2001 Mercury Mariner 200hp Optimax Jet Drive Service Manual

2001 Mercury Mariner 200hp Optimax Jet Drive Service Manual.

Starting Model Year 2001

Starting Serial Number 0E384500 for Powerhead
Starting Serial Number 0E379931 for Pump Unit

Manual chapters:
200 OptiMax Jet Drive
  - Notice
  - Notice to Users of This Manual
  - Cleanliness and Care of Mercury Jet Unit
  - Page Numbering
  - Service Manual Outline
Section 1A - Specifications
  - Table of Contents
  - Master Specifications
Section 1B - Maintenance
  - Table of Contents
  - Specifications
  - Special Tools
  - Quicksilver Lubricant/Sealant
  - Maintenance
  - Fuel System
  - Spark Plug Inspection
  - Battery Inspection
  - Fuse Replacement
  - Compressor Air intake Filter
  - Flushing Cooling System
  - Out-of-Season Storage
Section 1C - General Information
  - Table of Contents
  - Serial Number Location
  - Conditions Affecting Performance
  - Following Complete Submersion
  - Model 200 HP Front View
  - Model 200 HP Starboard View
  - Model 200 HP Port View
  - Model 200 HP Aft View
  - Model 200 HP Top View
  - Mercury Jet Pump Starboard View
  - Mercury Jet Pump Port View
Section 1D - Mercury Jet Installation
  - Table of Contents
  - General Information
  - Installation Requirements
  - MercuryJet Drive Hull Dimensions
  - Installing Jet Pump
  - Bilge Siphon Feature
  - Water By-Pass System
  - Installing Powerhead
  - Throttle Cable
  - Oil Injection Set-Up
  - Trim Plate Adjustment
  - Muffler Installation
  - Pre-delivery Inspection
Section 2A – Ignition
  - Table of Contents
  - Specifications
  - Special Tools
  - Electrical Components
  - Theory of Operation
  - Ignition Component Description
  - Troubleshooting Without Digital Diagnostic Terminal
  - Troubleshooting with the Digital Diagnostic Terminal
  - DDT Functions – Optimax Models Software Version 1.0 (P/N 880118)
  - Ignition Components Removal and Installation
Section 2B – Charging & Starting System
  - Table of Contents
  - Specifications
  - Special Tools
  - Battery Cable Size
  - Replacement Parts
  - Recommended Battery
  - Battery
  - Charging a Discharged Battery
  - Winter Storage of Batteries
  - Flywheel Removal and Installation
  - Flywheel/Alternator
  - System Components
  - Alternator Description
  - Diagnosis of Alternator System on Engine
  - Alternator System Circuitry Test
  - Repair
  - Installation
  - Alternator Belt Tension Adjustment
  - Starter System
  - Starter Motor (Solenoid Driven Bendix)
  - Troubleshooting the Solenoid Driven Bendix Starter Circuit
  - Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)
  - Starter Removal and Installation
  - Disassembly (Solenoid Driven Bendix Starter)
  - Cleaning and Inspection
  - Reassembly (Solenoid Driven Bendix Starter)
  - Starter Cleaning, Inspection and Testing
  - Commander 2000 Key Switch Test
Section 2C - Timing, Synchronizing & Adjusting
  - Table of Contents
  - Specifications
  - Special Tools
  - Crank Position Sensor
  - Throttle Cam Adjustment
  - Throttle Position Sensor (TPS) Adjustment
  - Idle Speed
Section 2D - Wiring Diagrams
  - Table of Contents
  - 200 OptiMax Jet Drive Wiring Diagram 2001 Model Year
Section 3A – Electric Fuel Pump
  - Table of Contents
  - Specifications
  - Fuel Pump Assembly
  - Special Tools
  - Fuel Lift Pump Description/Operation
  - Checking for Restricted Fuel Flow Caused by Anti-siphon Valves
  - Checking Fuel Pump Lift (Vacuum)
  - Fuel Lift Pump Removal/Disassembly
Section 3B – Direct Fuel Injection
  - Table of Contents
  - Specifications
  - Special Tools
  - Air Handler
  - Air Handler Components
  - Vapor Separator Components
  - Air Hoses
  - Water Hoses
  - Fuel Hoses
  - Fuel Rails
  - Air Compressor Components
  - DFI Operation
  - Testing Electric Fuel Pump Pressure Output
  - Fuel Management Assembly Removal
  - Air Compressor
Section 3C – Oil Injection
  - Table of Contents
  - Special Tools
  - Oil System Operation
  - Oil System Troubleshooting
Section 3D – Emissions
  - Table of Contents
  - Exhaust Emissions Standards
  - Outboard Hydrocarbon Emissions Reductions
  - Stratified vs Homogenized Charge
  - Emissions Information
  - Service Replacement Certification Label
Section 4A
  - Table of Contents
  - Powerhead Specifications
  - Special Tools
  - Cylinder Block Assembly
  - Cylinder Head Assembly
  - Crankshaft, Pistons and Connecting Rods
  - Expansion Chamber and Adaptor Plates
  - Torque Sequence
  - General Information
  - Powerhead Removal from Pump Unit
  - Removing Engine Components
  - Starboard Side Oil Hose Routing
  - Port Side Oil Hose Routing
  - Water By-Pass Hose Routing
  - Powerhead Disassembly
  - Cleaning and Inspection
  - Powerhead Reassembly and Installation
  - Reinstalling Engine Components
  - Throttle Lever/Throttle Cam Assembly
  - Throttle Lever and Shift Shaft
  - Powerhead Installation on Pump Unit
  - Break-ln Procedure
Section 4B - Cooling
  - Table of Contents
  - Specifications
  - Special Tools
  - Model 200 Water Flow
  - 200 OptiMax Jet Drive Water Flow
  - Water Pressure Check
Section 5 - Jet Pump
  - Table of Contents
  - General Information
  - Drive Housing Components
  - Pinion & Impeller Shaft
  - Nozzle/Rudder Components
  - Servicing Stator, Impeller and Wear Ring
  - Removing Jet Drive From Boat
  - Drive Housing Disassembly and Reassembly
Section 6 - Color Diagrams
  - Table of Contents
  - 200 Optimax Jet Drive Engine Wiring
  - 200 Optimax Jet Drive Typical Key Switch Wiring
  - 200 Optimax Jet Drive Typical Remote Control and Dash Wiring Non-Smartcraft
  - 200 Optimax Jet Drive Typical Remote Control and Dash Wiring With Smartcraft
  - 200 Optimax Jet Drive Fuel & Air Flow Diagram
  - 200 Optimax Jet Drive Water Flow

Manual is indexed with searchable text.