Mercury Mariner

SERVICE
MANUAL
MODELS
30 JET 40 (4 CYL)

With Serial Numbers

United States . . . . . . . 0C159200 and Above
Belgium . . . . . . . . . . . 9570305 and Above
Canada . . . . . . . . . . . . 0A748269 and Above
Notice We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
Throughout this publication, “Dangers”, “Warnings” vice might be performed and of the possible hazards
and “Cautions” (accompanied by the International and/or results of each method. We have not under-
HAZARD Symbol ) are used to alert the mechanic taken any such wide evaluation. Therefore, anyone
to special instructions concerning a particular service who uses a service procedure and/or tool, which is
or operation that may be hazardous if performed in- not recommended by the manufacturer, first must
correctly or carelessly. OBSERVE THEM CARE- completely satisfy himself that neither his nor the
FULLY! products safety will be endangered by the service
procedure selected.
These “Safety Alerts” alone cannot eliminate the haz-
ards that they signal. Strict compliance to these spe- All information, illustrations and specifications con-
cial instructions when performing the service, plus tained in this manual are based on the latest product
“Common Sense” operation, are major accident pre- information available at the time of publication. As re-
vention measures. quired, revisions to this manual will be sent to all deal-
ers contracted by us to sell and/or service these prod-
DANGER ucts.
DANGER - Immediate hazards which WILL result It should be kept in mind, while working on the prod-
in severe personal injury or death. uct, that the electrical system and ignition system are
capable of violent and damaging short circuits or se-
WARNING vere electrical shocks. When performing any work
where electrical terminals could possibly be
WARNING - Hazards or unsafe practices which grounded or touched by the mechanic, the battery
COULD result in severe personal injury or death. cables should be disconnected at the battery.

CAUTION Any time the intake or exhaust openings are exposed

during service they should be covered to protect
Hazards or unsafe practices which could result against accidental entrance of foreign material which
in minor personal injury or product or property could enter the cylinders and cause extensive inter-
damage. nal damage when the engine is started.
It is important to note, during any maintenance proce-
dure replacement fasteners must have the same
Notice to Users of This measurements and strength as those removed.
Numbers on the heads of the metric bolts and on the
Manual surfaces of metric nuts indicate their strength. Ameri-
This service manual has been written and published can bolts use radial lines for this purpose, while most
by the Service Department of Mercury Marine to aid American nuts do not have strength markings. Mis-
our dealers’ mechanics and company service per- matched or incorrect fasteners can result in damage
sonnel when servicing the products described here- or malfunction, or possibly personal injury. There-
in. fore, fasteners removed should be saved for reuse in
It is assumed that these personnel are familiar with the same locations whenever possible. Where the
the servicing procedures of these products, or like or fasteners are not satisfactory for re-use, care should
similar products manufactured and marketed by be taken to select a replacement that matches the
Mercury Marine, that they have been trained in the original.
recommended servicing procedures of these prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.

90-814676R1 DECEMBER 1996 i

Cleanliness and Care of
Outboard Motor
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten thousands of
an inch./mm. When any product component is serv-
iced, care and cleanliness are important. Throughout
this manual, 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 specif-
ically stated.
Whenever components are removed for service,
they should be retained in order. At the time of instal-
lation, they should be installed in the same locations
and with the same mating surfaces as when re-
moved.
Personnel should not work on or under an outboard
which is suspended. Outboards should be attached
to work stands, or lowered to ground as soon as pos-
sible.
We reserve the right to make changes to this manual
without prior notification.
Refer to dealer service bulletins for other pertinent in-
formation concerning the products described in this
manual.

ii 90-814676R1 DECEMBER 1996

Service Manual Outline
Section 1 - Important Information
Section 2 - Electrical & Ignition
A - Ignition System
Important
Information
1
B - Battery, Charging System & Starting System
C - Timing, Synchronizing & Adjustment
D - Wiring Diagrams
Section 3 - Fuel System & Carburetion
Electrical & Ignition
2
Section 4 - Powerhead
Section 5 - Mid-Section
A - Clamp/Swivel Bracket & Drive Shaft Housing
B - Power Trim (Design I)
Fuel System &
Carburetion
3
C - Power Trim (Design II)
D - Power Trim (Design III)
E - Power Trim (Design IV)
F - Manual Tilt System (Design I, II, III)
Powerhead
4
G - Manual Tilt System (Design IV)
Section 6 - Lower Unit
A - Lower Unit
B - Jet Drive
Section 7 - Outboard Motor Installation/Attachments
Mid-Section
5
A - Outboard Motor Installation/Attachments
B - Tiller Handle and Co-Pilot
C - Rewind Starter
Section 8 - Oil Injection System
Lower Unit
6
7
Outboard Motor
Installation/
Attachments

Oil Injection System

8

90-814676R1 DECEMBER 1996 iii