Mercury 100 FourStroke, Service Manual

Page: 268 / 574

4-56 - POWERHEAD 90-830234R3 DECEMBER 1997
REATTACH CRANKCASE COVER
•
After the application of the Loctite Master Gasket
Sealing Kit, place crankcase cover onto block,
and align.
•
Recheck that bolt holes and bolts are clean to as-
sure accurate torque.
•
Insert bolts - note 2 sizes and finger tighten.
•
Install last end cap bolt in remaining (End Cap to
Cover) hole.
•
Torque Crankcase Cover Bolts.
IMPORTANT: This is a Double Torque Pattern.
10 6
2 4
8 12
9 5 1 3
7
11
6
5
2
1
4
3
8
7
3 Cylinder Models
4 Cylinder Models
Torque large bolt sequence first.
1st Torque Pattern (#1-8) on Large Bolts -
25 lb. ft. (33.9 N
m)
2nd Torque Pattern (#1-12) on Small Bolts -
18 lb. ft. (24.4 N
m)
•
Torque all (lower) end cap bolts (3 bolts) to
18 lb. ft. (24.4 N
m).
•
Reattach bleed line hose.
NOTE: Inspect ALL hoses on reinstallation; replace
when necessary.
Note on Major Cover Gaskets: These are new gas-
kets impregnated with a coating that causes the gas-
ket to retain torque. It is not necessary to use sealant
on gasket, or Loctite on bolts.
Cylinder Block Cover
•
Align cover and gasket on block.
a
b
a - Cover
b - Gasket
•
Install thermostat cover and components, as fol-
lows:
1. Insert poppet valve (a) into valve seat (b).
2. Install cover gasket (c) over poppet.
3. Insert thermostat (d) into well.
4. Align cover, with poppet spring (e) seated as
shown.
5. Depress cover, and insert bolts - finger tighten.
Note seating of thermostat gasket (f) and poppet dia-
phragm (g). These, and carrier (h) are replaceable
when necessary.
a
b
h
d
e
c
g
f
1
2
2
1 - Screw – Drive Tight
2 - Thermostat/Poppet Valve Cover Screws – Torque to
18.lb.ft (24.5Nm)