Mariner Mercury 135 JET User Manual

4A-0 - POWERHEAD 90-824052R3 JUNE 2002
Table of Contents
Page
Powerhead Specifications 4-1. . . . . . . . . . . . . . . . . .
Special Tools 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powerhead Repair Stand 4-3. . . . . . . . . . . . . . . .
Cylinder Block and End Caps 4-4. . . . . . . . . . . . . . .
Exhaust Manifold and Exhaust Plate 4-6. . . . . . . . .
Reed Block and Cylinder Head 4-8. . . . . . . . . . . . . .
Crankshaft, Pistons and Connecting Rods 4-10. . .
Torque Sequence 4-12. . . . . . . . . . . . . . . . . . . . . . . .
General Information 4-13. . . . . . . . . . . . . . . . . . . . . .
Powerhead Removal from Driveshaft
Housing 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Engine Components 4-17. . . . . . .
Powerhead Disassembly 4-18. . . . . . . . . . . . . . . . . .
Water Pressure Relief Valve Components 4-24.
Torque Specifications 4-24. . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4-25. . . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover 4-25. . . . .
Special Service Information 4-25. . . . . . . . . . . . .
Cylinder Bores 4-25. . . . . . . . . . . . . . . . . . . . . . . .
Honing Procedure 4-25. . . . . . . . . . . . . . . . . . .
Pistons and Piston Rings 4-27. . . . . . . . . . . . . . .
Cleaning Piston Ring Grooves 4-27. . . . . . . .
Measuring Piston Roundness 4-28. . . . . . . . .
Cylinder Heads and Exhaust Divider
Plate 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft (and End Cap) Bearings 4-29. . . . . .
Reed Block Assembly 4-30. . . . . . . . . . . . . . . . . .
Reed Block Housing 4-30. . . . . . . . . . . . . . . . . . .
Connecting Rods 4-30. . . . . . . . . . . . . . . . . . . . . .
Thermostats 4-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Powerhead Reassembly and Installation 4-33. . . .
General 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Installation 4-36. . . . . . . . . . . . . . . . . .
Special Information 4-36. . . . . . . . . . . . . . . . . .
Page
Piston and Connecting Rod Reassembly 4-37.
Piston and Piston Ring Combinations 4-39. . . .
Piston Installation (Standard and High
Performance Models) 4-40. . . . . . . . . . . . . . . .
Crankcase Cover Installation (Standard and
High Performance Models) 4-42. . . . . . . . . . . .
Assembly of Reed Blocks to Intake Manifold
(Standard and High Performance
Models) 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of Exhaust Divider Plate to Block
(Standard and High Performance
Models) 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Installation (Standard and
High Performance Models) 4-44. . . . . . . . .
Bleed Line Routing (Carbureted Models) 4-45. . . .
Front View 4-45. . . . . . . . . . . . . . . . . . . . . . . . .
Port Side View 4-45. . . . . . . . . . . . . . . . . . . . . .
Starboard Side View 4-45. . . . . . . . . . . . . . . . .
Bleed Line Routing (Fuel Injected Models) 4-45. . .
Front View 4-45. . . . . . . . . . . . . . . . . . . . . . . . .
Port Side View 4-46. . . . . . . . . . . . . . . . . . . . . .
Starboard Side View 4-46. . . . . . . . . . . . . . . . .
Reinstalling Engine Components 4-46. . . . . . . . . . .
Notes: 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Lever and Shift Shaft 4-48. . . . . . . . . . . . . .
Powerhead Installation on Driveshaft
Housing 4-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Break-ln Procedure 4-57. . . . . . . . . . . . . . . . . . . . . . .
Break-in Fuel Mixture 4-57. . . . . . . . . . . . . . . . . .
Gasoline/Oil Mixing Ratio Chart 4-57. . . . . . .
Engine Break-in Procedure
(All Models) 4-57. . . . . . . . . . . . . . . . . . . . . .

Mariner Mercury 135 JET Specifications

General

Brand	Mariner Mercury
Model	135 JET
Category	Engine
Language	English