Mercury 150 EFI Service Manual page 318

Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reed Valve Opening . . . . . . . . . . . . . . . . . .
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powerhead Repair Stand
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Assembly . . . . . . . . . . . . . . . . .
Exhaust Manifold and Exhaust Plate
Crankshaft, Pistons and Connecting Rods
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleed System Routing . . . . . . . . . . . . . . . . . . .
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . .
Powerhead Removal from Driveshaft
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Engine Components
Removing Engine Components
Individually . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Engine Components as an
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil Plate and Harness Removal
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Plate Removal
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Plenum . . . . . . . . . . . . . . . . . . . . . . . . . .
Powerhead Disassembly . . . . . . . . . . . . . . . . .
Water Pressure Relief Valve Components 4A-41
Torque Specifications . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover
90-883728 JULY 2001
POWERHEAD
Section 4A - Powerhead
4A-2
4A-2
4A-2
4A-2
4A-2
4A-3
. . . . . . . . . . . . . . 4A-4
4A-5
4A-6
. . . . . . . 4A-8
. . 4A-10
4A-12
4A-14
4A-16
4A-17
4A-18
. . . . . . . . . . . 4A-24
4A-24
4A-25
4A-27
4A-28
. . . . . . . . . . . . . . 4A-29
4A-30
4A-31
4A-32
4A-41
4A-42
. . . 4A-42
Special Service Information
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Piston Rings
Cylinder Heads and Exhaust Divider Plate 4A-45
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft (and End Cap) Bearings
Reed Block Assembly . . . . . . . . . . . . . . . . .
Reed Block Housing . . . . . . . . . . . . . . . . . .
Connecting Rods . . . . . . . . . . . . . . . . . . . . .
Powerhead Reassembly and Installation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Installation
Piston and Connecting Rod Reassembly
Piston and Piston Ring Combinations
Piston Installation . . . . . . . . . . . . . . . . . . . .
Crankcase Cover Installation
Reed Block Assembly . . . . . . . . . . . . . . . . .
Assembly of Reed Blocks to Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of Exhaust Divider Plate to
Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover
Reinstalling Engine Components
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Lever and Shift Shaft
Powerhead Installation On Driveshaft
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Break-in Procedure
Gasoline/Oil Break-In Mixture
Break-In Procedure . . . . . . . . . . . . . . . . . . .
POWERHEAD
. . . . . . . . . . . . 4A-42
4A-43
. . . . . . . . . . . . . . 4A-44
4A-46
. . . . 4A-46
4A-47
4A-48
4A-48
. . . 4A-51
4A-51
. . . . . . . . . . . . . . . . 4A-55
4A-57
. . . 4A-58
4A-59
. . . . . . . . . . . 4A-62
4A-64
4A-64
4A-64
4A-66
. . . 4A-66
. . . . . . . 4A-68
4A-69
. . . . . . . . . . . . . 4A-70
4A-74
. . . . . . . . . . . . . . . 4A-81
. . . . . . . . . . 4A-81
4A-81
Page 4A-1
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