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  1. #1
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    May 2011
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    Twin Cities
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    115 Optimax Oil Tank Removal/Install

    I'm in the process of testing my warning horn/buzzer, which has a constant "buzz" at a low volume and wanted to remove the oil tank (2004 115 opti) to test the oil sensor. I have the service manual and it makes it seem pretty straightforward, however it is quite the challenge. Getting it out was a pain, but getting it back in is even more challenging. Is there a special trick to make this happen? Does part of the bottom cover on the engine need to come off? Part of the challenge is getting the tank in far enough to plug the wire harness and oil line back in, and then to get the plenum on the air intake seated properly as well.

    Thanks!
    Last edited by RetroActv; 07-24-2012 at 09:50 AM.

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  3. Mercury - 3 Liter Moderator EuropeanAM's Avatar
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    Apr 2008
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    #2
    Remove the lower cowlings.... it's almost impossible to reinstall the oil tank properly (otherwise).


    Dual Mercury Master Technician- for Mercury Outboards, Racing & Mercruiser Sterndrives in Greenville, SC.
    Still consider myself a "Marine Apprentice" after 38 years (learn something new every day).
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  4. Member
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    Oct 2008
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    Mid-TN
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    #3
    to remove lower cowl is it just the screw on each side? i need to remove mine for spark plug swap.

  5. Mercury - 3 Liter Moderator EuropeanAM's Avatar
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    Apr 2008
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    51,866
    #4
    Quote Originally Posted by smbass View Post
    to remove lower cowl is it just the screw on each side? i need to remove mine for spark plug swap.
    Depends on what engine you have. You shouldn't need to remove the lower cowlings to change spark plugs on a 115 Optimax....


    Dual Mercury Master Technician- for Mercury Outboards, Racing & Mercruiser Sterndrives in Greenville, SC.
    Still consider myself a "Marine Apprentice" after 38 years (learn something new every day).
    Mercury Parts, Mercury Outboards, Smartcraft & Accessories, Injector Service, TDR Reeds- BBC Sponsor