Mercury 45 Service Manual

4
A
CYLINDER HEAD
90-828631R3 MARCH 1999 Page 4A-1
POWERHEAD
Section 4A - Cylinder Head
Table of Contents
Specifications 4A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 4A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 4A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft/Oil Pump 4A-6. . . . . . . . . . . . . . . . . . . . . . . .
Intake/Exhaust Valves 4A-8. . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustment 4A-10. . . . . . . . . . . . . . .
Cylinder Head Cover Removal 4A-10. . . . . . . . . .
Adjusting Valves 4A-11. . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover Installation 4A-13. . . . . . . .
Timing Belt Inspection 4A-14. . . . . . . . . . . . . . . . . . . .
Timing Belt Removal 4A-14. . . . . . . . . . . . . . . . . . . . . .
Timing Belt Installation 4A-17. . . . . . . . . . . . . . . . . . . .
Cylinder Head Disassembly 4A-21. . . . . . . . . . . . . . .
Cylinder Head Cover Removal 4A-21. . . . . . . . . .
Cylinder Head Removal 4A-22. . . . . . . . . . . . . . . .
Rocker Arm Assembly Removal 4A-23. . . . . . . . .
Oil Pump Removal 4A-23. . . . . . . . . . . . . . . . . . . .
Camshaft Removal 4A-24. . . . . . . . . . . . . . . . . . . .
Valve Removal 4A-25. . . . . . . . . . . . . . . . . . . . . . . .
Anode Removal 4A-26. . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Disassembly 4A-26. . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-27. . . . . . . . . . . . . . . . . . .
Oil Pump 4A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Shaft and Rocker Arm 4A-27. . . . . . . . . . .
Camshaft 4A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 4A-29. . . . . . . . . . . . . . . . . . . . . . . .
Valve Guides 4A-29. . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide Replacement 4A-30. . . . . . . . . . . . . .
Valves 4A-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs 4A-32. . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Reconditioning 4A-33. . . . . . . . . . . . . .
Valve Refacing Steps 4A-34. . . . . . . . . . . . . . . . . .
Cylinder Head Reassembly 4A-35. . . . . . . . . . . . . . . .
Valve Installation 4A-35. . . . . . . . . . . . . . . . . . . . . .
Camshaft Oil Seal Installation 4A-37. . . . . . . . . . .
Camshaft Installation 4A-38. . . . . . . . . . . . . . . . . .
Oil Pump Assembly 4A-39. . . . . . . . . . . . . . . . . . . .
Oil Pump Installation 4A-40. . . . . . . . . . . . . . . . . . .
Rocker Arm Shaft Assembly 4A-41. . . . . . . . . . . .
Rocker Arm Shaft Installation 4A-41. . . . . . . . . . .
Cylinder Head Gasket 4A-42. . . . . . . . . . . . . . . . . .
Cylinder Head Installation 4A-42. . . . . . . . . . . . . .
Cylinder Head Cover Installation 4A-44. . . . . . . .
Specifications
CAMSHAFT
Camshaft Dimensions
Intake “A”
Exhaust “A”
Intake “B”
Exhaust “B”
Run-out Limit
A
B
1.216 - 1.220 in. (30.89 - 30.99 mm)
1.213 - 1.217 in. (30.82 - 30.92 mm)
1.022 - 1.025 in. (25.95 - 26.05 mm)
1.022 - 1.025 in. (25.95 - 26.05 mm)
0.0039 in. (0.1 mm)
VALVE SPRING
Free Length “a”
Tilt Limit “b”
Compressed Pressure (Installed)
Intake
Exhaust
Tilt Limit (Intake & Exhaust)
Dir. of Winding (Intake & Exhaust)
a
b
1.491-1.569 in. (37.85-39.85 mm)
Less than 0.060 in. (1.7 mm)
19.8 - 22.0 lb (9.0 - 10.0 kg)
19.8 - 22.0 lb (9.0 - 10.0 kg)
0.043 in. (1.1 mm)
Left Hand

Mercury 45 Specifications

General

Horsepower	45 HP
Cylinders	3
Starting	Electric
Full Throttle RPM Range	5000-6000 RPM
Steering	Remote
Exhaust	Through Prop
Shaft Length	20 in