Flushing The Cooling System; Liner Replacement; Jet Drive Removal - Mercury 40 Service Manual

Flushing The Cooling
System
Use Quicksilver accessory hose coupling Part Num-
ber 24789A1.
1. Remove plug and gasket and thread-in hose cou-
pling.
2. Attach a water hose to the hose coupling. Turn on
the water gently, start the engine, and run it at idle
speed only.
3. Check for a steady stream of water flowing out of
the water pump indicator hole. Continue flushing
the outboard for 3 to 5 minutes; adjust water pres-
sure if needed.
4. Stop the engine, turn off the water, and remove
the hose coupling. Reinstall the plug and gasket.
a
a - Plug and Gasket
b - Hose Coupling

Liner Replacement

1. Mark the liner mounting bolts for reassembly into
the same holes. Remove the bolts.
6D-16 - LOWER UNIT
b
2. Remove the liner. If the liner is tight, tap on the in-
ner edge of the liner with a long drift punch
through the intake grate.
NOTE: Apply grease to the liner mounting bolt
threads before assembly.
3. Position the liner into the water intake housing.
Line up one of the liner bolts and lightly thread it
in. It may be necessary to tap or press the liner
into the water intake housing to locate the liner for
installation of the remaining bolts. Torque bolts to
100 lbs. in. (11.2 N·m)
4. Grind off the ends of any bolts that may extend
beyond the inner liner surface.

Jet Drive Removal

1. Shift outboard to NEUTRAL (N) position and dis-
connect the shift linkage.
2. Remove spark plug leads to prevent engine from
starting.
3. Remove the water intake housing that is fastened
with six screws.
90-852572R1 JANUARY 1998