Mercury Mariner 200, 225 Optimax Outboards Service Manual, 90-855348, Page 213Get this manual
Table of Contents Page Powerhead Specifications 4-1 Tools for Powerhead Repair 4-1 Powerhead Torque Sequence and Torque Specifications 4-2 Notes: 4-5 CrankshaftPistonsand Connecting Rods 4-6 Cylinder Block and End Cap 4-8 General Information 4-12 Powerhead Removal from Driveshaft Housing 4-12 Powerhead Disassembly 4-15 Lower End Cap 4-16 Crankcase Cover Removed 4-16 Cleaning and Inspection 4-23 Cylinder Block and Crankcase Cover 4-23 Special Service Information 4-23 Cylinder Bores 4-23 Honing Procedure 4-23 Pistons and Piston Rings 4-25 Cleaning Piston Ring Grooves 4-25 Measuring Piston Roundness 4-25 Cylinder Heads 4-25 Crankshaft 4-26 Crankshaft (and End Cap) Bearings 4-26 Reed Block Assembly 4-27 Reed Block 4-28 Connecting Rods 4-28 Thermostats 4-29 Page Powerhead Reassembly and Installation 4-30 General 4-30 Crankshaft Installation 4-33 Special Information 4-33 Piston and Connecting Rod Reassembly 4-34 Piston and Piston Ring Combination 4-36 Piston Installation 4-36 Crankcase Cover Installation 4-38 Assembly of Reed Blocks to Intake Manifold 4-39 Exhaust Plate 1997 Model 200 DFI 4-40 Exhaust Plate 1998 Model 200225 DFI 4-42 Bleed System 1997 Model 200 DFI 4-46 Front Bleed View 1997 Model 200 DFI 4-48 Bleed System 1998 Model 200225 DFI 4-50 Reinstalling Engine Components 4-51 Anchor BracketlThrottle Linkage Model 1997 200 DFI 4-52 Throttle Linkage 1998 Model 200225 DFI 4-54 Powerhead Installation on Driveshaft Housing 4-56 Break-In Procedure 4-59 Fuel Requirements 4-59 Engine Break-in Procedure (All Models) 4-59