Powerhead Removal - Mercury 25 EFI Service Manual

Cylinder Block/Crankcase

Powerhead Removal

1. Disconnect the battery positive and negative cables from the battery.
2. Remove the remote control cables (if equipped).
3. Drain the oil sump into an appropriate container. Refer to Section 1B ‑ Maintenance.
4. Relieve the fuel pressure in the fuel rail. Refer to Section 3C ‑ Vapor Separator Tank (VST).
5. Remove the VST. Refer to Section 3C ‑ Vapor Separator Tank (VST).
6. Remove the engine wire harness. Refer to Section 2B ‑ Engine Wire Harness.
7. Remove the IAC. Refer to Section 3C ‑ Idle Air Control (IAC).
8. Disconnect the hose from the fuel inlet fitting.
9. Remove the water pump indicator hose from the fuel cooler.
a
10. Disconnect the throttle actuating link from the throttle cam.
11. Remove the shift link from the horizontal shift shaft.
a
b
12. Remove two bolts securing the horizontal shift shaft bracket.
a
13. Move the horizontal shift shaft to the starboard side to disengage the upper shift shaft from the horizontal shift shaft.
Page 4A-8
b
11178
© 2016 Mercury Marine
a - Fuel inlet hose
b - Water pump indicator hose
b
11471
a - Throttle actuating link
b - Shift link
11453
a - Bolts securing the horizontal shift shaft bracket (2)
b - Horizontal shift shaft
90-8M0105568 eng MARCH 2016