C-11. . . . . . . . .
Preliminary Steps 3C-12. . . . . . . . . . . . . . . . . . . . . . .
Ignition Spark Check 3C-12. . . . . . . . . . . . . . . . . .
Electronic Fuel Injection Set Up 3C-12. . . . . . . .
Fresh Quality Fuel 3C-13. . . . . . . . . . . . . . . . . . . .
Low Battery Voltage 3C-13. . . . . . . . . . . . . . . . . . .
Fuel Flow Diagram 3C-14. . . . . . . . . . . . . . . . . . . . . .
Fuel Flow Components 3C-15. . . . . . . . . . . . . . .
EFI Electrical Diagram 3C-16. . . . . . . . . . . . . . . . . . .
EFI Electrical Components 3C-17. . . . . . . . . . . . .
EFI Fuel Management
(Low Pressure Fuel Route) 3C-19. . . . . . . . . . . . .
EFI Fuel Management
(High Pressure Fuel Route) 3C-20. . . . . . . . . . . . .
Fuel Rail Electrical/Fuel Determination 3C-21. . . . .
EFI System Test Procedures 3C-22. . . . . . . . . . . . . .
Fuel Gauge Connection/Pressure Test 3C-22. .
Vapor Separator Fuel Delivery Test 3C-23. . . . .
Vapor Separator Float Test 3C-23. . . . . . . . . . . . .
Water Separating Filter Flow Test 3C-24. . . . . . .
Pulse Fuel Pump Delivery Test 3C-25. . . . . . . . .
Final Filter Check and De-pressurizing
EFI System Procedures 3C-26. . . . . . . . . . . . .
Pressure Regulator Test 3C-27. . . . . . . . . . . . . . .
Electric Fuel Pump Test 3C-28. . . . . . . . . . . . . . .
Voltage Test Chart 3C-30. . . . . . . . . . . . . . . . .
Injector Electrical Harness Test 3C-31. . . . . . . . .
Injector Fuel Delivery Test 3C-31. . . . . . . . . . . . .
Injector Operation Test 3C-32. . . . . . . . . . . . . . . .
Induction Manifold Leak Check 3C-33. . . . . . . . .
Air Temperature Sensor Test 3C-34. . . . . . . . . . .
Engine Head Temperature Sensor Test 3C-35. .
Detonation Control System Test
(200 Models Only) 3C-35. . . . . . . . . . . . . . . . . .
Detonation Sensor Check 3C-36. . . . . . . . . . . . . .
Detonation Control Module Check 3C-36. . . . . .
Throttle Position Sensor Test 3C-37. . . . . . . . . . .
Map Sensor Test 3C-37. . . . . . . . . . . . . . . . . . . . .
Problem Diagnosis 3C-37. . . . . . . . . . . . . . . . . . . .
Page
Engine Head Temperature Sensor Removal 3C-40
EFI Induction Manifold Removal 3C-40. . . . . . . . . . .
Water Separating Filter Assembly
Removal 3C-41. . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor/Temperature Sensor/
Fuel Injector Harness Disconnections 3C-41.
Oil Reservoir Removal 3C-42. . . . . . . . . . . . . . . .
Final Filter Assembly Removal 3C-42. . . . . . . . .
Electric Fuel Pump Removal 3C-43. . . . . . . . . . .
Vapor Separator Removal 3C-43. . . . . . . . . . . . .
Vapor Separator Disassembly 3C-44. . . . . . . . . .
Pressure Regulator Removal and
Disassembly 3C-44. . . . . . . . . . . . . . . . . . . .
Vapor Separator Float Removal 3C-44. . . . . .
Vapor Separator Component Reassembly 3C-46
Vapor Separator Float Installation 3C-46. . . . . . .
Manifold Removal 3C-47. . . . . . . . . . . . . . . . . . . .
EFI Induction Manifold Disassembly 3C-48. . . . . . .
Air Temperature Sensor Removal 3C-48. . . . . . .
Throttle Position Sensor Removal 3C-49. . . . . . .
Fuel Rail Removal 3C-49. . . . . . . . . . . . . . . . . . . .
Fuel Rail Disassembly 3C-50. . . . . . . . . . . . . . . . .
Fuel Injector Removal and Disassembly 3C-51.
Injector Harness Removal 3C-52. . . . . . . . . . . . .
Throttle Linkage Removed 3C-52. . . . . . . . . . . . .
EFI System Cleaning and Inspection 3C-53. . . . . . .
Cleaning 3C-53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3C-53. . . . . . . . . . . . . . . . . . . . . . . . . . .
Induction Manifold Assembly 3C-54. . . . . . . . . . . . . .
Injector Harness Installation 3C-54. . . . . . . . . . . .
Fuel Injector Assembly and Installation 3C-55. .
Fuel Rail Assembly 3C-55. . . . . . . . . . . . . . . . . . .
Fuel Rail Installation 3C-56. . . . . . . . . . . . . . . . . .
Throttle Position Sensor Installation 3C-57. . . . .
Air Temperature Sensor Installation 3C-57. . . . .
EFI Induction Manifold Installation 3C-58. . . . . . . . .
Vapor Separator Installation 3C-60. . . . . . . . . . . .
Electric Fuel Pump Installation 3C-60. . . . . . . . .
Final Filter Assembly Installation 3C-61. . . . . . . .
Oil Reservoir Installation 3C-62. . . . . . . . . . . . . . .
Throttle Position Sensor and Temperature
Sensor Fuel Injector Harness
Connections 3C-62. . . . . . . . . . . . . . . . . . . . . . .
Water Separating Filter Assembly
Installation 3C-63. . . . . . . . . . . . . . . . . . . . . . . . .
ECM Installation 3C-63. . . . . . . . . . . . . . . . . . . . . .
Engine Head Temperature Sensor
Installation 3C-64. . . . . . . . . . . . . . . . . . . . . . . . .

Mariner Mercury 135 JET Specifications

General

Engine Type	2-Stroke
Horsepower	135 hp
Fuel Type	Gasoline
Fuel Induction	Carbureted
Steering	Remote
Type	Outboard
Cooling System	Water-cooled
Alternator Output	16 Amps
Weight	121 kg (267 lbs)