Mercury 150 2.0L to 175 2.5L Swap

[Capnmoench]

I read that this is a go and that the lower leg is the same. I just need to use the exhaust adapter from the 2.5. I bought a rebuilt, freshwater only, 2.5L on another boat with a 20" shaft for $500 less than a rebuilt bare bones powerhead would have cost me. It's immaculate and had only been run twice in a driveway since overhaul. I'll be swapping it on to my 25" lower and exhaust housing. Any special information I need to know? Also, I have a Marine Solutions EOI kit on my 150HP I plan on swapping over to the 175HP. Does anyone know the setup and adjustment on these?

[Capnmoench]

OK I found an archived setup and adjustment for the Marine Solutions EOI. I'm going to post the instructions in text format here for anyone that may be having a problem finding them as well. It is the same as setting up the regular oil injection, the pump is computer controlled for speed. The dump port is still adjusted the same.


Electronic Oil Injection
1989 - 1999 Mercury and Mariner V-6 Carb Models
Installation Instructions

Test the Oil Warning System per the applicable Mercury Service Manual and assure normal engine compression before beginning installation. Replace all defective and suspect parts, with original Mercury parts. Installation requires resistor spark plugs such as NGK BUZ8H.
Remove oil pump
1.

Disconnect the 12V starting battery.

2.

Remove the oil lines from and drain the engine oil reservoir tank.

3.

Remove the link rod from the oil pump and carburetor linkage.

4. Remove the oil pump, bearing assembly and driven gear from the crankcase.
5. Clean and check that the oil pump rotates freely in a counter-clockwise direction.
6. Clean and check that the magnet plug is recessed, that the bearing is not damaged, and that the outside diameter of the bearing is under .626 inch to avoid excess friction.






Bearing Assembly


Driven Gear

7. Apply Loctite to the mounting screws and install the crankcase plug supplied.
Remove rotation sensor and oil warning module
1.

Remove the rotation sensor from the engine.


2.


Remove the oil warning module mounting screws and place module on top of the block.

Install bearing assembly, oil pump and rotation sensor

1.


Replace the o-ring on the bottom of the oil pump with the o-ring supplied.


2.


Install bearing, oil pump, and rotation sensor to the coupler with original hardware








Crankcase plug installation
Oil pump and rotation sensor
Assemble EOI mounting plate to the engine

1.
Apply Loctite and install (3) studs into the crankcase with the short stud in the bottom boss. Tighten the 3/8 long hex spacers securely against the engine block.

2.
Assemble and hold the EOI mounting plate on the studs. Advance the throttle and check for spark advance lever clearance behind the mounting plate. Correct as necessary.





(3) bosses on side of crankcase

Check for trigger arm clearance

3. Secure the mounting plate with (2) 3/8 inch hex spacers on the top studs and one hex nut on the bottom stud.
4. Secure the oil warning module on the studs with (2) hex nuts and washers and the 1-1/4 inch screw, nylon spacer, washer and hex nut at the top of the mounting plate.
Assemble Carburetor Linkage


Style #1 for carburetor with threaded shaft. Style #2 for carburetor with smooth shaft.

1.


For Style #1, removed the nut from the throttle shaft and install the link pointing up and to the left. Replace the nut and bend the lock tab over.


2.


For Style #2, remove the throttle lever. Install the link under the lever pointing down and to the left. Re-install the throttle lever and secure it with the screw.


3.


Remove the rod end from the original link rod and assemble it to the new link rod


4.


Connect and adjust the link rod to assure that the 1st mark on the pump arm is in alignment with the mark on the oil pump with the throttle at the idle position.


5.


Assure free movement of the oil pump link rod as the throttle is advanced. Note that the oil pump lever needs only to reach just over half the way between the 2nd and 3rd mark to assure full oil delivery at wide open throttle.


6.


Re-route and secure the fuel lines, and check for free operation of the oil pump link rod.




Connect wiring

1.


Route the rotation sensor wires behind the EOI electric motor.


2.


Reconnect the white rotation sensor wire to the oil warning module.


3.


Connect the blue/white rotation sensor, and the oil warning module wires to the blue controller wire.


4.


Connect the black rotation sensor wire and black controller wire to the ground on the top of the crankcase.


5.


Connect the gray controller wire to the unused gray terminal and the 2nd voltage regulator. Or, use the gray jumper wire to tap into the tachometer wire on a single regulator system.


6.


Secure all wiring with the cable ties supplied.


Install oil lines

1.


Check that the 2 psi check valve opens between 1.5 and 2 psi. Replace if necessary.


2


Trim and install the new oil lines and clamps. Reposition the oil pump fittings as needed to assure clearance with the oil pump link rod and throttle linkage.


3.


Refill the oil reservoir and check for leaks.

[PanRonnie]

http://boatinfo.no/lib/mercury/manuals/105and140jet-135-150-175-200-225.html#/0

[Capnmoench]

Thanks. I did have this link and use the crap out of it. I just wasn't aware if the pushrod adjustment was any different with the EOI setup vs the OEM injection system. I do wish there was a straight PDF version of this exact manual. The navigation of it is rather cumbersome to get to the page you're looking for.



http://boatinfo.no/lib/mercury/manuals/105and140jet-135-150-175-200-225.html#/0

[PanRonnie]

http://www.hedges-uk.com/boat/Merc/outboards/2-stroke/2-stroke/135-150-175-200-225/MODELS%20135-150-175-200-225%201992%20and%20Newer%20%96%20135-150-150-%20XR6-150%20Magnum%20III-150%20EFI-175-175%20EFI-200-200%20EFI-150-200-225%20Pro%20Max-150-200-225%20Super%20Magnum%20.pdf

[Capnmoench]

Dang, you are the man. I did look at this before, but was scared that it might not be fully applicable due to my 150 being a carbureted 2.0L, but I guess I've joined the XR6 crowd with the 2.5L. It will come in handy.



http://www.hedges-uk.com/boat/Merc/outboards/2-stroke/2-stroke/135-150-175-200-225/MODELS%20135-150-175-200-225%201992%20and%20Newer%20%96%20135-150-150-%20XR6-150%20Magnum%20III-150%20EFI-175-175%20EFI-200-200%20EFI-150-200-225%20Pro%20Max-150-200-225%20Super%20Magnum%20.pdf

[Slow]

Thanks. I did have this link and use the crap out of it. I just wasn't aware if the pushrod adjustment was any different with the EOI setup vs the OEM injection system. I do wish there was a straight PDF version of this exact manual. The navigation of it is rather cumbersome to get to the page you're looking for.


I have the PDF for the marine solutions installation and trouble shooting guide. System was awesome for 10 years now the controller failed. So if anyone has or knows where a controller could be had I would be interested. Otherwise premix will have to do.


EOI TROUBLESHOOTING GUIDE
Run the engine at idle on premix fuel and cooling water and watch the motion of the stub shaft on the silver EOI electric motor. Or, remove the oil pump and observe the drive bearing on black EOI motors.
Be sure that the engine has (6) NGK BUZ8H spark plugs.

• If the shaft or drive bearing is turning slowly for at least 30 seconds the EOI system is OK.
• If the shaft /db does not turn the controller may not be getting a good tachometer signal.
• If the shaft/db runs fast for 10-15 seconds and then stops the controller may not be getting a good rotation sensor signal.

Tachometer signal
• Check for correct and secure wire connections per the Installation Instructions.
• Connect the grey EOI wire to the 2nd voltage regulator, if the engine is so equipped. Note that an inoperative tachometer may indicate a failed voltage regulator.
• Assure that the grey EOI wire is not tied to other wires and is flat to the block.
• Add a ground wire from the EOI ground to the voltage regulator plate, if not already installed.
• Start the engine and check for a minimum of 5 VDC and 60 - 100 Hz on the grey voltage regulator wire. Replace the voltage regulator if values are not met.*

Rotation sensor signal
• Check that the blue-white oil warning module wire is connected to the blue EOI wire.
• Relocate the green oil warning module wire to another switch box or coil.
• Run the engine at idle and check for 3-5 VDC and 5 to 10 Hz from the blue-white rotation sensor wire to ground. Check the oil warning module if values are not met.
• Disconnect the white and blue-white oil warning module wires and check for 5-6 ohms resistance between the two wires. Replace the module if values are not met.*
• Turn the ignition key to the on position and check for 12 VDC from the white oil warning module wire to ground. Replace the warning module if values are not met.*
• Replace the rotation sensor if the oil warning module checks OK.*

Other causes for oil warning horn sounding
• The warning horn may sound briefly if the throttle is advanced rapidly when running on a hose or when a surfacing propeller or jet impeller slips. This is normal sensitivity of the system. The horn sounds because the EOI needs a second or two to catch up with the engine speed.
• Check the float switch on the engine oil tank. Disconnect the wire on the cap. If the warning horn stops fill the tank with oil and retest or replace the float switch.*
• On EFI engines, check for water in the water separating fuel filter. Disconnect the wire on the fuel filter canister. If the warning horn stops empty water from filter.
• Check the EOI electric motor by connecting a 1.5V D size battery across the red and black motor wires. The motor should run the oil pump. If it doesn’t:
1. Remove the oil pump and check that the pump shaft turns freely counterclockwise. Replace the oil pump, and probably the EOI controller, if the oil pump is hard to turn.*
2. Check for wrong or excess grease on the bearing. Lube the bearing with 1/4 X 3/8 inch white lithium grease only.
3. Check for a loose magnet in the black plastic bearing. Replace as necessary.
4. Check for corrosion on the motor bearing.
• Check the EOI controller. Separately check for DC volts on the red and black EOI motor wires to ground. Replace the controller if both wires do not show some DC volts with the engine not running and the ignition key in the off position.*
• Note that the EOI controller draws less than 20 milliamps when the engine is not running.


* Consumers should consult with their Marine Dealer or Marine Solutions Inc before replacing expensive parts as other problems could cause these parts to fail.


Marine Solutions Inc ​ 262-524-0719 (tel:262-524-0719)​ ​January 2015


Marine Solutions Inc. Electronic Oil Injection1989 -1999 Mercury and Mariner V-6 EFI ModelsInstallation Instructions
Test the Oil Warning System per the applicable Mercury Service Manual and assure normal engine compression before beginning installation. Replace all defective and suspect parts with original Mercury parts. EOI requires resistor spark plugs such as NGK BUZ8H.

Remove oil pump, bearing and driven gear
1. Disconnect the 12V starting battery.
2. Remove the oil lines from the oil pump and drain the engine oil reservoir tank.
3. Remove the oil pump link rod.
4. Remove the oil pump, bearing assembly and driven gear from the crankcase.
5. Clean and check that the oil pump rotates freely in a counter-clockwise direction.
6. Clean and check that the magnet plug is recessed, that the bearing is not damaged, and that the outside diameter of the bearing is under.626 inch to avoid excess friction.

http://www.screamandfly.com/x-apple-ql-id://83558954-A295-47BE-B9C9-387CEA257371/x-apple-ql-magic/14D7EDBF-F324-4342-91A4-9DE20B97415A.jpg
Bearing Assembly​ ​Driven gear

Remove rotation sensor and oil warning module
1. Remove the rotation sensor from the crankcase.
2. Remove the oil warning module if mounted on the left side of the block.

Install crankcase plug and fit link lever on the throttle cam
1. Apply Loctite to the mounting screws and install the crankcase plug supplied.
2. Remove the throttle cam from the engine.
3. Clamp the lever to the cam. Locate, drill .159” and tap for the #10-32 screw.
4. Apply Loctite to the link lever screw and install securely with the lock washer supplied.
5. Reassemble the throttle cam to the engine and assure free rotation of the cam.

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​
Crankcase plug installation ​ Link lever on throttle cam



Marine Solutions Inc. 1915 Tallgrass Circle Waukesha, WI. 53188
Phone 262-524-0804 (tel:262-524-0804)​ Fax 262-524-0804 (tel:262-524-0804%207-18-12)​ ​ ​ 7-18-12 (tel:262-524-0804%207-18-12)
Install bearing assembly, oil pump and rotation sensor
1. Replace the o-ring on the bottom of the oil pump with the o-ring supplied.
2. Install bearing, oil pump, and rotation sensor to the coupler with the original hardware.

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Oil pump and rotation sensor
installed on coupler

Assemble the EOI mounting plate to the engine

1. Apply Loctite and install (3) studs into the crankcase with the short stud in the bottom boss. Tighten the 3/8 long hex spacers securely against the engine block.
2. Assemble and hold the EOI mounting plate on the studs. Advance the throttle and check for spark advance lever clearance behind the mounting plate. Correct as necessary.

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(3) bosses on side of crankcase​ Check for clearance behind plate






Marine Solutions Inc. 1915 Tallgrass Circle Waukesha, WI. 53188Phone 262-524-0804 (tel:262-524-0804)​ Fax 262-524-0804 (tel:262-524-0804)​ 7-18-123. Secure the mounting plate with (2) 3/8 inch hex spacers on the top studs and one hex nut on the bottom stud.
4. Secure the oil warning module on the studs with (2) hex nuts and washers and the 1-1/4 inch screw, nylon spacer, washer and hex nut at the top of the mounting plate.
5. Remove the rod end from the original link rod and assemble it on the new link rod.
6. Connect and adjust the link rod to assure that the 1st mark on the pump arm is aligned with the mark on the oil pump boss with the throttle at the idle position. Hold the link rod in a vise and turn the ball-joint barrel counterclockwise to increase overall length if necessary.
7. Assure free movement of the oil pump link rod as the throttle is advanced. Note that the oil pump lever needs only to reach half way between the 2nd and 3rd mark to assure full oil delivery at wide open throttle.

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Adjust link rod so first mark aligns Engine with EOI installed
with mark on the pump boss at idle

Install oil lines and spark plugs
1. Check that the 2 PSI check valve between the oil line and fuel line opens at 1.5 to 2 PSI.
2. Trim and install the new oil lines and clamps. Reposition the oil pump fittings as needed to assure clearance with the oil pump link rod and throttle linkage.
3. Refill the oil reservoir and check for leaks.
4. Install NGK BUZ8H spark plugs

Connect wiring
1. Route the rotation sensor wires behind the EOI electric motor.
2. Reconnect the white rotation sensor wire to the white oil warning module wire.
3. Connect the blue/white rotation sensor wire and the blue/white oil warning module wires to the blue EOI Y adapter wire
4. Connect the black rotation sensor wire, the black EOI controller wire, the black oil warning module wire, and the long black ground wire to the right side EOI mounting plate stud and secure all with the hex nut.
5. Connect the other end of the long black ground wire to the voltage regulator mounting plate on the back of the engine.
6. Disconnect the grey tachometer wire from the voltage regulator. Connect the grey EOI wire to the voltage regulator. Reconnect the grey tachometer wire to the grey EOI Y adapter.
7. Secure all wiring with the cable ties supplied but do not tie the gray wire to the red, black or blue wires to avoid electrical noise.


Marine Solutions Inc. 1915 Tallgrass Circle Waukesha, WI. 53188Phone 262-524-0804 (tel:262-524-0804)​ Fax 262-524-0804 (tel:262-524-0804)​ 7-18-12System test and start-up
1. Connect the red wire to the starter solenoid and reconnect the battery.
2. Turn the ignition key to on and check for audible oil warning module signal. Do not deliver the engine to the customer without an audible oil warning module signal.
3. Start the engine on 50:1 pre-mix fuel and oil and cooling water. Assure that the oil warning horn is not sounding.
4. Disconnect the 3/16” oil pump output line to bleed air from the pump and assure oil flow. The pump delivers 1 drop of oil every 3-4 seconds at idle rpm. Reconnect the oil line.
5. With the engine running, disconnect the blue-white rotation sensor wire and assure that the oil warning horn sounds. Reconnect the wire and restart the engine to silence the horn.
6. Spray electric motor and pump with Quicksilver Corrosion Guard in saltwater areas.
7. Cut away the inner air duct on early model bucket cowls to clear the motor and pump.
8. Deliver to customer and explain Operation and Maintenance Instructions.

Troubleshooting
Run the engine at idle on premix fuel and cooling water and watch the motion of the stub shaft on the electric motor. Or, remove the oil pump and observe the bearing.
• If the shaft is turning slowly for at least 30 seconds, the EOI system is OK.
• If the shaft does not turn the controller may not be getting a good tachometer signal.
• If the shaft runs fast for 10-15 seconds and then stops the controller may not be getting a good rotation sensor signal.
Tachometer signal
• Check for correct and secure wire connections.
• Connect the grey EOI wire to the 2nd voltage regulator if the engine is so equipped. Note that an inoperative tachometer may indicate a failed voltage regulator.
• Assure that the grey EOI wire is not tied to other wires and is flat to the block.
• Assure that all 6 spark plugs are NGK BUZ8H.
Rotation sensor signal
• Check for correct and secure wire connections.
• Check that the blue-white oil warning module wire is connected to the blue EOI wire.
Other causes for oil warning horn sounding
• The warning horn may sound briefly if the throttle is advanced rapidly when running on a hose or when a surfacing propeller slips. This is normal sensitivity of the system.
• Check the float switch on the engine oil reservoir tank. Disconnect the wire on the reservoir cap. If the warning horn stops fill the tank with oil or replace the float switch.
• Check for water in the water separating fuel filter. Disconnect the wire on the bottom of the fuel filter canister. If the warning horn stops empty water from filter.
• Check for additional Troubleshooting tips at www.marinesolutionswi.com.




Note: Do not make unauthorized changes. Call Marine Solutions for advice.