Mercury 200 OptiMax Jet Drive Service Manual page 266

Table of Contents
Powerhead Specifications..................................................4A-2
Cylinder Block and End Caps............................................4A-6
Exhaust Manifold and Exhaust Plate...............................4A-10
Cylinder Head..................................................................4A-12
Crankshaft, Pistons, and Connecting Rods.....................4A-14
Expansion Chamber and Adapter Plate Components.....4A-16
Powerhead Removal from the Pump Unit........................4A-20
Removing Powerhead Components................................4A-21
Individual Components.............................................4A-21
Vapor Separator Tank Removal...............................4A-22
Electrical Plate and Harness Removal.....................4A-24
Fuel Rail Removal....................................................4A-26
Air Compressor Removal..........................................4A-29
Oil Hoses and Reservoir Removal............................4A-31
Throttle Body and Air Plenum Removal....................4A-32
Powerhead Disassembly.................................................4A-33
Lower Crankshaft Ball Bearing Removal..................4A-38
Cleaning and Inspection..................................................4A-39
Cylinder Block and Crankcase Cover.......................4A-39
Special Service Information......................................4A-39
Cylinder Bores..........................................................4A-39
Pistons and Piston Rings..........................................4A-40
Cylinder Heads and Exhaust Divider Plate...............4A-41
Crankshaft................................................................4A-41
Crankshaft and End Cap Bearings...........................4A-42
Connecting Rods......................................................4A-43
Reed Block Assembly...............................................4A-45
End Bearing Bleed System.......................................4A-45
90-8M0050731 MAY 2011
Powerhead
Section 4A - Powerhead
Powerhead Assembly......................................................4A-46
Powerhead Preassembly Cleaning Recommendations
Crankshaft Bearings Installation...............................4A-46
Crankshaft Installation..............................................4A-49
Piston and Connecting Rod Assembly.....................4A-50
Piston and Piston Ring Combinations......................4A-52
Piston Installation......................................................4A-52
Crankcase Cover Installation....................................4A-55
Reed Block Assembly...............................................4A-57
Reed Block Adapter Plate Assembly........................4A-58
Exhaust Divider Assembly........................................4A-58
Cylinder Head Installation.........................................4A-59
Starboard Side Oil Hose Routing.....................................4A-61
Port Side Oil Hose Routing..............................................4A-62
Water Bypass Hose Routing............................................4A-63
Installing Powerhead Components..................................4A-63
Installing Individual Engine Components..................4A-63
Oil Hoses and Reservoir Installation.........................4A-64
Air Compressor Installation.......................................4A-65
Electrical Plate and Harness Installation..................4A-68
Powerhead Installation on the Pump Unit........................4A-70
Engine Break-in Procedure After Powerhead Assembly. 4A-72
Recommended Break-in Procedure.................................4A-73
Fuel Requirements...................................................4A-73
Initiating Engine Break-in Sequence (Priming Oil
Engine Break-in Procedure (All Models)...................4A-73
..............................................................................4A-46
Pump)....................................................................4A-73
Powerhead
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