Mercury Optimax Operating and installation instructions

99-6 JUNE 1999 Printed in U.S.A. - 1999, Mercury Marine Page 1 of 6
No. 99-6
❑ADVISORY
❑BULLETIN
End Cap OptiMax Air Compressor
Models Affected
MERCURY/MARINER
135/150 HP, 2.5 LITRE OPTIMAX
S/N 0G868674 Thru 0G925496
200/225 HP, 3.0 LITRE OPTIMAX
S/N 0G869454 Thru 0G925439
The air compressor end cap retaining bolts may become loose due to a machining error.
Thelooseboltscouldallowtheendcaptoliftoutofthecompressorbodycausinganoilleak,
and/or loss of air pressure.
Owner Notification
A letter will be sent to every registered owner of an affected outboard. The letter will advise
theownertoreturntheiroutboardtotheirsellingdealeroranyauthorizeddealerforreplace-
ment of the compressor end cap.
Dealer Outboard Inventory
Affected outboards in dealer inventory MUST BE reworked prior to customer delivery.
Service Parts Stock
Return all compressor end cap assemblies P/N 1173-828131A4 to Mercury Marine for
credit.
Correction
Replace the air compressor end cap assembly with P/N 1173-828131A5. The new assem-
bly includes the end cap, crankshaft, bearings, pulley flange, seals, and O-rings.

END CAP OPTIMAX AIR COMPRESSOR
Page 2 of 6 99-6 JUNE 1999
Disassembly
•Remove flywheel cover
•Use 3/8-inch (9.5 mm) drive on belt tensioner arm to relieve belt tension, and remove
belt.
•Remove the 5 bolts that retain the pulley to the pulley flange.
57784
a
b
c
a
b
c
57489
2.5 Liter 3.0 Liter
a-Pulley retaining bolts (5)
b-Tensioner
c-3/8 (9.5 mm) square drive

END CAP OPTIMAX AIR COMPRESSOR
99-6 JUNE 1999 Page 3 of 6
•Remove the 4 bolts that retain the end cap to the compressor body.
57809
a
a-End cap retaining bolts (4)
•While rotating the pulley flange alternately clockwise and counterclockwise about 1/8
to1/4turn, pull outward on the pulley flange.Continuerotating until the end cap assem-
bly has been removed from the compressor body.

END CAP OPTIMAX AIR COMPRESSOR
Page 4 of 6 99-6 JUNE 1999
Reassembly
•Lubricateend capO-ringandO-ring contactareaincompressor bodywithtwocycle oil.
•Slide the new end cap assembly into the compressor body, keeping the connecting rod
journal lined up with the open end of the connecting rod, until the crankshaft just enters
the open end of the connecting rod.
a
b
a-Connecting rod open end
b-Crankshaft connecting rod Journal
•While rotating the pulley flange clockwise and counterclockwise, push the end cap into
the compressor. Continue rotating the flange until the end cap is all the way down
against the compressor body.
•Toconfirmthattheconnectingrodjournalhasproperlyengagedwiththeconnectingrod,
rotate the flange until you feel resistance from the piston trying to compress air in the
cylinder.
•Apply Loctite 271 (P/N 92-809820) to the threads of the end cap retaining bolts and
torque to 100 lb. in. (11.5 Nm).
•Apply Loctite 271 (P/N 92-809820) to the pulley retaining bolts and torque to 100 lb. in.
(11.5 Nm).
•Install compressor/alternator belt.
•Run engine to confirm that compressor is functioning correctly.

END CAP OPTIMAX AIR COMPRESSOR
99-6 JUNE 1999 Page 5 of 6
Part required
Qty. one (1) End cap assembly P/N 1173-828131A5
Repair Identification
FACTORY REWORK IDENTIFICATION
Engines reworked at the factory have a GREEN dot on the engine carton, near the serial
number location, and a WHITE dot on the compressor near the bar code identification.
DEALER REWORK
Aftertheendcaphasbeenreplaced,placeaWHITEpaintdotonthecompressorbodynear
the bar code identification.
Warranty
The normal 2 year Optimax warranty applies. Complete warranty claim listing.
•Outboard serial number
•Qty. 1 End cap assembly P/N 1173-828131A5
•Eight tenths (0.8) hour labor
•Warranty Flat Rate Code: NJC
•Failure Code : 761-00
U.S. and Canada: Return end cap with completed warranty claim.
INTERNATIONAL: Follow instructions issued by Marine Power International office or by
your distributor.

END CAP OPTIMAX AIR COMPRESSOR
Page 6 of 6 99-6 JUNE 1999
Dear Mercury Marine Customer:
Ourrecords indicate that youare the owner ofa Mercury Marine outboardincluded in a recall.
Duetoanaircompressormanufacturingerror,theaircompressor endcapretaining boltsmay
becomeloose.Thelooseboltscould allowtheendcapto liftoutofthecompressorbodycaus-
ing an oil leak, and/or loss of air pressure.
WHAT YOU SHOULD DO
Contact your authorized dealer, preferably the one who sold you the engine, and make ar-
rangements to determine if your engine needs to be repaired. The dealer will refer to Mercury
Marine Service Bulletin 99-6 for instructions. You must deliver your engine to the dealer and
present this letter, the reverse side of which is a claim-form your dealer needs to send to us
for reimbursement.
NOTE: Ifyourboatis in storage, youmaywant to wait untilyouremove it from storagetohave
this service performed.
WHAT WE WILL DO
Wewillreimbursetheauthorizeddealerforinspectingand/orreplacingtheaircompressorend
cap assembly in line with the service bulletin.
We apologize for any inconvenience this recall may have caused you. However, we have tak-
en this action to assure your boating enjoyment and continued satisfaction with our product.
Sincerely,
Mercury Marine
Mercury Marine
Marine Products and Services
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939 USA
Phone: [phone]
www.mercurymarine.com